TL-Series AEMVC
Contents
1. operation follow these instructions carefully in the exact sequence A THE CHARGER MUST BE SWITCHED OFF BEFORE CONNECTING IT TO THE BATTERY Check that both the Volt Meter and the Amp meter indicate ZERO Check that the Current Potentiometer is in position ZERO B CONNECT THE BATTERY The charger is protected against the polarity reversal however check the battery polarity when connecting the battery leads When the battery is connected read its voltage on the Volt Meter Page 10 12 TOTALIFT MULTI VOLTAGE CHARGER MVC USER S MANUAL C SWITCH ON THE CHARGER BV PROGRAMMING THE TIME OF CHARGE ON THE TIMER The control circuits and the cooling system of the charger are powered D WHILE THE CURRENT POTENTIOMETER IS STILL IN POSITION ZERO SELECT THE REQUIRED BATTERY VOLTAGE WITH THE APPROPRIATE KNOB The current remains ZERO Please look and understand how the voltage selector works there are two sectors which can be selected with the small switch and the knob can move on six nominal voltages 2 4 6 8 10 12 V or 24 36 48 72 80 96 V The table below the selector indicates the actual regulated voltages To use the MVC as Current Generator set the voltage Knob to 96V and the small switch to 2 4V cell The maximum output voltage provided by the MVC in this configuration is 115 2V The MVC can provide the maximum output current shown on the technical label with a maximum output voltage of 115 2V E ADJUST THE OUTPUT CURREN2. T TO THE DESIRED VALUE USING THE CURRENT POTENTIOMETER While you increase the current be sure the battery connectors are making 100 contact to avoid the risk of sparks and or fire During the charge the current and the voltage can be modified directly with the appropriate knob and potentiometer HOW TO STOP THE CHARGER AND DISCONNECT THE BATTERY A Caution Before using the charger take the time to read all this manual carefully A Caution For a safe operation follow these instructions carefully in the exact sequencel A SET THE CURRENT POTENTIOMETER TO ZERO Check on the AMP METER that the current is now ZERO B SET THE VOLTAGE SELECTION KNOB TO 24V C MOVE THE TIMER TO POSITION ZERO D DISCONNECT THE BATTERY Page 11 12 TOTALIFT MULTI VOLTAGE CHARGER MVC USER S MANUAL THERMAL PROTECTION If the cooling system fails and or the electronic components of the charger reach a temperature higher than a maximum value the current is automatically set to ZERO until the temperature decreases below the limit and the red status LED THERMAL PROTECTION is activated END OF MANUAL Page 12 12
3. TOTALIFT TL Series AEMVC User Manual KOAU Index 1 2 Hak gore li eji le tA Responsibility disclaimer Safety Instructions and Warningg GONnClal ka sa A ENA hee Shock PrEVENTON sees iissesssrssndveedisnscidecvendeceens Burn and bodily injury prevention Fire and explosion prevention Arcing and burning of connector Medical and first aid treatment Equipment warning labels senere Description of the Charger fechnicaladatat sis ma rem Installation of the Charger AC input connection of the charger How to move the charger en How to Use the Charger How to connect the batterv and start the charge How to stop the charger and disconnect the batterv Thermal protection Page 2 12 OMDONAAAAAARA A HRW OW TOTALIFT MULTI VOLTAGE CHARGER MVC USER S MANUAL 1 INTRODUCTION Before using your MVC battery charger please take the time to read these instructions carefully The owner s manual is an important part of the charger It s recommended to keep it in good condition for the lifetime of the charger It should be kept in a dry and clean place always available to the users To indicate important instructions the following pictures are used Caution This operation can be dangerous for the user Attention This operation is important for the good workin
4. a place subject to direct sunlight excessive dust mechanical vibration or shock AC INPUT CONNECTION OF THE CHARGER Check the quality of the input building circuitry Connect the charger to the mains using an adequate plug with switch and fuses Use an adequate wire and plug to connect the charger to the battery Refer to the data label on the charger for maximum input power KVA and current AMPS The charger doesn t need AC input voltage adjustments however it s recommended to check with an adequate AC voltmeter that the input voltage is within the specified range Page 8 12 TOTALIFT MULTI VOLTAGE CHARGER MVC USER S MANUAL HOW TO MOVE THE CHARGER gt gt gt gt Caution Caution Caution Caution Before moving the charger disconnect it from the main supply and from the battery To protect the charger while moving use the original package or equivalent Don t use hooks to lift a charger Don t rotate the charger while moving it must be kept in a vertical position If the charger is moved using a forklift or a transpallet the cables should be fixed to the top of the charger with adhesive tape Page 9 12 TOTALIFT MULTI VOLTAGE CHARGER MVC USER S MANUAL 5 HOW TO USE THE CHARGER VOLTMETER TIMER AMPEROMETER CURRENT POTENTIOMETER HOW TO CONNECT THE BATTERY AND START THE CHARGE A Caution Before using this charger take the time to read all this manual carefully A Caution For a safe
