Curtis Computer 1608 User Manual

MANUAL  
1604/1608  
SWITCH MODE  
BATTERY CHARGERS  
for Lead-Acid Batteries  
Before charging, read  
instructions carefully!  
CONTENTS  
1. MODEL ENCODEMENT.............................. page 1  
2. TECHNICAL SPECIFICATIONS .................. page 2  
3. INSTALLATION.............................................. page 4  
4. OPERATION .................................................. page 5  
5. TROUBLESHOOTING .................................. page 9  
6. MAINTENANCE .......................................... page 9  
MODEL ENCODEMENT  
Model1  
Input  
Output  
Output  
Series  
Voltage 2 Voltage 3  
Series 4 Number 5  
1604CS  
-
-
-
-
-
-
AVS  
AVS  
AVS  
AVS  
AVS  
AVS  
/
/
/
/
/
/
12  
24  
12  
24  
12  
24  
/
/
/
/
/
/
04  
04  
08  
08  
08  
08  
-
-
-
-
-
-
xxx  
xxx  
xxx  
xxx  
xxx  
xxx  
1
1604FV  
1608FS  
1
1604CS: Convection cooled, sealed to IP-54  
1604FV: Fan cooled, protected to IP-31  
1608FS: Fan cooled, electronics sealed to IP-54, fan protected to IP-31  
2
3
AVS: Auto Voltage Select, operates at 120VAC or 230VAC automatically  
12: 12VDC  
24: 24VDC  
4
5
04: 4A  
08: 8A  
Series Number: Identifies charger features, consult Curtis  
page 1  
Curtis 1604/08 Manual  
TECHNICAL SPECIFICATIONS  
2.1 Electrical  
Nominal Operating Voltage  
12V / 24V, 4A Chargers  
12V, 8A Chargers  
24V, 8A Chargers  
120VAC  
230VAC  
120VAC  
230VAC  
120VAC  
230VAC  
Input Voltage (VAC)  
90 - 132  
180 - 264  
90 - 132  
180 - 264  
105 - 132  
210 - 264  
Operating Frequency (Hz)  
Input Current (A rms, max.)  
47 - 63  
1.0 @  
90V/60Hz  
2.0 @  
0.5 @  
180V/50Hz  
1.0 @  
2.0 @  
90V/60Hz  
1.0 @  
180V/50Hz  
N/A  
N/A  
12VDC nominal outputs  
24VDC nominal outputs  
2
4.0 @  
105V/60Hz  
2.0 @  
210V/50Hz  
N/A  
N/A  
90V/60Hz  
180V/50Hz  
Input Leakage  
(µA, max.)  
<500 @  
120V/60Hz  
<500 @  
230V/50Hz  
<500 @  
120V/60Hz  
<500 @  
230V/50Hz  
<500 @  
120V/60Hz  
<500 @  
230V/50Hz  
Output Power (W, nom./max.)  
12VDC nominal outputs  
24VDC nominal outputs  
48 / 67.5  
96 / 135  
4.0  
96 / 125  
192 / 240  
8.0  
Output Current (A, max.)  
Output Voltage (VDC, nom./range)  
12VDC nominal outputs  
24VDC nominal outputs  
12 / 6.0 - 15.0  
24 / 12.0 - 30.0  
2.2 Mechanical  
Case:  
Aluminum alloy, black finish  
Polycarbonate, black  
End caps:  
Dimensions (mm max.):  
1604CS & 1604FV:  
1608FS:  
160 L x 96 W x 52 H  
160 L x 140 W x 52 H  
Weight (kg) 1604/1608:  
1.0/1.5  
2.3 Connections  
AC Power Inlet:  
DC Power:  
IEC 320/C14 Male on cable  
ITT Cannon XLR-3-12C Male Plug or equivalent on cable  
Pin Function  
1
2
3
B+  
B-  
Motor Controller Charging Indicator  
Programming Port: Molex 39-01-2040 with four female crimp terminals  
(Molex 39-00-0056). Use with Curtis Model 1311 Hand  
Held Programmer only.  
Pin Function  
1
2
3
4
Rx  
SEC_RTN  
Tx  
+12V  
Output Adapters:  
P/N 17604348-1 for use with  
Model 1288 Motor Controller  
P/N 17604348-2 for use as  
ISO-7176 compliant Off-board Charger  
Pin  
1
Function  
Pin  
Function  
Motor Controller  
1
2
3
B+  
B-  
B- (inhibit)  
Charging Indicator  
2
3
4
5
6
B+  
N/C  
N/C  
B-  
N/C  
Charge Indicator: Low impedance capable of sinking 60 mA DC to B-.  
Remote LED: Some models come with a wire harness for remote LED capability.  
