TOTALIFT Industrial Battery Chargers USER`S MANUAL
Contents
1. Singlephase 208 240V Threephase 208 240 480V 1 1x 240 VAC 240 VAC 490 VAC 1x 220 VAC 220 VAC 480 VAC 1x 208 VAC 208 460 VAC e Using an adequate AC voltmeter measure the value of the REAL AC input voltage available at the mounting location of the charger e Identify which of the NOMINAL voltage values available is closest to the REAL measured value e For the single phase units the wires to be moved are the TWO that are connected to the AC contactor marked with the letter A e For the three phase units the wires to be moved are the THREE that are connected to the AC contactors marked with the letters A and 4 HOW TO USE THE CHARGER PROGRAMMING THE GASSING POINT The possibility to program the gassing point may help the user to adjust the charging curve to the requirements of the battery during all its life The default value is 2 40 Volt cell This value can be modified by moving two dipswitches that are located on the MTL board near the microprocessor and the black heat sink see next picture The dipswitch unit has 4 switches the two central switches number 2 and number 3 are used for the programmation of the gassing point To modify the value follow these steps Disconnect the charger from main supply and battery Locate the dipswitches on the digital electronic board see next picture Set the dipsw2. WARNINGS Before using your TOTALIFT 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 blocks are used throughout this manual GENERAL Battery charging products can cause serious injury or death or damage to other equipment or property if the operator does not strictly observe all safety rules and take precautionary actions Safe practices must be learned 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 locate
3. When the power supply is available again the charger will re start automatically from the exact point of interruption and the charge will be normally completed BLOWN FUSE DETECTION e lf the output fuse is blown or absent the display will show the message Fuse Page 12 16 This message may appear also if the battery has been left discharged for long time causing the sulphation process on the plates AUTOMATIC CHARGE TERMINATION e When the charge is complete the charger shuts down and the display shows the scrolling message End Elapsed x x h The time indicated by the display is the time elapsed after the charge has been terminated This indication is useful when there is two or more forklift operated with FIFO First In First Out rotation when the user picks up a forklift he will always chose the one with highest he time elapsed after charge termination The final values of Voltage cell time of charge and capacity charged remain stored in memory If the red STOP pushbutton is pressed the display will show these values in sequence AUTOMATIC SHUTDOWN ON BATTERY DISCONNECTION If the battery is disconnected while the charge is in progress the TOTALIFT switches off automatically EQUALIZE amp REFRESH MODES TOTALIFT chargers have a complete set of programmable equalize amp refresh functions MANUAL EQUALIZE 4 hours extension of the charge time selected by user DAILY EQU
4. ALIZE 4 hours extension of the charge time everyday AUTO EQUALIZE amp REFRESH Weekly equalize cycle long term battery refresh The MANUAL EQUALIZE function is intended for the users that prefer to manage the equalization of the batteries personally It will extend the time of the charge cycle by 4 hours and it can be enabled by pushing the EQUALIZE button located on the right side of the front panel during the first minutes of charge The display will add the message Eq On to the cyclical visualization of the charge parameters and the charge will proceed normally Once the manual equalize has been selected the only way to deselect it is to disconnect and re connect the battery The DAILY EQUALIZE function will extend all the charge cycles by 4 hours and it s suitable to recover batteries that are lightly sulphated It can be enabled by moving the internal DIPSWITCH 1 to position ON see the description of the programming dipswitches in the previous paragraphs The DAILY EQUALIZE function is DISABLED by default Since the DAILY EQUALIZE is a very intense equalize program and may tend to overcharge the battery it s recommended to limit it to short periods then to return to a normal equalize program It s also recommended to survey the operation of the charger and keep the temperature of the battery under precise control while the DAILY EQUALIZE function is enabled The AUTO EQUALIZE REFRESH function is
5. TOTALIFT Industrial Battery Chargers TL24 TL36 TL48 TL72 TL80 USER S MANUAL V2 3 2010 Page 1 16 INDEX 1 Safety Instructions and Gener al E Shock Prevention Burn and Bodily Injury Fire and Explosion Arcing and Burning of Medical and First Aid 2 Description of The Charger 3 Installation of The Charger AC Input Connection AC Input Voltage Selection AG Input VoltaAGe S Cin Ste 4 How to Use The Charger Programming the Gassing Battery Connection Automatic Voltage Check and Auto Start Charge Operation Safety Timer Emergency Automatic Data Savings Blown Fuse Detection Automatic Charge Shut Down on Battery Equalization 8 Refresh Manual Charge Termination Page 2 16 1 SAFETY INSTRUCTIONS AND
6. atically disabled end of manual TOTALIFTE TL Series Ba ttery Charger Description The TOTALIFT TL series charger can be used with batteries of any type voltage and capacity at almost any temperature The output voltage and current normally follow a programmed charge curve however it s possible to also use the unit as a stabilized power supply with manually adjustable current limits This feature is useful to recover sulfated batteries Standard Features Fully automatic and fully digital Exclusive MTL2 digital technology Auto start stop Fully programmable microprocessor controlled charger with digital display Auto amp manual equalize options Start delay Anti scratch surface 10ft standard cables Programmable gassing voltages Elapsed time and elapsed time memory Push button memory readout Adaptive algorithm for charge time calculations Charger can be used with different battery capacities depending on time available for charge without the need for any adjustments by user Independent safety button for emergency shutdown selectable de sulfating cycle Self adjusts to 50 60 cycle to US Canada amp International specs Automatic maintenance refresh system for long time battery storage Automatic data saving in case of blackout amp auto start from point of interruption automatic saving of charger parameters Digital indication of voltage capacity return time of charge and cool do
