TLX Opportunity
Contents
1. 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 programmation 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 AUTO EQUALIZE REFRESH The AUTO EQUALIZE REFRESH function is 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 e2. STOP 14 AUTOMATIC DATA SAVING 15 BLOWN FUSE DETEG THON O 15 AUTOMATIC CHARGE TERMINATION eseseeseneennen mener nnne 15 AUTOMATIC SHUTDOWN ON BATTERY DISCONNECTION 16 EQUALIZE amp REFRESH MODES 16 MANUAL CHARGE TERMINATION 222 000 00000 a a 19 Page 2 19 TOTALIFT Battery Chargers User s Manual 1 SAFETY INSTRUCTIONS AND WARNINGS Before using your TOTALIFT OPPORTUNITY 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
3. and the second phase of charge can be modified by moving two dip switches 2 and 3 that are located on the MTL board near the microprocessor and the black heatsink see next picture To modify the value follow these steps Disconnect the charger from main supply and battery Locate the dip switches on the digital electronic board see next picture Set the dip switches according with the following table and pictures Connect the charger to main supply DIPSWITCHES OPPORTUNITY DS 2 DS 3 PAUSE 0 0 hour 1 0 1 hour 0 1 2 hours 1 1 3 hours When a battery is connected to the charger the programmed Opportunity Pause will be shown on the display during the start up sequence Page 11 19 TOTALIFT Battery Chargers User s Manual OPPORTUNITY PAUSE PROGRAMMABLE VALUE FERE 3 HOURS 2 HOURS 1 HOURS 0 HOURS PROGRAMMING DIPSWITCHES FACTORY PRESET POSITION EQUALIZE AUTOMATIC EVERYDAY EQUALIZE amp REFRESH Default OFF Default ON OPPORTUNITY PAUSE PROGRAMMING Default OFF OFF The other dip switches 1 and 4 are used to set the daily and or the weekly equalization 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 is lower than the minimum threshold of 1 62 V cell the charger doesn t s
4. 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 damp areas 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 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
5. TOTALIF1 TLX Opportunity Charger TA TSG TLS 1117779 fir TOTALIFT Battery Chargers User s Manual INDEX 1 SAFETY INSTRUCTIONS AND WARNINGS sssssssssssssssssssssssesssssssseeeesee 3 er Oe MEM Maii Mu ee Ce 3 OHOOIS ee INTO 0 9 8 b ac actrees hae ae 3 BURN AND BODILY INJURY PREVENTION esso aiken 4 FIRE AND EXPLOSION PRE VIEIN VION wie 4 ARGING AND BURNING OF CONNECTOR sissies 5 4 VMIEDICALSAND FIRST AID aeneo pa ceu be Etpe 4 2 DESCRIPTION OF THE CHARGER 5 3 INSTALLATION OF THE 222 6 TAG AINE OU TION Dh 6 AG INE Uh VOETAGE SEI TING ated cubus M EN OR Muse 7 4 HOW TO USE THE CGHAR GER 9 PROGRAMMING OF THE OPPORTUNITY PAUSE eee 9 BATTERY CONNECTION VOLTAGE CHECK AND AUTOSTART 12 ACAI GE Echanges Neq adve iit mM n RES 13 14 SAFETY NMER EMERGENCY
6. 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 OPPORTUNITY Charger switches off automatically EQUALIZE amp REFRESH MODES TOTALIFT OPPORTUNITY chargers have a complete set of programmable equalize amp refresh functions MANUAL EQUALIZE 4 hours extension of the charge time selected by user DAILY EQUALIZE 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 Page 16 19 TOTALIFT Battery Chargers User s Manual 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
7. age 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 often activated and the battery will be kept charged without problems MANUAL CHARGE TERMINATION Page 18 19 TOTALIFT Battery Chargers User s Manual 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 automatically disabled Page 19 19 All parts All lift trucks For Opportunity Chargers Only Amp Output VS Ah Capacity Return 6HOURS
8. damage to the insulation Replace or repair cracked or worn leads immediately Use leads having sufficient capacity to carry the operating current without overheating Page 3 19 TOTALIFT Battery Chargers User s Manual 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 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 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 sl
9. e finishes or it has been set equal to 0 hour the second final phase of charger begins The second phase will be ON for one half of the time needed to reach the gassing voltage time of first phase with a minimum total time of 30 minutes Examples Page 13 19 TOTALIFT Battery Chargers User s Manual If the battery reaches the gassing voltage 1 minute the second phase will be ON for 30 minutes If the battery reaches the gassing voltage 5 hours the second phase will be ON for 2 hours and 30 minutes If the battery reaches the gassing voltage in 10 hours the second phase will be ON for 5 hours If the battery reaches the gassing voltage 11h59m59s the second phase will be ON 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 OPPORTUNITY PAUSE During the Opportunity Pause the display shows the battery voltage and the remaining pause time When the Opportunity Pause finishes the display shows SAFETY TIMER EMERGENCY STOP e f the 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 c
