Legacy Insight Standard LI3, Service Manual

Page 1: ...v A 6 10 14 IMPORTANT Read and understand your user s manual before installing operating or servicing this product DO NOT DESTROY THIS BOOK Model Standard LI3 LI3C CEC Legacy Insight Battery Charger Service Manual ...

Page 2: ...11 Wall Charger Control Panel 12 Floor Charger Control Panel 13 Menu Access 14 Main Menu 14 Memorizations 14 Status 15 USB 16 Record Memo 16 Update Software 16 Configuration 16 Battery 16 Auto Manu Capacity 16 Capacity 16 Temperature 17 High Temperature 17 Charge 17 Profile 17 Charge Delay 17 Condition Charge 18 Float Charge 18 Maximum Current 18 Equalization 18 Manu Current 18 Time 18 Delayed Sta...

Page 3: ...6L 3 T 208 50 60 208 VAC only AC power line filter X020 6L 3 SPECIALTY CHARGER OPTIONS LIST Suffix Description C6 6 of 10AWG AC Cord with 30 AMP Plug C10 10 of 10AWG AC Cord with 30 AMP Plug C12 12 of 10AWG AC Cord with 30 AMP Plug C8 8 of 10AWG AC Cord with 30 AMP Plug CF 10 of 8AWG AC Cord with 50 AMP Plug CF12 12 of 8AWG AC Cord with 50 AMP Plug CR 6 of 10AWG AC Cord with 30 AMP Plug and 30AMP ...

Page 4: ...les Avant tout emploi il est fortement conseillé de lire l ensemble des instructions recommandations et avertissements concernant le chargeur et la batterie 2 Ce chargeur a été conçu pour la charge des batteries industrielles type plomb acide dite ouverte Il ne peut pas être adapté pour les batteries étanches 3 Lisez toutes les condisnes d installation et d utilisation avant d employer le chargeur...

Page 5: ...s unit is designed to charge is given in this part of the nameplate L A Lead Acid Ampere Hours The information supplied here is the maximum ampere hours capacity of this charger Charging batteries of ampere hour capacities not specified here might cause the charger to deviate from the specifications Cells This portion of the nameplate gives the number of cells this unit will charge This number mus...

Page 6: ...rent frequency or from a generator with unstable frequency Phase Number 3 indicates a Three Phase Charger DC Volts This gives the nominal DC output voltage of the system Rated DC Amps This is the nominal DC value of current that this unit will deliver to a battery that is 100 discharged CEC This logo is applied to chargers that are certified by California Energy Commission ...

Page 7: ... least six 6 inches of clearance at rear and sides of the charger for air circulation Stacking Multiple Floor Cabinet Chargers These chargers can be stacked up to a maximum of 3 units high Chargers are not designed to be stacked side by side due to ventilation requirements 1 Position the first charger so that a minimum of 6 inches of space is between the charger and any wall and 12 inches between ...

Page 8: ...l electrical or National Electric Code in making these connections AC Connection The user must provide suitable branch circuit protection and a disconnect method from the AC power supply to the charger to allow for safe servicing Plug Polarity The charging cable is connected to the DC output of the charger with the positive lead marked RED The output polarity of the charger must be strictly observ...

Page 9: ...on the nameplate Beginning the Charge When a battery is connected to the charger the control board senses voltage and after a 20 second delay the charger energizes Charging Charging current is determined by the battery voltage and interaction of the charger Charging current declines automatically as battery voltage rises during the charge As the battery charges the LCD display will output various ...

Page 10: ...on The profile is an IEI constant current constant voltage constant current type with a number of user configurable parameters Equalization Charging Equalization charging performed after normal charging balances the electrolyte densities in the battery s cells IGBT The IGBT controls the charger output by rapidly switching the transformer primary at 20 to 30 kHz Ionic Profile Also called ionic mixi...

Page 11: ... Profile is set to Opp the Value programmed will be the time of day for a Complete Ionic charge Type is ignored when Profile is set to Opp One complete Ionic charge per day is recommended Note The user must configure the charger for the time of day that the full recharge is to take place they must also configure the day of the week that the equalize charge will take place Power Diodes The power di...

Page 12: ...V or 48 80V Note 72V or 80V is selected by switching jumpers on the control board See chart and illustration below Battery recognition voltage capacity and state of charge is accomplished automatically by the microprocessor Several charging profiles are available Cold Storage IONIC Opportunity VRLA based on the configuration chosen by the operator Furthermore equalization and compensation charges ...

