Legacy Insight Standard LI3, Insight Standard LI3C Service Manual

Model: Standard LI3

&

LI3C (CEC)

Legacy® Insight™ Battery Charger

Service Manual

Read and understand your user’s manual before installing, operating, or servicing this product.

I.B. 1621

Rev. A (6/10/14)

IMPORTANT

DO NOT DESTROY THIS BOOK

Legacy® Insight™

TABLE OF CONTENTS

AC Line Voltage Letter Codes .................... 2

Specialty Charger Option List .................... 2

Important Safety Instructions ..................... 3

Technical Information ................................. 4

Part Number ............................................ 4

Serial Number ......................................... 4

Battery Type ............................................ 4

Ampere-Hours ......................................... 4

Cells ........................................................ 4

Input AC Volts ......................................... 4

Input AC Amps ........................................ 4

Hz ............................................................ 5

Phase ...................................................... 5

DC Volts .................................................. 5

Rated DC Amps ...................................... 5

CEC ......................................................... 5

Installation .................................................... 6

Location ................................................... 6

Mounting Wall Chargers ......................... 6

Placing Floor Cabinet Chargers .............. 6

Stacking Multiple Chargers ..................... 6

Electrical Connections ............................ 7

On three phase units ............................... 7

Connecting Input Power .......................... 7

AC Connection ........................................ 7

Plug Polarity ............................................ 7

Grounding the Charger ........................... 7

Description of Operation ............................ 8

General ................................................... 8

Beginning the Charge ............................. 8

Charging .................................................. 8

AC Power Fail ......................................... 8

Series Charging ...................................... 8

Glossary ....................................................... 9

Wi-IQ™.................................................... 9

Charging Coefficient................................ 9

Compensation Charging ......................... 9

Charging Profile ...................................... 9

Cold Storage ........................................... 9

Equalization Charging ............................. 9

IGBT ........................................................ 9

Ionic Profile ............................................. 9

OPPOR Profile ........................................ 10

Power Diodes .......................................... 10

Refresh Charging .................................... 10

Power Diodes .......................................... 10

Rest Function .......................................... 10

CEC ......................................................... 10

Operating Instructions ................................

Wall Charger Control Panel ................. 12

Floor Charger Control Panel ................ 13

Menu Access ......................................... 14

Main Menu ........................................ 14

Memorizations ....................................... 14

Status ..................................................... 15

USB ......................................................... 16

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Service Manual I.B. 1621 Rev.A (6/10/14)

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 Start .................................... 18

Frequency ......................................... 18

Cable ................................................. 18

Network ............................................. 18

Option ............................................... 19

Electrovalve Time ............................. 19

Rst Memo/Status .............................. 19

Parameters ............................................. 20

Date/Time ......................................... 20

Daylight Savings ............................... 20

Language .......................................... 20

Region ............................................... 20

Contrast ............................................ 20

Change Password ............................ 20

Password ............................................... 20

Information ............................................. 20

Charging the Battery ............................. 21

Charger Idle Display ......................... 21

Delayed Start .................................... 21

Starting a Charge Cycle .................... 22

Effective Charge ............................... 22

End of Charge w/o Equalize ............. 23

End of Charge with Equaliz

Fault Codes ............................................ 24

Maintenance & Service ................................ 25

Testing of Components ............................... 26

Component Replacement ........................... 29

Wall Mounting Dimensions ......................... 30

Exterior Wall Cabinet Dimensions ............. 31

Floor Mounting Dimensions ....................... 32

Exterior Floor Cabinet Dimensions ........... 33

Technical Specifications ............................. 34

Replacement Parts ...................................... 35

Component Locations ................................. 39

Schematic ..................................................... 43

Mounting the Wi-iQ™ Adapter ................... 44

Wi-iQ™ Communications Setup ................ 45

e ............ 23

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Legacy® Insight™

Service Manual I.B. 1621 Rev.A (6/10/14)

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)

(volts rms)

Line

Frequency

(Hertz)

Comments

C 600 50 / 60 600 VAC only / AC power line filter X020-6L-4
Y 480 50 / 60 480 VAC only / AC power line filter X020-6L-3

W 240 50 / 60 240 VAC only / AC power line filter X020-6L-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

receptacle.
L10 10’ of DC cable.
L13 13' of DC cable.
L15 15' of DC cable.
L18 18' of DC cable.
L20 20' of DC cable.
L25 25' of DC cable.
L30 30' of DC cable.