7. d 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 continuity 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 the 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 Page 3 16 Disconnect power to equipment if it is to be left unattended or out of service Disconnect battery from charger Keep insid
8. e 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 Battery acid is very corrosive Always wear correct eye 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 cha
9. ell the charger shuts down automatically and the error message Voltage High will appear on the display CHARGE OPERATION When the charge is started the digital display will start showing the following parameters e Voltage per cell of the battery U Volt e Charge current A Ampere e Capacity charged Time of charge h Hours During all the charge cycle these parameters are displayed in sequence as indicated in the picture The letter U A C h indicates which parameter is being displayed To display the time the charger uses this format HOURS MINUTE DECADES h Examples Time of charge 3h 30minutes Displayed 3 3h Time of charge 7h 50minutes Displayed 7 5h e The charge current follows the Wa curve as described in the norm DIN 41774 while the charge parameters continue to be shown on the digital display Current Tension 7 Tension Initial Current about 16 of battery capacity Tension 2 40 Current 50 of Initial Current Tension 2 00 Current Time Page 11 16 When the battery reaches the gassing voltage the charge continues for one half of the time needed to reach the gassing voltage with a minimum total time of 30 minutes Examples e if the battery reaches the gassing voltage in 1 minute the final charge will continue for 30 minutes e if the battery reaches the gassing voltage in 5 hours the final charge will continue for 2 hou
10. gital Charge Controller which is a microprocessor based electronic board of the latest generation Important features of the MTL2 Digital charge controller are Easy Programming by DIP switches Programmable Gassing Voltage Proportional Algorithm for charge time calculation Programmable Equalize System Automatic Pulsed amp Manual Automatic voltage controlled maintenance Wrong battery detection Battery desulphation cycle Independent safety timer Automatic data saving in case of black out of the mains Cyclical indication of V cell AMPS Ah returned time Cool down time counter Scrolling messages in plain text The MTL2 Charge Controller monitors the entire charging curve and it incorporates several safety features The front panel of the MTL2 Digital charge controller contains the digital display 4 Digits the STOP button and the MANUAL EQUALIZE button 3 INSTALLATION OF THE CHARGER Conditions of use e Operating temperature 5 C to 45 C e Storage temperature 20 C to 60 C e Relative humidity less than 75 Page 5 16 ATTENTION Make sure that the unit s maximum input power reported on the data label is available from your power supply and verify that the unit s operating voltage is correct Allow adequate air circulation to prevent internal heat buildup Page 6 16 AC INPUT CONNECTION TERMINAL BLOCKS FOR AC INPUT WIRES The charge
11. itches according with the following table and pictures Connect the charger to main supply PROGRAMMATION DIPSWITCHES FACTORY PRESET POSITION EQUALIZE AUTOMATIC EVERYDAY EQUALIZE amp REFRESH Default OFF Default ON GASSING VOLTAGE PROGRAMMATION Default OFF ON PROGRAMMABLE GASSING VOLTAGE VALUES 2 35 Vicell 2 40 Vicell 2 45 Vicell 2 50 W cell GASSING POINT 2 35 V cell 2 40 V cell 2 45 V cell 2 50 V cell OO When a battery will be connected to the charger the programmed gassing voltage will be shown on the display during the start up seguence Page 9 16 BATTERY CONNECTION VOLTAGE CHECK AND AUTOSTART Connect the battery to the charger using an adequate plug When the battery is correctly connected the display turns on and shows the battery voltage If the battery voltage lower than the minimum threshold of 1 62 V cell the charger doesn t start and the display will show the error message Voltage Low If the battery voltage is higher than the maximum threshold of 2 60 V cell the charger doesn t start and the display will show the flashing error message Voltage High If the voltage of the battery is between the minimum and maximum thresholds the charger will wait for 3 seconds before to start charging while the display will show the programmed gassing voltage If during the charge the voltage of the battery exceeds the maximum threshold of 2 80 V c
12. oltage drops below a predefined minimum theshold While the battery is monitored by the charger the display will show the scrolling message Volt Control If the voltage drops down below the minimum threshold the charger will give an extra charge cycle to keep the battery in perfect condition and the display will show the scrolling message Refresh Page 15 16 Each Refresh charge terminates when the battery voltage reaches a predefined maximum threshold e NOTE With this voltage controlled refreshing system the battery will be kept in perfect condition for an undefined time without any risk of undercharge or overcharge If the battery is in ideal condition self discharge absent the refresh charge will never be activated In the opposite case if the battery is in bad condition and the self discharge is significant the refresh charge will be frequently activated and the battery will be kept charged without problems MANUAL CHARGE TERMINATION While the charge is in progress it s possible to shut down the charger by pressing the red button MANUAL STOP on the front panel The display will show the message Stop The final values of Voltage cell Time of charge and Capacity Charged remain stored in memory If the MANUAL STOP button is pressed again these values will be displayed in sequence When the charge is terminated manually the equalization and refresh functions are autom
