Douglas Battery LegaC2 DL1 User manual

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I.B. 1660
Rev A (5/16)
IMPORTANT
Read and understand your user’s manual before installing, operating or servicing this product.
DO NOT DESTROY THIS BOOK
Model: DL1/DL3
LegaC
2™Battery Charger
Owner’s Manual

LegaC2 ™
Owner’s Manual
I.B. 1660
1
TABLE OF CONTENTS
Important Safety Instructions ............. 2
Technical Information.......................... 3
Part Number............................................3
Output Power Letter Codes..............3
Cabinet Size/Gauge Letter Codes....4
DC Voltage Number Codes..............4
AC Line Voltage Letter Codes..........4
Charge Profile Letter Codes.............5
Specialty Charger Option List...........5
Serial Number .........................................5
Battery Type............................................5
Max AH....................................................5
No. Cells..................................................5
Max Modules...........................................5
Config Modules .......................................6
Hertz........................................................6
Phase......................................................6
AC Volts ..................................................6
Config AC Amps......................................6
Max AC Amps .........................................6
Max DC Amps.........................................6
DC Volts..................................................6
Config DC Amps .....................................6
CEC .........................................................6
cULus......................................................6
Installation............................................ 7
Location...................................................7
Wall Mount Cabinet Chargers.................7
Electrical Connections.............................7
Connecting Input Power..........................7
AC Connection........................................7
Plug Polarity............................................7
Grounding the Charger ...........................7
Description of Operation..................... 8
General....................................................8
Starting the Charge Cycle.......................8
Charging Current.....................................8
AC Power Fail .........................................8
Series Charging ......................................8
Glossary............................................... 9
Charging Profile ......................................9
Cold Storage Profile................................9
Equalization Charging.............................9
STD Flooded (IEI) Profile........................9
Gel-Bloc Profile .......................................9
VRLA Profile............................................9
Opportunity Profile ..................................9
Operation............................................9
Complete Charge Time......................9
Refresh Charging....................................9
Operating Instructions ........................ 10
Control Panel ....................................... 11
Menu Access........................................ 12
Main Menu...............................................12
Memorizations......................................12
Memorizations Display Screen................12
Displaying a Charge Cycle......................12
Memorization Data ..................................13
Status....................................................13
Status Screen..........................................13
USB .......................................................14
Update Software....................................14
Parameters ...........................................14
Date/Hour ..............................................14
Language...............................................14
Region ...................................................14
Display...................................................14
Contrast..............................................14
Screen Saver......................................14
Delay ..................................................14
Daylight Savings....................................14
Password..............................................15
Charging the Battery............................16
Charger Idle Display..............................16
Starting a Charge Cycle ........................16
Delayed Start.........................................16
Effective Charge....................................17
End of Charge without Equalization ......18
End of Charge with Equalization ...........18
Automatic Equalization Start .................18
Fault Codes ..........................................19
Fault Display..........................................19
Maintenance and Service.....................21
1 kW Stand Alone Cabinet Mounting
Dimensions.....................................22
1 kW 3 Bay Cabinet Mounting
Dimensions.....................................23
1 kW 6 Bay Cabinet Mounting
Dimensions.....................................24
3.5 kW 4 Bay Cabinet Mounting
Dimensions.....................................25
3.5 kW 6 Bay Cabinet Mounting
Dimensions.....................................26
Technical Specifications......................27
Maintenance Log..................................33

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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 charge 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 32º to 113º F (0º to 45º C); 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.

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TECHNICAL INFORMATION
The nameplate, located on the outside of the charger, should be used to check this application
before installation.
Part Number
This is the charger part number and specifies the characteristics of
this particular charger and for this reason it is required in any
discussion or correspondence regarding this unit.
DL3 - LP –4YOR
Model Type
Phase
Output Power
Cabinet Size
DC Voltage Code
AC Line Voltage Code
Charge Profile
Options
Output Power Letter Codes
The following table describes the letter codes to be used in charger
part numbers to indicate the Output Power of the charger.
Letter
Code
Output Power
(kW)
Number
Modules
Module Power
(kW)
A
1.0
1
1.0
B
2.0
2
1.0
C
3.0
3
1.0
D
4.0
4
1.0
E
5.0
5
1.0
F
6.0
6
1.0
G
3.5/2.5*
1
3.5/2.5*
H
7.0/5.0*
2
3.5/2.5*
I
10.5/7.5*
3
3.5/2.5*
J
14.0/10.0*
4
3.5/2.5*
K
17.5
5
3.5
L
21.0
6
3.5
*Three-phase/single-phase