NC

No DC cables ( NOT UL APPROVED)

PP Charger shipped on a Plastic Pallet

S Series DC Cables

Reference page 33 “Technical Specs” for charger cable sizes.

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Legacy® Insight™

Service Manual I.B. 1621 Rev.A (6/10/14)

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 the battery.

2. This charger has been designed to only charge flooded, lead-acid batteries. Read and understand all setup
and operating instructions before using the battery charger to prevent damage to the battery and to the
charger.

3. Do not touch non-insulated parts of the output connector or the battery terminals to prevent electrical shock.

4. During charge, batteries produce hydrogen gas which can explode if ignited. Never smoke, use an open
flame, or create sparks in the vicinity of the battery. Ventilate well when the battery is in an enclosed space.

5. Do not connect or disconnect the battery plug while the charger is on. Doing so will cause arcing and
burning of the connector resulting in charger damage or battery explosion.

6. Lead-acid batteries contain sulfuric acid which causes burns. Do not get in eyes, on skin, or on clothing. In
cases of contact with eyes, flush immediately with clean water for 15 minutes. Seek medical attention
immediately.

7. Only factory qualified personnel can service this equipment. De-energize all AC and DC power connections
before servicing the charger.

8. The charger is not for outdoor use.

9. Do not expose the charger to moisture. Operating conditions should be 0º to 104º F; 0 to 70% relative
humidity.

10. Do not operate the charger if it has been dropped, received a sharp hit, or otherwise damaged in any way.

11. For continued protection and to reduce the risk of fire, install chargers on a floor of non-combustible material
such as stone, brick, or grounded metal.

WARNING: The shipping pallet must be removed for proper and safe operation.

INSTRUCTIONS DE SÉCURITÉ IMPORTANTES

1. Ce manuel contient des informations et des consignes importantes pour l’emploi et l’utilisation du chargeur de
batteries industrielles. 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 de batterie pour
empêcher des dommages à la batterie et / ou au chargeur.

4. Ne pas être en contact avec les pièces sous-tension non-isolées tels que la prise de charge ou des
éléments de connexion de la batterie pour empêcher le choc électrique.

5. Pendant la charge, le dégagement d’hydrogène rend l’emploi de feu strictement interdit «risque d’explosion ».
Ne jamais fumer, employer une flamme nue, ou créez les étincelles à proximité de la batterie. Ventiler
suffisamment pour éviter toute condensation de gaz dans un espace restreint.

6. Ne brancher ou débrancher la batterie que si le chargeur est à l’arrêt. Faire ainsi risque d’endommager
la prise de charge pouvant avoir pour conséquence des dommages du chargeur ou l’explosion de la batterie.

7. Les batteries d’acide au plomb contiennent l’acide sulfurique, qui cause des brûlures. Eviter le contact avec
les yeux, la peau, ou sur l’habillement. Dans le cas de contact avec les yeux, et faut nettoyer immédiatement
avec de l’eau propre pendant 15 minutes et consulter un médecin immédiatement.

8. Seul le personnel qualifié par l’usine peut entretenir cet équipement. Pour le service, veuillez contacter la
société EnerSys ou l’un de ces représentant (1-800-251-6560)

9. Avant toute intervention d’entretien ou de réparation il faut s’assurer que le chargeur est hors tension et la
batterie est déconnectée.

10. Le chargeur n’est pas pour un usage extérieur.

11. Ne pas exposer le chargeur à l’humidité. Les conditions de fonctionnement devraient être – 15° à 40°c;
humidité relative de 0 à de 70%.

