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Legacy Insight Standard LI3 Service Manual

Summary of Insight Standard LI3

  • Page 1

    I.B. 1621 rev. 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

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 1 table of contents ac line voltage letter codes .................... 2 specialty charger option list .................... 2 important safety instructions ..................... 3 technical information ................................. 4 part...

  • Page 3

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 2 ac line voltage letter codes the following table describes the code letters to be used in new charger part numbers to indicate the ac line voltage(s) and ac line frequency at which the charger can be operated. Code letters voltage(s) (volt...

  • Page 4

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 3 important safety instructions 1. This manual contains important safety and operating instructions. Before using the battery charger, read all instructions, cautions, and warnings on the battery charger, the battery, and the product using t...

  • Page 5

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 4 technical information the nameplate, located on the outside of the charger, should be used to check this application before installation. Part number this number specifies in general the characteristics of this particular charger and for t...

  • Page 6

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 5 hz this gives the frequency in cycles per second of the ac input voltage. Under no conditions operate charger at a different frequency or from a generator with unstable frequency. Phase number "3" indicates a three phase charger. Dc volts ...

  • Page 7

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 6 two stacked chargers, right side view metal strap installation warning: the shipping pallet must be removed for proper and safe operation. Location for maximum trouble-free service, choose a location which is free of excess moisture, dust,...

  • Page 8

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 7 electrical connections to prevent failure of the charger, be sure it is connected to the correct line voltage. On three phase units connect all chargers as follows: phase a to l1 (fuse block) phase b to l2 (fuse block) phase c to l3 (fuse ...

  • Page 9

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 8 description of operation general legacy ® insight™ chargers are microprocessor-controlled. The processor calculates the battery’s capacity so that the charging profile can be automatically adapted to the battery’s actual state over a wide ...

  • Page 10

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 9 glossary charging coefficient the ratio of the number of ampere-hours restored during charging to the number of ampere- hours consumed during discharge. Charging profile the charging profile defines the rate of current charge over time. Th...

  • Page 11

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 10 oppor profile the oppor charge profile is used when opportunity charging is desired. It has a start rate of 25% of the batteries rated amp hour capacity, requires one opportunity recharge in every 24 hours of service and must have an equa...

  • Page 12

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 11 operating instructions the legacy ® insight™ series of chargers are compatible with batteries at 12, 24, 36, 48, 72 and 80 volts (depending on the version supplied). Thesechargers can automatically recharge batteries in the following rang...

  • Page 13

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 12 control panel 003 ref. Function description 1. Graphical lcd display. Display charger operation info/menus 2. Navigate up button navigate menus/change values 3. Enter/stop&start button select menu items/enter values/stop and restart batte...

  • Page 14

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 13 menu access when the charger is idle, press and hold , the main menu is then displayed. The current menu is automatically exited after six minutes of inactivity or can be exited voluntarily by pressing the button. The menus provide access...

  • Page 15

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 14 displaying a charge cycle proceed as follows: 1. Select a record (memo x) using the ▲/▼ buttons. 2. Display the first history screen by pressing enter. 3. Display the second history screen by pressing ▼. 4. Return to the main menu by pres...

  • Page 16

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 15 usb this menu provides access to the usb function. The charger can store charging data in a usb memory. Password is required to view this menu. Record memo enables the storage of charge memorizations and the status data to a usb data stor...

  • Page 17

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 16 capacity battery capacity used by the charger (must be set to “manu” for ionic profile) to determine start and finish rates. Temperature this parameter adjusts the regulation voltages on the charging profile (values between –15°c / 5°f an...

  • Page 18

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 17 float charge this feature can be turned on or off depending on the application. A float charge at the end of standard charge is intended to compensate for consumption by the truck electronics that are left on when truck is not used (typic...

  • Page 19

    Legacy ® 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

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 19 parameters date/time sets date and time of the charger. The clock has a battery backup which will preserve the time when power to the charger is off. Daylight savings enable or disable automatic clock adjustment for daylight savings time....

  • Page 21: Connbatt

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 20 charging the battery at this point, the charger should have been set up by a qualified service person. Charging can only begin with a battery of the proper type, capacity and voltage connected to the charger. Charger idle display with the...

  • Page 22: Charge

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 21 starting a charge cycle the charger will start automatically when a battery is connected or push the stop/start button if the battery is already connected. Effective charging starts after a 20 second countdown. The charger uses profile, c...

  • Page 23

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 22 end of charge without equalization the green complete led comes on after proper end of charge. The green complete led is on and the display shows avail. The display alternates between:  total charging time.  amp/hrs restored to the batt...

  • Page 24: Tº

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 23 fault codes in case of a fault, one of the corresponding fault codes listed below will appear on the display. If it is a critical fault, charging will stop and the red fault led will be illuminated. Fault critical cause solution df1 yes l...

  • Page 25

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 24 maintenance & service caution: there are dangerous voltages within the battery charger cabinet. Only qualified personnel should attempt to adjust or service this battery charger the charger requires a minimum amount of maintenance. Connec...

  • Page 26

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 25 testing of components only qualified personnel should service this battery charger 1: input fuses schematic symbol: f1, f2, f3 disconnect the ac power and the battery before opening the charger door. This check is carried out using a mult...