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Cabinet Size/Gauge Letter Codes
The following table describes the letter codes to be used in charger part numbers to indicate
the number of slots and size of DC cables.
Letter
Code
Module
Positions
Standard Cable
Gauge
Comments
K
1
10 AWG
Stand alone, 1kW cabinet
L
2
1/0
Two slots, 3.5kW cabinet
M
3
4 AWG
Three slots, 1kW cabinet
N
4
3/0
Four slots, 3.5kW cabinet
P
6
2/0
Six slots, 1kW cabinet
P
6
3/0
Six slots, 3.5kW cabinet
DC Voltage Number Codes
The following table describes the number codes to be used in charger part numbers to
indicate the DC output voltage(s) of the charger.
Number
Code
Output
Voltage(s)
1
12
2
24
3
36/48
4
24/36/48
5
72/80
AC Line Voltage Letter Codes
The following table describes the letter codes to be used in charger part numbers to indicate
the AC line voltage(s) and AC line frequency at which the charger can be operated.
Letter
Code
Voltage(s)
(Volts RMS)
Line
Frequency
(Hertz)
Comments
A
120
50/60
120 VAC only
C
600
50/60
600 VAC only
G
208/220/240
50/60
208/220/240 VAC
Y
480
50/60
480 VAC only

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Charge Profile Letter Codes
The following table describes the letter codes to be used in charger part numbers to indicate
the Charging profile of the charger.
Letter
Code
Profile
C
Cold Storage
E
STD Flooded (IEI)
G
Gel-Bloc
O
Opportunity
V
VRLA
Specialty Charger Options List
Suffix
Description
C6
6’ of #12AWG AC Cord
C10
10' of #12AWG AC Cord
C12
12' of #12AWG AC Cord
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
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)
Max AH
This is the maximum amp-hours capacity of this cabinet.
No. Cells
This is the number of battery cells this unit will charge. This number must match exactly with
any battery connected to the charger output.
Max Modules
This is the maximum number of modules the cabinet can hold.

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WARNING: THE NUMBER OF MODULES MUST MATCH THE NUMBER OF “CONFIG
MODULES” ON THE NAMEPLATE. DO NOT ADD MORE MODULES IN THE FIELD.
CONSULT THE MANUFACTURER IF MORE MODULES ARE NEEDED.
Config Modules
This is the number of modules this cabinet is configured for.
Hertz
This gives the frequency in cycles per second of the AC input voltage. Under no conditions
operate the charger at a different frequency or from a generator with unstable frequency.
Phase
Number "3" indicates a Three Phase Charger and “1” indicates a Single Phase Charger.
AC Volts
This is the nominal voltage this charger is rated for. The charger will only operate on this voltage.
Config AC Amps
This is the AC Amps this charger is configured for.
Max AC Amps
This is the maximum AC Amps this cabinet is rated for.
Max DC Amps
This is the maximum output DC Amps this charger is rated for.
DC Volts
This gives the nominal DC output voltage of the charger.
Config DC Amps
This is the output DC Amps this charger is configured for to deliver to a battery that is over 20%
discharged.
CEC
This logo is applied to chargers that are certified with the California Energy Commission in
compliance with Appliance Efficiency Regulations:
cULus
This logo is applied to chargers that have been tested to applicable standards and requirements
by Underwriters Laboratories (UL) and the Canadian Standards Association (CSA):
INSTALLATION

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WARNING: The shipping pallet must be removed for proper and safe operation.
Location
For maximum safe operation, 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 ventilation openings or the space under the charger.
Wall Mount Cabinet Chargers
The charger must be mounted on a wall or stand in a vertical position. The minimum distance
between two chargers must be 12”.
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.
NOTE: Ambient temperature at all levels cannot exceed 113° F (45° C).
Electrical Connections
To prevent failure of the charger, make sure it is connected to the correct line voltage.
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 and
National Electric Codes 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 may open the DC fuse and/or damage the charger.
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 Ground lug provided on the horizontal support panel.
This lug is marked as shown:

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DESCRIPTION OF OPERATION
General
Douglas LegaC2™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. LegaC2™chargers adapt to the battery’s capacity and its discharge level.
LegaC2™chargers can easily be set to charge flooded batteries used in cold or freezer storage
applications, IEI or opportunity profiles. This battery charger is also designed to charge flooded
and valve regulated lead acid storage batteries within the range of the cell and ampere-hour
rating as marked on the nameplate.
Starting the Charge Cycle
When a battery is connected to the charger, the control board senses the voltage and after a
short delay, the charger starts charging the battery.
Charging Current
Charging current is determined by the battery voltage and its state of charge condition. 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
DC Volts rating. The charger’s ampere-hour ratingmust be equal to each of the battery’s ampere-
hour rating. Charge cycle will not start unless both batteries are connected.