Page 13: ... 4 Navigate RIGHT EQUALIZE button Scroll right Start equalize or desulfation 5 Navigation DOWN button Navigate menus Change values 6 Navigation LEFT ESC button Enter Main Menu Scroll left Exit menus 7 RED fault indicator OFF no fault FLASHING ongoing fault detected ON fault 8 YELLOW charging indicator OFF charger output is off ON charging in progress 9 GREEN charge complete indicator OFF charger o...

Page 14: ...ment of password PASSWORD menu Viewing basic charger information INFORMATION menu Main Menu All menus are accessed from Main Menu a detailed description of each menu is included in the next sections of this manual The menus that require a password are not displayed until the correct password has been entered Memo Status USB password Configuration password Parameters Information Password Memorizati...

Page 15: ...u displays the status of the charger s internal counters number of normal and equalize charges faults by type etc Access On the Main Menu select Status and then press Enter STATUS SCREEN Status Information Charge Total number of charges Corresponds to the total of normally terminated charges and charges terminated with or by faults Number of charges terminated abnormally Number of charges normally...

Page 16: ... file creation Update Software Update chargers internal software The software is provided by EnerSys and only authorized service personnel should perform this function Eject For safe removal of the USB stick without damaging the data file Configuration This menu allows for configuration of the charger Password is required to view this menu Configuration access code is 0099 Access On the Main Menu ...

Page 17: ... 24 00 Delay Start of charge is delayed for the amount of time stored in VALUE 0 to 24 hours Time of Day Charge will not start until the time of day stored in VALUE 24 hour format Daily Charge If charger profile is set to OPP one complete Ionic charge per day is recommended Enough down time should be allowed so the battery can remain plugged in to receive a full charge Typically 4 to 5 hours depen...

Page 18: ...ity cycles Time Sets the equalization time from 1 to 48 hrs Delayed start delay Sets the delay between the normal charge and the equalization charge from 0 hr to 23 hrs Frequency Selects one or several periods for carrying out the equalization charge The user can select one or several days per week Cable Length Select the length of DC cables from the charger to the battery terminals in 1 foot incr...

Page 19: ...y Insight Service Manual I B 1621 Rev A 6 10 14 18 Rst Memo Status Resets and clears all memorizations and status history WARNING ONCE THE MEMORIZATIONS AND STATUS HAVE BEEN CLEARED THEY CANNOT BE RECOVERED ...

Page 20: ...e charger must be powered up at the time of the change for it to take effect Language Selects the language displayed in the menus French English German and Italian Region Select the format for date metric EU or imperial US units for temperature length and cable gauge Contrast Modifies the display contrast level 40 to 49 Change Password Password required to view this menu Change the password to any...

Page 21: ... display will show the following information Ref Description 1 Charger type 2 Firmware version 3 CONNect Battery 4 Selected charge profile 5 Programmed battery parameters Cap temp 6 System time and date S11 Delayed Start If the charger was programmed for delayed start Configuration Charge Delay charging will begin following that delay When the battery is plugged in to the charger the display shows...

Page 22: ...charge A few moments into the effective charge the display will begin alternating between the following charging information Ref Description 1 Charger type 2 Firmware version 3 Charger status CHARGE AVAIL EQUAL FAULT 4 Selected charge profile 5 Programmed battery parameters Cap temp 6 System time and date if set 7 Charger output current 8 Alternating battery charge statistics Batt V Vpc Ah returne...

Page 23: ...en an equalize is manually started the output current will be set to the value saved in Configuration Equalize Manu Current 2 The start of the equalization charge is indicated by the message EQUAL During the equalization charge the charger displays the output current and alternating the battery voltage voltage per cell remaining time L2010 24 36 48V US11 3 The battery will be available when the gr...

Page 24: ... lift interrupts may need calibration DF5 No Battery requires inspection Non critical fault Check battery cables for condition and size check for loose connections check for defective cells TH Yes Charger overheating Check that fans are working Verify that ambient temperature is not too high Inspect to see if charger ventilation is obstructed or impaired STOP Yes Critical battery electrolyte level...

Page 25: ...unt of maintenance Connections and terminals should be kept clean and tight The unit especially the heatsink should be periodically cleaned with an air hose to prevent any excessive dirt build up on components Care should be taken not to bump or move any adjustments during cleaning Make sure that both the AC lines and the battery are disconnected before cleaning The frequency of this type of maint...