5. and body protection when near batteries FIRE AND EXPLOSION PREVENTION When batteries are being recharged they generate hydrogen gas that is explosive in certain concentrations in air the flammability or explosive limits are 4 1 to 72 hydrogen in air The spark retarding vents help slow the rate of release of hydrogen but the escaping hydrogen may form an explosive atmosphere around the battery if ventilation is poor The ventilation system should be designed to provide an adequate amount of fresh air for the number of batteries being charged This is essential to prevent an explosion Always keep sparks flames burning cigarettes and other sources of ignition away from the battery recharging area Do not break live circuits at the terminals of batteries Do not lay tools or anything that is metallic on top of any battery ARCING AND BURNING OF CONNECTOR To prevent arcing and burning of the connector contacts be sure the charger is OFF before connecting or disconnecting the battery The ammeter should NOT indicate current flow MEDICAL AND FIRST AID TREATMENT First aid facilities and a qualified first aid person should be available for each shift for immediate treatment of electrical shock victims EMERGENCY FIRST AID Call phisician and ambulance immediately and use First Aid techniques recommended by the American Red Cross In case of acid in the eyes flush very well with clean water and obtain professional medical attentio
6. are the following devices not available to the user AC and DC power contactors Power transformer Rectifier DC link Capacitors Cooling system heatsink fan High Frequency Power Module Main driver board Auxiliary board for reverse polarity protection Auxiliary board for voltage control Output inductor Output fuse Please refer to the MVC SERVICE MANUAL for a detailed description of the internal parts and circuits Page 7 12 TOTALIFT MULTI VOLTAGE CHARGER MVC USER S MANUAL 4 INSTALLATION OF THE CHARGER Conditions of use e Operating temperature 5 C to 40 C e Storage temperature 20 C to 60 C e Relative humidity less than 75 Caution The charger should be installed by qualified personnel only Attention Check that the unit s maximum input power is available from your power supply Check that the unit s operating voltage is identical to your local power supply Attention To prevent fire or shock hazard do not expose the unit to rain or moisture Do not use the unit in presence of flammable gas because it can generate sparks Caution To avoid electrical shock do not open the cabinet Refer servicing to qualified personnel only gt gt gt PP Attention Allow adequate air circulation to prevent internal heat build up Do not place the unit near materials that may block the ventilation slots Do not install the unit near heat sources such as radiators or air ducts or in
7. d through study and training before using this equipment Only qualified personnel should install use or service this equipment SHOCK PREVENTION Bare conductors or terminals in the output circuit or ungrounded electrically live equipment can fatally shock a person To protect against shock have a certified electrician verify that the equipment is adequately grounded and identify what terminals and parts are electrically HOT The body s electrical resistance is decreased when wet permitting dangerous current to flow through the body Do not work in a damp area without being extremely careful Stand on a dry rubber mat or dry wood and use insulating gloves when dampness or sweat cannot be avoided Keep clothing dry INSTALLATION AND GROUNDING A power disconnect switch must be located at the equipment Check the data label for voltage and phase requirements If only 3 phase power is available connect single phase equipment to ONLY TWO WIRES of the 3 phase line DO NOT CONNECT the equipment grounding conductor to the third live wire of the 3 phase line as this makes the equipment frame electrically HOT which can cause a fatal shock If a grounding conductor is part of the power supply cable be sure to connect it to a properly grounded switch box or building ground If not part of the supply cable use a separate grounding conductor Don t remove a ground prong from any plug Use correct mating receptacles Check ground for electrical c