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GLOSSARY
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 Profile
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.
STD Flooded (IEI) Profile
The profile is an IEI (constant current, constant voltage, constant current) type with a number of
user configurable parameters.
Gel-Bloc Profile
This charging profile is an IEI (constant current, constant voltage, constant current) charging
profile designed for gelled electrolyte type sealed lead acid batteries.
VRLA Profile
This charging profile allows for valve regulated lead acid batteries to be charged. This charging
profile is an IEIE (constant current, constant voltage, constant current, constant voltage) type.
Opportunity Profile
This charging profile is used when opportunity charging is desired. It has a start rate of 25% of
the battery’s 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 equalize
charge to allow the battery to completely cool to ambient temperature before use.
Complete Charge Time
This is the time of day for a Complete charge.
NOTE: The factory default is complete charge disable, 6 hour Equalize, Sunday at 00 hour.
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.

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OPERATING INSTRUCTIONS
The LegaC2™series of chargers are compatible with batteries of 12, 24, 36, 48, 64, 72 and 80
volts (depending on the version supplied).
Battery recognition (voltage, capacity and state of charge) is accomplished automatically by the
microprocessor. Several charging profiles are available (Cold Storage, STD Flooded [IEI],
Opportunity, Gel-Bloc, VRLA) based on the configuration chosen by the operator. Furthermore,
equalization and refresh charges are integrated.

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CONTROL PANEL
Ref.
Function
Description
1
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
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 off or battery not available
Flashing = cooling phase
ON = battery ready and available
10
USB port
Download memos/Upload software
8
9
6
1
2
5
7
4
3
10

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MENU ACCESS
When the charger is idle, press and hold <ESC>, the Main Menu is then displayed. The main
menu is automatically exited after 60 seconds of inactivity or can be exited voluntarily by pressing
the <ESC> button.
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.
The menus provide access to the following functions:
View last 200 charging cycles (Memo menu).
View of faults, alarms, etc. (Status menu).
USB functions (USB menu).
Setting of date, language and others (Parameters menu).
Management of password (Password menu)
MEMORIZATIONS
Memorizations Display Screen
The charger can display the details of the last 200 charge cycles.
The display below shows one charge stored in memory. MEMO 1 is the latest charge memorized.
After memorizing the two-hundredth charge, the oldest record is deleted and replaced by the next
oldest.
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 pressing Esc.
The charge history is displayed; use the ▲/▼ to scroll through the parameters.

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Memorization Data
Memo
Description
Memo
Description
Profile
Selected profile
Chg Time
Time of the charge
cycle (minutes)
Capacity
Rated battery capacity
(AH)
Ah
Amp-hours returned
during charge cycle
U batt
Rated battery voltage (V)
SoC
Start of charge date
and time
Temp
Battery temperature at
start of charge (F)
DBa
Battery disconnect date
and time
% init
State of charge at start of
charge (%)
Status
Partial or complete
U start
Battery voltage at start of
charge (Vpc)
Fault
Fault Codes
U end
Battery voltage at end of
charge (Vpc)
CFC
Termination code (for
service tech)
I end
Current at end
of charge
STATUS
This menu displays the status of the charger’s internal counters (number of normal and partial
charges, faults by type, etc.).
Status Screen
Status
Description
Charge
Total number of charges –corresponds to the total of normally
terminated charges and charges terminated with or by faults
Number of charges normally terminated
Number of charges terminated abnormally
DF1 etc.
Number of faults recorded by the charger (see Fault Codes)
TH
Number of charger temperature faults

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USB
This menu provides access to the USB function to update software.
Update Software
Updates charger’s internal software. The software is provided by EnerSys®.
PARAMETERS
Date/Hour
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.
Language
Selects the language displayed in the menus.
Region
Selects the format for date, metric (EU) or imperial (US) units for temperature, length and cable
gauge.
Display
Set screen saver function.
Contrast
Modifies the display contrast level (20 to 29).
Screen Saver
Enable or Disable the screen saver function.
Delay
Set the time the screen stays illuminated. The delay time is adjustable in minutes up to
one hour and 59 minutes.
DayLight
Enables or disables automatic clock adjustment for daylight savings time. When enabled, time
will move ahead on hour at 02:00 on the second Sunday in March and will move back one hour
at 02:00 on the first Sunday of November. The charger must be powered up at the time of the
change for it to take effect.