  • Page 27

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 26 3: dc output fuse schematic symbol: f3 disconnect the ac power and the battery before opening the door. The checking of output fuse f3 is carried out with the multimeter in Ω position. 4: output diodes schematic symbol: g3, g4, g5, g6 dis...

  • Page 28

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 27 5: fans (thermal fault) schematic symbol: ev1, ev2, ev3 (some models) set the multimeter to position vac turn on the charger (ac power supply, battery connected). Open the door and carefully measure the fan voltage. To check fan coil, dis...

  • Page 29

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 28 component replacement important: disconnect battery and turn ac power off before servicing. Igbt, bridge rectifier, or diode replacement on aluminum heatsink: removal igbt: remove mov, snubber caps, and unscrew the buss bars from the igbt...

  • Page 30

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 29 wall mounting dimensions wall 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...

  • Page 31

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 30 exterior wall 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...

  • Page 32

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 31 floor mounting dimensions front back.

  • Page 33

    Legacy ® insight™ 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

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 33 technical specifications kw - output voltage codes ac input dc output max 8 hour capacity (ah) charger cable awg voltage max amps phase cells max current (a) 4-1t 208 12.4 3 12/18/24 85/80/70 530/500/400 #2 4-1w 240 11.4 3 12/18/24 85/80/...

  • Page 35

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 34 replacement parts and quantity part number description 4 ‐1t 4 ‐1w 4 ‐1y 4 ‐1c 4 ‐3t 4 ‐3w 4 ‐3y 4 ‐3c 6 ‐1t 6 ‐1w 6 ‐1y 6 ‐1c 6 ‐3t 6 ‐3w 6 ‐3y 6 ‐3c 8 ‐1t 8 ‐1w 8 ‐1y 8 ‐1c 10 ‐1w 10 ‐1y 10 ‐2y 10 ‐1c 10 ‐2c 15 ‐1y 15 ‐1c 15 ‐2y 15 ‐2c ...

  • Page 36

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 35 replacement parts and quantity part number description 4 ‐1t 4 ‐1w 4 ‐1y 4 ‐1c 4 ‐3t 4 ‐3w 4 ‐3y 4 ‐3c 6 ‐1t 6 ‐1w 6 ‐1y 6 ‐1c 6 ‐3t 6 ‐3w 6 ‐3y 6 ‐3c 8 ‐1t 8 ‐1w 8 ‐1y 8 ‐1c 10 ‐1w 10 ‐1y 10 ‐2y 10 ‐1c 10 ‐2c 15 ‐1y 15 ‐1c 15 ‐2y 15 ‐2c ...

  • Page 37

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 36 replacement parts and quantity part number description 4 ‐1t 4 ‐1w 4 ‐1y 4 ‐1c 4 ‐3t 4 ‐3w 4 ‐3y 4 ‐3c 6 ‐1t 6 ‐1w 6 ‐1y 6 ‐1c 6 ‐3t 6 ‐3w 6 ‐3y 6 ‐3c 8 ‐1t 8 ‐1w 8 ‐1y 8 ‐1c 10 ‐1w 10 ‐1y 10 ‐2y 10 ‐1c 10 ‐2c 15 ‐1y 15 ‐1c 15 ‐2y 15 ‐2c ...

  • Page 38

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 37 replacement parts and quantity part number description 4 ‐1t 4 ‐1w 4 ‐1y 4 ‐1c 4 ‐3t 4 ‐3w 4 ‐3y 4 ‐3c 6 ‐1t 6 ‐1w 6 ‐1y 6 ‐1c 6 ‐3t 6 ‐3w 6 ‐3y 6 ‐3c 8 ‐1t 8 ‐1w 8 ‐1y 8 ‐1c 10 ‐1w 10 ‐1y 10 ‐2y 10 ‐1c 10 ‐2c 15 ‐1y 15 ‐1c 15 ‐2y 15 ‐2c ...

  • Page 39

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 38 large wall charger component locations ac fuse display board bridge rectifier resonant capacitors power transformer diodes shunt dc fuse igbt snubber capacitor control board power board line choke resonant choke cooling fan ac power line ...

  • Page 40

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 39 small wall charger component locations ac fuse display board bridge rectifier resonant capacitors power transformer diodes shunt dc fuse igbt snubber capacitor control board power board line choke resonant choke cooling fan ac power line ...

  • Page 41

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 40 floor charger large configuration component locations ac fuse bridge rectifier resonant capacitors power transformer 090-6l10158 shunt dc fuse igbt snubber capacitor control board power board 10uf capacitors resonant choke cooling fan igb...

  • Page 42

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 41 floor charger small configuration component locations ac fuse bridge rectifier resonant capacitors power transformer diodes shunt dc fuse igbt mov snubber capacitor control board power board line choke resonant choke cooling fan bridge mo...

  • Page 43

    Legacy ® insight™ service manual i.B. 1621 rev.A (6/10/14) 42 schematic n/a for cec chargers.

  • Page 44

    I.B. 1621 rev.A 4/13 ©2013 enersys delaware 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.