TOTALIFT TLX24 User manual

TOTALIFT®TLX Opportunity Charger
TLX24, TLX36, TLX48, TLX72, TLX80
User Manual

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INDEX
1. SAFETY INSTRUCTIONS AND WARNINGS.................................................3
·GENERAL.............................................................................................................................. 3
·SHOCK PREVENTION .......................................................................................................... 3
·BURN AND BODILY INJURY PREVENTION ........................................................................ 4
·FIRE AND EXPLOSION PREVENTION................................................................................. 4
·ARCING AND BURNING OF CONNECTOR ......................................................................... 4
·MEDICAL AND FIRST AID TREATMENT.............................................................................. 4
2. DESCRIPTION OF THE CHARGER ..............................................................5
3. INSTALLATION OF THE CHARGER.............................................................6
·AC INPUT CONNECTION...................................................................................................... 6
·AC INPUT VOLTAGE SETTINGS.......................................................................................... 7
4. HOW TO USE THE CHARGER......................................................................9
·PROGRAMMING OF THE OPPORTUNITY PAUSE ............................................................. 9
·BATTERY CONNECTION – VOLTAGE CHECK AND AUTOSTART ...................................12
·CHARGE OPERATION.........................................................................................................13
·OPPORTUNITY PAUSE .......................................................................................................14
·SAFETY TIMER – EMERGENCY STOP...............................................................................14
·AUTOMATIC DATA SAVING................................................................................................15
·BLOWN FUSE DETECTION.................................................................................................15
·AUTOMATIC CHARGE TERMINATION ...............................................................................15
·AUTOMATIC SHUTDOWN ON BATTERY DISCONNECTION ............................................16
·EQUALIZE & REFRESH MODES.........................................................................................16
·MANUAL CHARGE TERMINATION .....................................................................................19

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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 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 damage to the insulation. Replace or repair
cracked or worn leads immediately. Use leads having sufficient capacity to carry the operating
current without overheating.
ATTENTION!
This operation is important for the functionality and reliability of the charger.
CAUTION!
This operation can be dangerous for the user.

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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 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 physician and ambulance immediately and use First Aid
techniques recommended by the American Red Cross.
DANGER: ELECTRICAL SHOCK CAN BE FATAL.
If a 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 away from
person if necessary.
IF BREATHING IS DIFFICULT, administer oxygen.
IF NO BREATHING EXSIST, 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.

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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 is of
the type WoWa.
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 & 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.

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3. INSTALLATION OF THE CHARGER
Conditions of use:
•Operating temperature: 5°C to 45°C
•Storage temperature: -20°C to 60°C
•Relative humidity: less than 75%
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
CAUTION!
Risk of electrical shock!
The charger can be installed by qualified personnel only.
To prevent fire or shock hazard, do not expose the unit to rain or moisture.
Don't use the unit in presence of flammable gas, because it can generate sparks.
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.
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.

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•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.
480 VAC 600 VAC
1 3x 490 VAC 3x 610 VAC
2 3x 480 VAC 3x 600 VAC
3 3x 460 VAC 3x 575 VAC
•Using an adequate AC-voltmeter, measure the value of the REAL AC input voltage
available at the mounting location of the charger.
•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 units (208-240 VAC)
208-240 VAC
1 3x 208 VAC
2 3x 220 VAC
3 3x 240 VAC
ATTENTION!
The proper setting of the power transformer taps is fundamental
for the correct operation of the TOTALIFT OPPORTUNITY chargers.
If the real AC input voltage is different than the AC nominal voltage to which the charger is set,
the charging current of the charger may be significantly different than the nominal.

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Three phase units (480 VAC)
Three phase units ( 600VAC)

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4. HOW TO USE THE CHARGER
PROGRAMMING OF THE OPPORTUNITY PAUSE

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On the TOTALIFT OPPORTUNITY charger, the charge current follows the WoWA curve, as
described in the norm DIN 41773.
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 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).
EQUALIZZATION
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.

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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 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.
When a battery is connected to the charger, the programmed Opportunity Pause will be shown
on the display during the start-up sequence.
DS #2 DS #3 OPPORTUNITY
PAUSE
0 0 0 hou
r
1 0 1 hou
r
0 1 2 hours
1 1 3 hours

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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
start, and the display will show the error message “Voltage Low”:
ATTENTION!
TOTALIFT OPPORTUNITY chargers are programmed to execute a complete cycle of charge
automatically, however it’s recommended to survey the operations when the battery remains
connected to the charger for more than 12 hours (example: week-ends).

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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:
•Voltage per cell of the battery (U) (Volt);
•Charge current; (A) (Ampere);
•Capacity charged; (C) (Ah);
•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 Pause 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:

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•If the battery reaches the gassing voltage in 1 minute, the second phase will
be ON for 30 minutes.
•If the battery reaches the gassing voltage in 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 in 11h59m59s, the second phase
will be ON for 5h 59m59s (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
•If 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 complete check of the
system.

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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
•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”:
•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
•If 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
•When the charge is complete, the charger shuts down, and the display shows the scrolling
message “End Elapsed x.x h”.
CAUTION!
NEVER disconnect the battery while it's being charged.
Disconnecting the battery while it's being charged is hazardous
for the user and voids the charger warranty.

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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 OPPORTUNITY
Charger switches off automatically.
EQUALIZE & REFRESH MODES
TOTALIFT OPPORTUNITY chargers have a complete set of programmable equalize & 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 & REFRESH: Weekly equalize cycle + long term battery refresh
MANUAL EQUALIZE
The MANUAL EQUALIZE function is intended for the users that prefer to manage the
equalization of the batteries personally.
ATTENTION!
The proper programmation of the equalize & refresh modes is important
for the correct operation of the TOTALIFT OPPORTUNITY chargers.
Only expert users should modify these settings.
CAUTION!
NEVER disconnect the battery while it's being charged.
Disconnecting the battery while it's being charged is hazardous
for the user and voids the charger warranty.

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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.
DAILY EQUALIZE
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 equalization chargers are in progress, the display will show the scrolling message:
“Equalization charge”:

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-followed by the indication of the charge current.
REFRESH OPERATION
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.
•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 often activated and the battery will be kept charged
without problems.
les are completed, the charger passes to REFRESH mode.
MANUAL CHARGE TERMINATION

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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.
CAUTION!
NEVER disconnect the battery while it's being charged.
Disconnecting the battery while it's being charged is hazardous
for the user and voids the charger warranty.

For Opportunity Chargers Only
Amp Output VS. Ah Capacity Return
6HOURS
100 400
O120 480 C
U140 560
A
T160 640 P
P180 720
A
U200 800 C
T220 880 I
240 960 T
A
260 1040
Y
M280 1120 -
P300 1200
A
S320 1280 h
340 1360