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PASSWORD
This is where the password is entered to gain access to service level menus by authorized
EnerSys®service personnel.

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CHARGING THE BATTERY
At this point, the charger should have been set up by a qualified service person. Charging can
only begin when a battery of the proper type, capacity and voltage is connected to the charger.
With the charger in wait mode (no battery connected) and without pressing the Stop/Start button,
the display will show the following information:
Charger Idle Display
Ref.
Description
1
Charger DC voltage
2
Firmware version
3
Selected charge profile
4
System time
5
System date
6
Connect battery
S11
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.
Delayed Start
If the charger was programmed for delayed start, charging will begin following that delay. When
the battery is plugged in to the charger, the display shows the time remaining before the
programmed charging starts.
Effective Charge
3
5
4
2
1
5
6

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A few moments into the effective charge, the display will begin alternating between the
following charging information:
Ref.
Description
1
Charge profile
2
Pending equalize symbol (if selected)
3
Charge current
4
Charge AH
5
Charge voltage (total V)
6
Charge time
7
Charge voltage (V/c)
8
Percent of charge
9
Estimated remaining charge time
End of Charge without Equalization
1
9
9
8
2
6
5
3
7
4

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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 battery
L2 0 1 0 24-3 6 -48V U S11
Any other lit LED indicates a problem during charging. Please refer to paragraph Control Panel
for more information.
If the battery remains plugged in and refresh charge has been enabled, refreshes will occur to
maintain an optimal charge.
The battery is now ready for use. Push the ON/OFF button before unplugging the battery.
End of Charge with Equalization
An Equalize charge can be started manually or automatically.
Manual Equalization Start
1. At the end of charge (green LED on or flashing), press on the <EQUALIZE> button. The
equalize button can also be pressed any time during the charge and an equalize charge
will be started after charging is complete.
NOTE: When an Equalize is manually started, the output current will be set to the value
saved in the charger configuration.
2. The start of the equalization charge is indicated by the message EQUAL. During the
equalization charge, the charger displays the output current and alternates, the battery
voltage and, voltage per cell, and remaining time.
L2010 24-36-48V US11
3. The battery will be available when the green LED comes back on and the display shows
AVAIL.
4. The battery is now ready for use. If the battery remains plugged in and refresh charge
has been enabled, refreshes will occur to maintain an optimal charge. Push the ON/OFF
button before unplugging the battery.
Automatic Equalization Start
If an equalization day has been programmed in Charger configurations the equalization charge
will start automatically on the programmed day of the week after charging is complete.
NOTE: The factory default IEI Equalize, 6 hour Equalize, Sunday at 00 hour.
The battery will be available when the green LED comes back on and the display shows AVAIL.
The battery is now ready for use. If the battery remains plugged in and refresh charge has been
enabled, refreshes will occur to maintain an optimal charge. Push the ON/OFF button before
unplugging the battery.
FAULT CODES

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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 Display
Fault
Critical
Cause
Solution
DF1
Yes
Low output current
Check input voltage and fuses. Call
for service.
DF2
Yes
Output fault
Check for proper battery connection
(reversed polarity). Check output fuse.
Call for service.
DF3
Yes
Improper battery
Battery voltage too high (>2.4 Vpc) or
too low (<1.6 Vpc). Use proper
charger for battery.
DF4
No
The battery has been
discharged more than 80%
of its capacity
Prevent future over discharging of
battery. Battery charge gauges and 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.
DF7
No
Inspect battery
Non critical fault. This will cause the
charge to terminate early. Battery may
require service.
Check the battery (temperature,
specific gravity…).
Check the battery condition of use.
Check the configuration in the menu
(charge cables parameters).
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.
MOD TH
No
Alternating with charge
parameters –one or more
module in thermal fault –the
charge process continues –
the fault module(s) is(are)
displayed + red led flashing.
Check that the fan(s) is(are) working
correctly and/or that the ambient
temperature is not too high or or
whether there is poor natural
ventilation to the charger. If all
modules are in thermal fault a TH fault
will follow.
MOD DFC
Yes
Alternating with charge
parameters –one or more
Check power modules. If all modules
in DF1 fault a DF1 error will follow.