Page 26: ...ore opening the charger door This check is made with the multimeter in the diode check position The test is run in several stages to check without disconnecting the bridge rectifier Repeat this test when replacing an IGBT module an IGBT module that is bad can mask a failed bridge rectifier THE IGBT AND IF NEEDED BRIDGE RECTIFIER CONNECTION TIGHTENING TORQUE 26in lb THERMAL GREASE IS REQUIRED ON TH...

Page 27: ...eter in Diode Check position If the indication is 0 3V in one direction and Open in the other all diodes are OK If one of the diodes is short circuited the measurement will be 0 0V in both directions Disconnect the wires from the secondary of power transformer TM1 to isolate the defective diodes one by one and identify the damaged one by repeating the steps above on each diode DIODE CONNECTION TIG...

Page 28: ... then disconnect one lead of the fan coil You should measure between 500 and 600 Ohms across the coil terminals 230 VAC voltage Fan s Action Present Working Refer to Test 8 Present Not working Replace the non working fan s Not present Not working Replace the A3 main board or control transformer 6 THERMOSTAT THERMAL FAULT Schematic symbol ST1 Disconnect the AC power and the battery before opening t...

Page 29: ...ve or other foreign substances are permitted in the contact area Apply a light coating of heat sink thermal compound to the flat metal side of the IGBT Bridge Rectifier or Diode Tighten the mounting screws with your fingers as far as possible Then use the torque wrench set as follows for mounting and terminal screws IGBT 26in lb Bridge Rectifier 26in lb Diodes 11in lb Install back all components r...

Page 30: ... SUPPORT BRACKET P N 159 6LA20319 SLOT CENTERS 3 8 HARDWARE IS RECOMMENDED DIMENSIONS SHOWN IN THE DRAWING TO THE LEFT ARE FOR WALL MOUNTING THE CHARGER AND ARE ACCURATE FOR BOTH THE LARGE AND SMALL WALL MODELS AS LONG AS THE MEASUREMENTS ARE TAKEN FROM THE BOTTOM OF THE CABINET S BASE ...

Page 31: ...L CABINET DIMENSIONS AND PARTS Kit P N X225 019 IQ 5 Includes sheet metal and plastic parts shipped in a box fully assembled 009 IQ 1 009 IQ 4 009 IQ 1 Kit P N X225 019 IQ 6 Includes sheet metal and plastic parts shipped in a box fully assembled X057 LTI3 1 X057 LTI3 2 ...

Page 32: ...Legacy Insight Service Manual I B 1621 Rev A 6 10 14 31 FLOOR MOUNTING DIMENSIONS FRONT BACK ...

Page 33: ...ight Service Manual I B 1621 Rev A 6 10 14 32 EXTERIOR FLOOR CABINET DIMENSIONS AND PARTS Top P N X052 99 3 12B Back P N X057 99 3 16B Right Side P N X057 99 0 6B Door P N X054 99 3 17B Left Side P N X057 99 0 7B ...

Page 34: ...655 2 6 3T 208 18 5 3 6 12 18 140 140 140 875 875 875 1 0 6 3W 240 17 0 3 6 12 18 140 140 140 875 875 875 1 0 6 3Y 480 8 5 3 6 12 18 140 140 140 875 875 875 1 0 6 3C 600 6 4 3 6 12 18 140 140 140 875 875 875 1 0 8 1T 208 24 7 3 12 18 24 150 150 140 940 940 875 1 0 8 1W 240 22 8 3 12 18 24 150 150 140 940 940 875 1 0 8 1Y 480 11 4 3 12 18 24 150 150 140 940 940 875 1 0 8 1C 600 8 5 3 12 18 24 150 1...

Page 35: ...d 1 X1060 IQ4 3C3 Control Board 1 X1060 IQ6 1T3 Control Board 1 X1060 IQ6 1W3 Control Board 1 X1060 IQ6 1Y3 Control Board 1 X1060 IQ6 1C3 Control Board 1 X1060 IQ6 3T3 Control Board 1 X1060 IQ6 3W3 Control Board 1 X1060 IQ6 3Y3 Control Board 1 X1060 IQ6 3C3 Control Board 1 X1060 IQ8 1T3 Control Board 1 X1060 IQ8 1W3 Control Board 1 X1060 IQ8 1Y3 Control Board 1 X1060 IQ8 1C3 Control Board 1 X1060 ...