10. from the gassing point until the end of the charge During the second phase the current value is reduced to avoid overheating of the battery and the charge continues in the same way standard Wa models SR series The TOTALIFT OPPORTUNITY chargers allows you to set a pause time between the first and the second phase of charge This pause can be used to implement the OPPORTUNITY CHARGE The Electronic Control Board allows the setting of the following pause 0 hour the charge works as a normal charger that implements the WoWa charge curve 1 hour 2 hours 3 hours The pause time has to be set longer than the maximum working pause that the forklift can have during a normal work shift During the work shift it s always possible to take advantage of the pause when the forklift is not used to recharge the battery TOTALIFT OPPORTUNITY charger will charge the battery until the gassing point then it stops This avoids the battery gassification and thus the production of dangerous gasses During the night the charger will execute the first phase of charge the Opportunity Pause and the second phase The charge will be fully completed Page 10 19 TOTALIFT Battery Chargers User s Manual Setting the Opportunity Pause correctly and taking advantage of the working pause it s possible to cover 2 work shifts 8 hours 8 hours with the same forklift without changing it or its battery The OPPORTUNITY PAUSE between the first
11. is of the type WoWa Time CHARGE CYCLE EQUAL Note TL48 pictured TLX 48 has TLX 48 decal on face The operation of the TOTALIFT OPPORTUNITY chargers is managed by the new MTL2 Digital Charge Controller which is a microprocessor based electronic board of the last 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 Page 5 19 TOTALIFT Battery Chargers User s Manual 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 ATTENTION Make sure that the unit s maximum input power reported on the data label is available from your power sup
12. omplete check of the system Page 14 19 TOTALIFT Battery Chargers User s Manual 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 f 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 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 This message may appear also if the battery has been left discharged for long time causing the sulphating 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 Page 15 19 TOTALIFT Battery Chargers User s Manual The time indicated by the display is the time elapsed after the charge has been terminated
13. ow 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 physician 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 attention immediately Page 4 19 TOTALIFT Battery Chargers User s Manual 2 DESCRIPTION OF THE CHARGER TOTALIFT OPPORTUNITY 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
14. ply and verify that the unit s operating voltage is correct Allow adequate air circulation to prevent internal heat buildup Don t place the unit near heat sources such as radiators or air ducts or in a place subject to direct sunlight excessive dust mechanical vibration or shock AC INPUT CONNECTION The charger must be connected to the AC input using an adequate cable and plug with disconnect switch and fuses The AC input wires have to be connected to the TERMINAL BLOCKS FOR AC INPUT WIRES that are located on 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 SETTINGS Page 6 19 TOTALIFT Battery Chargers User s Manual e 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 208 240 VAC 3x 208 VAC 3x 220 VAC 3x 240 VAC 1 3x 490 VAC 3x 480 VAC 3x 460 VAC 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 is closest to the REAL measured value Example If the measured voltage is 485 VAC the transformer should be connected to the tap number 1 that corresponds to 490 VAC Three phase uni
15. qualization chargers are in progress the display will show the scrolling message Equalization charge Page 17 19 TOTALIFT Battery Chargers User s Manual 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 OPPORTUNITY microprocessor will keep the battery voltage under control and will activate the charger automatically if the voltage 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 Each Refresh charge terminates when the battery voltage reaches a predefined maximum threshold e NOTE With this volt
16. tart and the display will show the error message Voltage Low Page 12 19 TOTALIFT Battery Chargers User s Manual 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 Opportunity Pause If during the charge the voltage of the battery exceeds the maximum threshold of 2 80 V cell 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 C e 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 being is 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 When the battery reaches the gassing voltage the charge stops and waits for the end of the Opportunity Pause When the Opportunity Paus
17. ts 208 240 VAC Page 7 19 TOTALIFT Battery Chargers User s Manual POWER TERMINAL TRANSFORMER BLOCKS FOR TAP AC INPUT CABLE Three phase units 480 VAC POWER TERMINAL BLOCK TRANSFORMER TAPS FOR AC INPUT CABLE mr Three phase units 600VAC Page 8 19 TOTALIFT Battery Chargers User s Manual TERMINAL BLOCK FOR POWER TRANSFORMER AC INPUT CABLE TAPS 4 HOW TO USE THE CHARGER 699 5 CURRENT TIME OF CHARGE VOLTAGE 22 1 PER CELL MANUAL CHARGE STUF EQUALIZE CAPACITY RETURNED DEDE Saat ts Cod 2531241 PROGRAMMING OF THE OPPORTUNITY PAUSE Page 9 19 TOTALIFT Battery Chargers User s Manual On the TOTALIFT OPPORTUNITY charger the charge current follows the WoWA curve as described in the norm DIN 41773 Voltage Current Initial Current Nominal Value about 2275 287 of the battery capacity Voltage 2 65 V cell Voltage Voltage 7 40 V cell Current 50 of Initial Current Voltage 7 10 cell Current 28 nf Initial Current Current 1 Phase 2 Phase Time OPPORTUNITY PAUSE The charge curve WoWa is divided in two charge phases The first phase starts from the beginning of the charge and finishes when the battery voltage reaches the gassing point 2 40V cell The current value during the first phase is 22 28 of the battery capacity This allows reduction of charge time The second phase starts
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