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You can keep the Sansa plugged in without fear of overcharging. The Sansa will play while it is connected to a USB port that is supplying only power, such as a USB charger operating off a car cigarette lighter. It will not play while connected to a computer.
If you can turn your player on while being plugged to your PC/Laptop or USB charger, then your internal Lion battery is most likely gone past its useful life (some 500 charges or 18 months usage) and may need replacing.
Most MP3 player may show 'fully charged' when plugged in either when the battery is truly fully charge or defective battery is no longer taking a charge: e.g. minimum or no current flow situation.
If you let the battery get too low, the battery will not charge because the motherboard does not have enough power to control the charge process. There are two ways to fix this. 1) buy a new battery that will be supplied fully charged. 2) borrow a friends HDD065, fully recharge the battery and remove it. Place the battery in your player and turn it on. Put your player on charge. Without turning your player off or removing the charger, remove your friends battery and place yours in it. It may take a couple of attempts but you should be able replace your battery and keep the player operational. Leave your battery to fully charge.
I would agree with what the tech support agent(s) told you. What you are describing sounds like a bad battery. The Insignia® Piliot MP3 players have a one year limited warranty. For service you should take the MP3 player into your local Best Buy™ store with the receipt. The store will be able to assist you in diagnosing the problem and if needed having the item serviced or replaced.
Charging the Player The player needs to be charged before it can be used and every time the battery gets low. It takes approximately 2.5 hours to charge the Player. Once fully charged, the Player lasts approximately 8 hours. To charge the Player: Remove the USB cover on the Player. Connect the Player to the PC using the Flash Plug. The Player will begin charging. The battery indicator should begin to flash, alternating red and green. Once the battery is fully charged, the indicator light will stay red. Note: If this is the first time the Player is connected, wait until Windows detects the Player and follow the prompts to install it.
This player shows the "Do not disconnect" message when it is doing something critical such as transferring tracks or updating firmware, which could corrupt the player if disconnected part way through.
The player shows the "OK to disconnect" when it is idle. As the message says, it's ok to disconnect, as the player will not corrupt if disconnected when it is idle.
These messages mean that the player does not need the "Safe to remove" procedure.
It is ok to disconnect part way through charging. Also the player will condition the battery once it is fully charged, so it's ok to leave it charging.
Occassionally batteries can "memorise" when constantly disconnect and reconnected without fully charging and discharging. To help prevent this, fully discharge the player (leave on until dead) and fully charge and condition (leave charging for about 12 hours) every couple of weeks or so.
If you leave your Sansa plugged into your charging source (wall charger, computer, car etc.), your player might still remain fully charged and just on. If you can, you may want to just leave it plugged into your charging source until you want to use it, so it stays fully charged.When its done, it will say fully charge...it should take a couple hours to charge the device....
Also, does your player have an auto power off or idle sleep setting? You can use this setting to set the amount of time you want your Sansa to automatically turn off after you don't use or listen to music on it.