Page 36: ...former 1 1 X127 6LA10678 Power Transformer 1 1 1 1 X127 6L10643 Power Transformer 1 X127 6L10644 Power Transformer 1 1 1 X127 6L10648 Power Transformer 1 1 X127 6L10649 Power Transformer 1 1 1 1 X127 6LA15252 Power Transformer 1 1 1 X127 6LA15262 Power Transformer 1 1 1 1 1 1 X014 99 8 8A AC Fuse 3 3 X014 99 10 10A AC Fuse 3 3 3 3 X014 99 12 12A AC Fuse 3 X014 99 15 15A AC Fuse 3 3 X014 99 20 20A ...

Page 37: ...18621 Resonant Choke 1 1 1 1 1 X020 6L10353 Resonant Choke 2 2 2 2 2 X020 6LA18614 Resonant Choke 2 2 X020 10 1 Resonant Choke 1 X020 10 2 Resonant Choke 1 X225 IQ 200 600 IGBT Kit 1 1 1 1 1 1 1 1 1 1 1 X225 IQ 6L19610 IGBT Kit 1 1 1 1 1 1 1 1 X225 IQ 200 1700 IGBT Kit 1 1 1 1 1 1 1 1 1 X225 IQ 6LA19617 IGBT Kit 1 029 101 Snubber Capacitor 2 2 2 2 2 4 4 2 4 4 029 6LA13170 Snubber Capacitor 2 2 2 2...

Page 38: ... Shunt MOV Assembly 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X1106 99 3 8 IGBT MOV Assembly 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 X1106 6LA00840 IGBT MOV Assembly 2 2 2 2 2 2 2 2 2 X1106 99 3 9 Bridge MOV Assembly 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 X1106 6LA20608 Bridge MOV Assembly 1 1 1 1 1 1 1 1 1 006 201 11A Insulated Standoff 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2...

Page 39: ... Power Transformer Diodes Shunt DC Fuse IGBT Snubber Capacitor Control Board Power Board Line Choke Resonant Choke Cooling Fan AC Power Line Filter IGBT MOV Bridge MOV Diode Suppressor 090 6L10158 Bleeder Resistor Board Current Sensor 10uF Capacitors Keypad AC Fuse Block 090 IQ 1 090 6LA20403 090 6LA20311 090 6LA20309 090 6LA20308 090 6L20042 Thermostat ...

Page 40: ...ors Power Transformer Diodes Shunt DC Fuse IGBT Snubber Capacitor Control Board Power Board Line Choke Resonant Choke Cooling Fan AC Power Line Filter AC Fuse Block Keypad Bridge MOV 10uF Capacitors Current Sensor Bleeder Resistor Board 090 11 1 Diode Suppressor IGBT MOV Thermostat 090 11 2 090 6L10158 090 11 6 090 11 5 090 11 4 090 6L20135 090 11 3 ...

Page 41: ...esonant Capacitors Power Transformer 090 6L10158 Shunt DC Fuse IGBT Snubber Capacitor Control Board Power Board 10uF Capacitors Resonant Choke Cooling Fan IGBT MOV Diode Suppressor Bridge MOV AC Fuse Block Bleeder Resistor Board Current Sensor Line Choke 090 6LA20436 090 6LA20403 090 6LA20311 090 6LA20308 090 6LA20309 090 6L20042 Diodes ...

Page 42: ...tifier Resonant Capacitors Power Transformer Diodes Shunt DC Fuse IGBT MOV Snubber Capacitor Control Board Power Board Line Choke Resonant Choke Cooling Fan Bridge MOV 10uF Capacitors Current Sensor AC Fuse Block Diode Suppressor Bleeder Resistor Board 090 11 4 090 6L20135 090 11 3 090 11 1 090 11 2 090 6L10158 090 11 6 090 11 5 ...

Page 43: ...Legacy Insight Service Manual I B 1621 Rev A 6 10 14 42 SCHEMATIC N A FOR CEC CHARGERS ...

Page 44: ... Inc d b a Douglas Battery All Rights Reserved Trademarks and logos are the property of EnerSys and its affiliates unless otherwise noted 1255 Creekshire Way Suite 221 Winston Salem NC 27103 1 800 DOUGLAS 1 800 368 4527 www douglasbattery com ...