8. g of the charger gt gt gt On the charger this picture is placed near devices having dangerous high voltages The charger is marked with a technical label reporting the following data C CSA US mark CE mark Model Serial number Weight Input voltage Maximum input current A Maximum power consumption KVA Input frequency Maximum voltage of the battery output voltage Maximum charge current output current RESPONSIBILITY DISCLAIMER The manufacturer of the MVC battery charger will not be responsible for damages and or injuries caused by the charger in these situations The charger is not installed properly by a qualified electrician Maintenance operations are not done by a qualified electrician The charger is not used according to the instructions included in this manual The charger is not connected to the correct input supply see data label on the box The battery is damaged during the charge The charger has been modified without the authorization of the manufacturer Non original spare parts are used in the charger Wrong spare parts are used in the charger Page 3 12 TOTALIFT MULTI VOLTAGE CHARGER MVC USER S MANUAL 2 SAFETY INSTRUCTIONS AND WARNINGS GENERAL Battery charging products can cause serious injury or death or damage to other equipment and property if the operator does not strictly observe all safety rules and take precautionary actions Safe practices must be learne
9. n immediately EQUIPMENT WARNING LABELS Inspect all precautionary labels on the equipment Order and replace all labels that cannot be easily read 3 DESCRIPTION OF THE CHARGER A Caution This charger should be used by qualified personnel only Page 5 12 TOTALIFT MULTI VOLTAGE CHARGER MVC USER S MANUAL AN Caution This charger has been designed for professional use All the charge parameters must be set bv the user at everv charge cvcle therefore it s not suitable as a replacement for traditional chargers TS TL ETC gt Attention This charger does not have protection devices for the battery and it s not automatic therefore it s necessary to set the charger parameters properly before every charge cycle A Attention If the charger is not configured properly the battery can be damaged Read the technical documentation of the charger and the battery before using them and keep the temperature of the battery under control as long as it is connected with the charger The AEMVC Multi voltage battery chargers have been designed to charge Pb batteries This equipment can convert the AC main supply in a DC output at the correct voltage in order to charge the battery cells This charger is controlled by a high frequency switch mode regulator therefore it can charge batteries of any type any voltage and ampere hour size Refer to the data label on the charger for the maximum output DC voltage and the maximum outpu
10. ontinuity before using equipment The grounding conductor must be of a size equal to or larger than the size of the line conductors CHARGING LEADS Inspect leads often for damage to the insulation Replace or repair cracked or worn leads immediately Use leads having sufficient capacity to carry the operating current without overheating BATTERY TERMINALS Do not touch battery terminals while equipment is operating SERVICE AND MAINTENANCE Shut OFF all power at the disconnect switch or line breaker BEFORE inspecting adjusting or servicing the equipment Lock switch OPEN or remove line fuses so that the power cannot be turned ON accidentally Disconnect power to equipment if it is to be left unattended or out of service Disconnect battery from charger Measure voltage on capacitors and if there is any voltage reading wait 5 minutes before to proceed Keep inside parts clean and dry Dirt and or moisture can cause insulation failure This failure can result in high voltage at the charger output BURN AND BODILY INJURY PREVENTION The battery produces very high currents when short circuited and will burn the skin severely if in contact with any metal conductor that is carrying this current Do not permit rings on fingers to come in contact with battery terminals or the cell connectors on top of the battery Page 4 12 TOTALIFT MULTI VOLTAGE CHARGER MVC USER S MANUAL Battery acid is very corrosive Always wear correct eye
11. t DC current Two operating modes can be chosen e Current generator e Ua battery charger Current Voltage Voltage Current Time In Current generator mode it s possible to connect any type of battery or other loads to the charger The output current is regulated from zero to the maximum value with the appropriate potentiometer and the timer is used to set the total time of charger at constant current This feature is useful to recover old sulphated batteries or to charge stacks of cells Page 6 12 TOTALIFT MULTI VOLTAGE CHARGER MVC USER S MANUAL In IUa battery charger mode it s possible to select the voltage threshold with the appropriate knob and selector The current can be regulated with the appropriate potentiometer from zero to the required value and the time of charge can be set with the timer When the voltage of the battery reaches the threshold value the charger keeps this voltage constant while the current decreases TECHNICAL DATA External size 500 x 440 x 900 mm Weight 90 150 kg see data label These are the principal devices included in the charger available to the user LED Control panel Amp meter Analog or Digital Volt meter Analog or Digital Timer Mechanical or Digital Knob Selector for battery voltage setting Potentiometer for output current setting No 2 Cables for battery connection No 1 Cable for main supply connection Inside the charger there
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