13. r must be connected to the AC input using an adequate cable and plug with disconnect switch and fuses TRANSFORMER TAPS 208 240 480 VAC SELECTION BOARD The AC input wires have to be connected to the TERMINAL BLOCKS FOR AC INPUT WIRES that are located on the right side of the internal panel just under the AC input contactor Make sure to tighten the terminal block screws with the proper torque and pull each wire separately in order to verify that they are mounted properly AC INPUT VOLTAGE SELECTION 208 240 480VAC The models for the US market can be configured for 208 240 VAC or 480 VAC nominal input voltage This selection can be made with the 220 240 480 VAC SELECTION BOARD that is located at the center of the internal panel near the terminal blocks for the AC input wires Disconnect the charger from main supply and battery Remove the plastic protection over the 220 240 480 VAC SELECTION BOARD Remove the three metal bars Place the metal bars in the required position with ref to the following pictures Tighten the nuts with the proper torque Apply the plastic protection Connect the charger to main supply Page 7 16 SELECTION BOARD SELECTION BOARD IN POSITION IN POSITION 208 240 VAC 480 VAC fo a O O G Ore AC INPUT VOLTAGE SETTINGS The POWER TRANSFORMER TAPS and the label with the list of the NOMINAL voltages that are available are located on the left side of the internal panel
14. rger 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 physician and ambulance immediately and use First Aid techniques recommended by the American Red Cross DANGER ELECTRICAL SHOCK CAN BE FATAL If person is unconscious and electric shock is suspected do not touch the person if he or she is in contact with charging equipment battery charging leads or other live electrical parts Disconnect power at wall switch and then use First Aid Dry wood wooden broom and other insulating material can be used to move cables if necessary away from the person IF BREATHING IS DIFFICULT give oxygen IF NOT BREATHING BEGIN ARTIFICIAL BREATHING such as mouth to mouth IF PULSE IS ABSENT BEGIN ARTIFICIAL CIRCULATION such as external heart massage In case of acid in the eyes flush very well with clean water and obtain professional medical attention immediately 2 DESCRIPTION OF THE CHARGER TOTALIFT battery chargers have been designed to charge Lead Acid batteries These units convert the AC input to a DC output at the correct voltage The charge curve is of the type Wa Page 4 16 Vi Time CHARGE CYCLE EQUAL The operation of the TOTALIFT chargers is managed by the new MTL2 Di
15. rs and 30 minutes e if the battery reaches the gassing voltage in 10 hours the final charge will continue for 5 hours e Ifthe battery reaches the gassing voltage in 11h59m59s the final charge will continue for 5h 59 595 this is the maximum total time allowed before going to Emergency state These time limits are ok to use the charger with different battery capacities depending on the time available for the charge from 8 to 16 hours and it s not needed to do adjustments on the board SAFETY TIMER EMERGENCY STOP e Ifthe battery doesn t reach the gassing voltage within 12 hours the charge is terminated by the safety timer and the display shows the error message Time Error If this error message appears it s recommended to call the service for a complete check of the system The cause if this problem may be a wrong setting of the input voltage if the input is set to a certain value for example 610 V but the real voltage is lower for example 575 V the charging current will be significantly lower than the nominal value thus causing a longer time to reach the gassing voltage AUTOMATIC DATA SAVING e If during the charge or equalization one or more black outs of the mains happen the microprocessor automatically saves all the relevant information about the state of the charge While the input power is absent and the battery is connected to the charger the display will show the message Black Out e
16. totally managed by the MTL2 microcontroller It can be enabled by moving the internal DIPSWITCH 4 to position ON see the description of the programmation dipswitches in the previous paragraphs The AUTOMATIC EQUALIZE REFRESH is ENABLED by default If the charge has been completed normally the charger will add 5 short additional charge cycles of 30 minutes with 14 hours and 30 minutes interval between each charge During the time interval between each equalization charge the display will show the scrolling message End Elapsed x x h When the equalization charger are in progress the display will show the scrolling message Equalization charge followed by the indication of the charge current If a battery is not used for a long time example seasonal works holiday periods it should be kept well charged to avoid a reduction of performance therefore it s very important to charge the battery before leaving it in stock for more than 24 hours The self discharge process makes it harder to keep a battery charged when the time of stocking is longer weeks or months The REFRESH function is useful to keep the battery in perfect condition when it s not used for an indefined time It is sufficient to leave the battery connected to the charger after the charge and the equalization is complete The TOTALIFT microprocessor will keep the battery voltage under control and will activate the charger automatically if the v
17. wn time Quick digital troubleshooting guide e 5 year warranty 7 year on transformer battery connectors not included TOT IF T www clarkmhe com parts batteries 877 662 5275
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