User Manual
Contents
1. At the end of the equalization the charger will remain in stand by mode while the front panel gives the message COMPLETE ON 22 ine BLINKING eee O OFF The MRG controller includes a quick test function that can be enabled by moving a jumper that is located on the board Quick Test jumper in Position TEST When the jumper is set to NORMAL position the MRG controller works normally When the jumper is set to position TEST the MRG controller performs the complete charge cycle in seconds instead of minutes When a battery is connected e Ifthe voltage is lower than the gassing value the TOTALIFT T Series will go in Emergency Stop after 20 30 seconds e Ifthe voltage is higher than the gassing value the TOTALIFT T Series will terminate the charge and pass to the automatic equalize in a few seconds end of manual Page 12 122. charge will be completed normally OVERCURRENT SHORT CIRCUIT PROTECTION If the output current exceeds 140 of the rated value the MRG Charge Controller will shut the charger down immediately and it will show the message OVERCURRENT on the front panel e ON 22 el KA i BLINKING eoo O OFF SHUTDOWN ON BATTERY DISCONNECTION Page 9 12 If the battery is disconnected while the charge is in progress the Totalift T Series charger will switch off automatically MANUAL CHARGE TERMINATION While the charge is in progress it s possible to turn off the charger by pressing the red button STOP The MRG front panel will show the message MANUAL STOP ON in K BLINKING OSLO O OFF In this condition it s safe to disconnect the battery EQUALIZATION The TOTALIFT T Series chargers Equalize the battery on a weekly basis The operation is totally automatic After the normal completion of the charge the TOTALIFT T Series chargers wait for 15 hours and it gives 4 equalization cycles of 30 minutes with 15 hours of interval between each cycle While the equalization charge is in progress the MRG Front Panel shows the message EQUALIZING ON fin N BLINKING ee O OFF With this timing system the equalization is performed only in the weekend when the battery remains connected to the charger for more than 15 hours after the completion of the charge
3. 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 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 12 Disconnect power to equipment if it is to be left unattended or out of service Disconnect battery from charger 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 t
4. TOTALIF1 T Series Industrial Battery Charger 1802 1824 1S8G 148 in 2 MMM IN Ac ST Gm OUT rara Vena V2 v 50 A 7 21140310 ey CHARGERS a lo di a al e a m INDEX 1 Safety Instructions and WarnihgsS ei coreani ShockiPreventionis sniiiiallili nea Burn amp Bodily Injury PFEVENTION ieri Fire amp Explosion Prevention i Arcing amp Burning of COnnNEctor rei Medical amp First Aid TreatMent iii Description of the Charge Installation of the Charger rolla AC Input Connection and Voltage Settings rr i HOW tO USethe Charselzaua ilaele Programming of the Finishing Charge TIME Battery Connection Automatic Voltage Check amp Auto start Charser0Operdtiol lecci Overvoltage Protection Safety Timer Emergency StOpizzicanii la Automatic Data Saving Over Current Short CircCUit iii Shutdown on Battery Disconnection rei Manual Charge Termination ii Quick Test FUNCTION wis eed es es ee eek ieee O WO WO 0 0 N DA UH HL SI SS HBP WW W e e N O Page 2 12 1 SAFETY INSTRUCTIONS AND WARNINGS Before using your TOTALIFT T Series 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 lifetim
5. e 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 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
6. ent 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 T Series 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 Wa with programmable finishing charge time and automatic equalization Page 4 12 The operation of the TOTALIFT T Series chargers is managed by the new MRG Charge Controller which is a microprocessor based electronic board of the last generation Time CHARGE CYCLE EQUAL The MRG Charge Controller monitors the entire charging curve and it incorporates several