12. Ne pas mettre en fonctionnement le chargeur s’il a reçu un choc mécanique ou tout autre dommage di quel
que façon.

13. Pour une protection permanente et pour réduire le ri sque du feu, installez les chargeurs sur un plancher ou
un matériel non-combustible tel qu’un mur plein en béton, en brique, ou l’acier.

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Legacy® Insight™

Service Manual I.B. 1621 Rev.A (6/10/14)

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 this reason it is required in any discussion or
correspondence regarding this unit.

L I 3 C– F 10 – 24 1Y O

Model type
Phase
CEC
Floor Cabinet (W = wall cabinet)
Power Level
Max Number of Cells
Input Volt code
Options

Serial Number

This number indicates complete information about the specific charger. It must be supplied
with the part number on any correspondence or discussion regarding this charger.

Battery Type

The chemical content construction of the battery this 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
must match exactly with any battery connected to the charger output.

Input AC Volts

The nameplate shows the input voltage accommodated by this charger.

IMPORTANT: The charger will operate only on nominal line voltages stamped on the
nameplate.

Failure to select the correct voltage will result in damage to the charger and/or the battery.

Input AC Amps

The external fusing and/or the line disconnect circuit breaker should be as specified in the
National Electrical Code or other local code agencies. (AC fuse values can be found on the
decal inside the charger).

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Legacy® Insight™

Service Manual I.B. 1621 Rev.A (6/10/14)

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

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.

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Legacy® Insight™

Service Manual I.B. 1621 Rev.A (6/10/14)

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,
and corrosive fumes. Also, avoid locations where temperatures are high or where liquids will
drip on the charger. Do not obstruct the ventilating openings or the space under the charger.

Mounting Wall Cabinet Chargers

The charger must be mounted on a wall or stand in a vertical position. The lower part of the
charger must be at least 24” from the ground and/or the charger below and the upper part 36”
from the ceiling. The minimum distance between two chargers must be12”.
The charger will be installed with four 5/16” bolts or with the bracket supplied. See the Wall
Mounting Dimensions section at the end of this manual for proper bolt pattern.

Placing Floor Cabinet Chargers

Allow at 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 the charger and any other chargers or equipment.

2. Place the second charger on top of the first. Align the bolt holes on each charger.

3. Fasten both charger cabinets together securely using 3/8” bolts and nuts.

NOTE: the two bolts toward the back of the
charger may be omitted if an after market metal

strap (about 8 inches) is used to secure both
chargers. Remove existing 1/4" screws of the
chargers' sides and attach strap with screws.
Refer to picture.
Hardware kit # X225-99-0-2 can be ordered to
attach two chargers.

4. Repeat steps 2 and 3 for the third charger.

5. Stacked chargers must be fastened to the
wall using devices suitable for the wall
construction and the bolt holes at the top of

TWO STACKED CHARGERS, RIGHT SIDE VIEW

the highest charger.

NOTE: Ambient temperature at all levels cannot exceed 104OF / 40OC.

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METAL STRAP

Legacy® Insight™

Service Manual I.B. 1621 Rev.A (6/10/14)

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 block)

Connecting Input Power

WARNING: Make sure the power to the charger is OFF and the battery is disconnected

before connecting the input power to the terminals of the charger.

Connect the input power to the appropriate terminals, including ground. Follow your local
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 observed when connecting to the
battery (read warning above).
Improper connection will open the DC fuse.

Grounding the Charger

DANGER: FAILURE TO GROUND THE CHARGER COULD LEAD TO FATAL ELECTRIC

SHOCK. Follow National Electric Code for ground wire sizing.

Connect a grounding conductor to the lug provided on the horizontal support panel. This lug is
marked as shown:

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Legacy® Insight™

Service Manual I.B. 1621 Rev.A (6/10/14)

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 range of capacities. The charging coefficient is maintained absolutely
on all types of batteries. Legacy® Insight™ chargers adapt to the battery’s capacity and its
discharge level.