7. ger will shut down automatically and the MRG front panel will show the message Voltage High i e ON iii KA BLINKING ee O OFF SAFETY TIMER EMERGENCY STOP The MRG controller includes a safety timer that shuts the charger down if the battery doesn t reach the gassing voltage within a defined time limit This time limit is not fixed but it depends on the finishing time selected by the user Page 8 12 If this condition occurs the MRG front panel shows the message Time Error ON in i BLINKING O OFF 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 therefore the battery will take too long to reach the gassing voltage AUTOMATIC DATA SAVING If during the charge or equalization one or more black outs of the AC input occur 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 MRG Charge Controller will show the message Black Out 4 status LEDs blinking alternately ON E ma N BLINKING one O OFF When the power supply is available again the charger will re start automatically from the exact point of interruption and the
8. he 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 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 treatm
9. orrespondent terminal block e Inthe bigger units with two primary windings the wires to be moved may be one or two both marked with the letter A e Tighten the terminal block screw with the right torque and pull the wire in order to make sure that it s properly mounted 4 HOW TO USE THE CHARGER PROGRAMMATION OF THE FINISHING CHARGE TIME The programming finishing charge times are 2 to 12 hours in the MRG Charge Controller The default value factory programmed is 3 hours Page 6 12 Behind the small hole located near the LED 80 CHARGED there is a button that is used to program the finishing charge time This button can be reached using a small object like a needle a small screwdriver or a toothpick e Disconnect the charger from the AC input e Connect a battery The four status LEDs will blink alternately e Push the button for the programming of the finishing charge time to enter the programming mode Only one LED will blink This LED corresponds to the finishing charge time that was previously programmed with reference to the picture on the right e Push the button again to move the blinking LED to the desired position e Wait for 5 seconds The charger will return to normal mode and the four status LEDs will blink alternately e Disconnect the battery e 12h e 8h Ah e h e 6h 2h e 5h BATTERY CONNECTION AUTOMATIC VOLTAGE CHECK AND AUTOSTART Connect the batte
10. ry to the charger using an adequate plug When the battery is correctly connected all the LEDs of the control panel will light on in sequence for a quick check If the voltage of the battery is below 1 60 V cell the charger will not start and the MRG front panel will show the error message Wrong Battery Voltage Low e ON 22 ie KA BLINKING oee O OFF If the voltage of the battery is higher than 2 50 V cell the charger will not start and the MRG front panel will show the error message Wrong Battery Voltage High e ON ie KA BLINKING eas O OFF If the voltage of the battery is in the correct range 1 60 to 2 50 V cell the charge will start automatically CHARGE OPERATION While the charge is in progress the 3 LED ammeter will indicate the output current level while the status LED Charging will blink continuously When the battery reaches the gassing voltage 2 40 V cell the status LED 80 Charged will start blinking together with the LED Charging The charge will continue for the programmed finishing time 2 to 12 hours following the Wa charge curve When the charge is complete the charger switches off automatically and the MRG front panel will give the message COMPLETE e ON ite EA BLINKING as Cs O OFF OVERVOLTAGE PROTECTION If during the charge the voltage of the battery increases above 2 80 V cell the char
11. safety features The front panel of the MRG charge controller is composed by 4 status LEDs CHARGING 80 CHARGED COMPLETE FAULT ALARM and 3 ammeter LEDs 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 AC INPUT CONNECTION AND VOLTAGE SETTINGS The charger must be connected to the AC input using an adequate cable and plug with disconnect switch and fuses e Find the POWER TRANSFORMER TAPS and the label with the list of the NOMINAL voltages available that are located on the left side of the internal panel 120 Vac input 240 Vac input 1 125 VAC 240 VAC 2 120 VAC 220 VAC 3 115 VAC 208 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 3 NOMINAL voltage values is closest to the REAL measured value Example 1 for a charger with 120 Vac input if the measured voltage is 118 VAC the transformer should be connected to the tap number 2 that corresponds to 120 VAC Example 2 for a charger with 240 Vac input if the measured voltage is 210 VAC the transformer should be connected to the tap number 3 that corresponds to 208 VAC e Inthe smaller units with a single primary winding it s sufficient to move the transformer wire marked with the letter A to the c
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