Legacy® Insight™ chargers can easily be set to charge flooded batteries used in cold or
freezer storage applications, ionic or opportunity profiles. This battery charger is also designed
to charge flooded and sealed lead-acid storage batteries within the range of the cell and
ampere-hour rating as marked 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 charge parameters including the percentage of
battery capacity.

AC Power Fail

If the AC power fails with a battery connected to the charger during a charge cycle, the charger
will reset and start a new charge cycle when power is restored. All charger settings as well as
the time and date are preserved.

Series Charging

In series charging, the voltages of both batteries add up and must match charger’s nameplate
rating. The charger’s ampere-hour rating must be equal to each of the batteries’ ampere-hour
rating. Charge cycle will not start unless both batteries are connected.

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Legacy® Insight™

Service Manual I.B. 1621 Rev.A (6/10/14)

GLOSSARY

Charging Coefficient

The ratio of the number of ampere-hours restored during charging to the number of ampere­hours consumed during discharge.

Charging Profile

The charging profile defines the rate of current charge over time. The charger adapts to the
battery’s age and level of discharge. Controlling the overcharge coefficient, whatever the
battery’s discharge level, reduces the amount of electricity consumed.

Cold Storage

This is a charging profile that allows the configuration of the charger for use with batteries in
cold storage application. 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 mixing”. This type of charging profile consists of sending short pulses of
current to stimulate gas formation in the active material, causing sulfuric acid to be distributed
outside the plates. This system of mixing the electrolyte enables more rapid charging of
flooded cell batteries subject to very high demands and balances out differences in density,
homogenizing the electrolyte across the surface of the plates.

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Legacy® Insight™

Service Manual I.B. 1621 Rev.A (6/10/14)

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 equalize charge done once a week which is programmed to
run automatically.

Operation:

During opportunity charging the user can plug the battery in and charge it during breaks,
lunch or any work stoppage time. Sufficient time should be scheduled after the full
charge to allow the battery to completely cool to ambient temperatures before use.

Daily Charge:

When 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 diodes rectify the AC input and the output of the transformer.

Refresh Charging

Refresh or maintenance charging enables the battery to be maintained at maximum charge all
the time that it is connected to the charger.

Rest Function

The Rest function prevents the battery from being disconnected for a pre-defined period to
ensure a period of inactivity after charging.

CEC

Describes that the chargers are certified by the California Energy Commission.

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Legacy® Insight™

Service Manual I.B. 1621 Rev.A (6/10/14)

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). These chargers can automatically recharge
batteries in the following ranges 12-24-36V, 24-36-48V, and 48-72V* 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 are integrated.

V Jumper I Jumper Charger Output

6 12 10KW 48V/72V
6 11 10KW 48V/80V
6 15 15KW 48V/72V
6 14 15KW 48V/80V

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Legacy® Insight™

Control Panel

Service Manual I.B. 1621 Rev.A (6/10/14)

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 battery charge

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

RED fault indicator OFF = no fault

7.
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 off or battery not available
Flashing = cooling phase

ON = battery ready and available

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Legacy® Insight™

Service Manual I.B. 1621 Rev.A (6/10/14)

Menu Access

When the charger is idle, press and hold <ESC>, 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 <ESC> button.

The menus provide access to the following functions:

 Last 896 charging cycles (MEMORIZATIONS menu).
 Viewing of faults, alarms, etc. (STATUS menu).
 Download of data stored in the charger via the USB storage memory.
 Charger configuration (CONFIGURATION menu).
 Setting of date, language and others (PARAMETERS menu).
 Management 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

Memorizations

The charger can display the details of the last 896 charge cycles.

Memorization Access

On the Main Menu, select Memo and press <Enter>.

Memorizations Display Screen

The display shows here the charges have been stored in memory (title line). MEMO 1 is the
latest charge memorized. After memorizing the two-hundredth charge, the oldest record is
deleted and replaced by the next oldest.

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