Contact your local Curtis sales office for details.  
page 2  
Curtis 1604/08 Manual  
2.4 Environmental  
Operating Range: -10˚C to + 50˚C  
Storage Range:  
Humidity:  
Shock:  
-40˚C to + 85˚C  
95% RH (non-condensing) at 35˚C  
SAE J1378, 55g  
Vibration:  
Protection:  
5g rms, 5-500 Hz, 2 hours per axis  
1604CS: IP54  
1604FV: IP31 (horizontal mounting)  
1608FV: IP54 (Electronics) IP31 (Fan)  
2.5 Compliance  
1604CS  
1604FV  
1608FS  
UL 1012  
UL 1012  
UL1012  
CAN/CSA-C22.2 No.107.2  
EN60335-1  
CAN/CSA-C22.2 No.107.2  
EN60335-1  
CAN/CSA-C22.2 No.107.2  
EN60335-1  
EN60335-2-29  
EN55011  
EN60335-2-29  
EN55011  
EN60335-2-29  
EN55011  
EN61000-3-3  
EN61000-4-2  
EN61000-4-3  
EN61000-4-4  
EN61000-4-5  
EN61000-4-6  
EN61000-4-8  
EN61000-4-11  
ENV 50204  
EN61000-3-3  
EN61000-4-2  
EN61000-4-3  
EN61000-4-4  
EN61000-4-5  
EN61000-4-6  
EN61000-4-8  
EN61000-4-11  
ENV 50204  
EN61000-3-3  
EN61000-4-2  
EN61000-4-3  
EN61000-4-4  
EN61000-4-5  
EN61000-4-6  
EN61000-4-8  
EN61000-4-11  
ENV 50204  
2.6 Battery Types  
All chargers are intended for use with lead acid or gel cell batteries only, for their  
respective voltages.  
2.7 Charge Cycle Profile  
Models 1604 and 1608 use a multi-stage charge cycle, dependent upon battery  
geometry, with software programmable set points.  
1. Constant Current Mode: Output current is 4.0A max for the 4A models or  
8.0A max for the 8A models. Current is held constant until the constant  
voltage is reached. Output current is reduced during the Constant Current  
Mode if the charger should begin to overheat.  
2. Constant Voltage Mode: Output voltage shall be held at an average voltage of  
approximately 14.3V for 12V chargers or 28.6V for 24V chargers. The charger  
will hold the voltage to within 100mV of this value, reducing the current  
gradually until the charging ends. Charging ends when the current falls below  
0.5A or the charger remains in Constant Voltage Mode for more than 4 hours.  
The charger will shut down and remain in standby.  
page 3  
Curtis 1604/08 Manual  
3. Restart: If the battery self-discharges below 12.9V for 12V batteries or below  
25.7V for 24V batteries while the charger is in standby, the charger cycles into a  
constant current of 1.0A (4A models)/2.0A (8A models) until the constant  
voltage setpoint is reached. The unit will regulate and terminate as in Constant  
Voltage Mode.  
2.8 Indication Lights  
The charger features built in diagnostics. Refer to the table below to interpret the  
flashing of the yellow and green indicator lights. Flashing of the yellow indicator  
means that the charging cycle has ended early and the battery may not be fully  
charged. Refer to the Troubleshooting section to correct these faults.  
Flash Pattern  
Indication  
Yellow on  
AC power present  
Green on  
Charge complete  
Green blinking  
Charging  
Yellow & Green on simultaneously  
Yellow & Green blink simultaneously  
Yellow blinks 1X  
Yellow blinks 2X  
Yellow blinks 3X  
Charger in standby mode  
No battery/reverse polarity  
Not reaching constant voltage setpoint  
Not reaching 24V within 2 hours  
Charge current/voltage does not normalize  
Battery voltage too high (over 32V)  
Charger over temperature  
Yellow blinks 4X  
Yellow blinks 5X  
INSTALLATION  
Charger should be securely mounted on a flat surface.  
The power cord to the IEC 320/C14 connector should be of the appropriate  
gauge to carry a 10A current @ 120VAC, or a 5A current @ 230VAC for  
the cable’s length, to meet the requirements of applicable electrical codes.  
3
A minimum of 30mm clearance should be provided at each end of the  
charger for vented models.  
The charger should not be installed in locations which restrict air flow.  
page 4  
Curtis 1604/08 Manual  
OPERATION  
4.1. Charging the Battery  
Note: If a DC output adapter is used, connect the adapter to the charger output  
connector prior to supplying AC power to the charger.  
4.1.1 Ensure that the charger is either unplugged from AC power or is in  
standby mode.  
4
4.1.2 Connect the charger output connector to the vehicle/battery connector.  
4.1.3 Plug the AC line cord into a nearby outlet. Turn on wall switch (if used).  
The yellow light will illuminate to indicate that AC power is present.  
After several seconds the green light will flash to indicate that charging is  
in process. If no lights are illuminated, or if the yellow light flashes,  
refer to the Troubleshooting section. Charge time may vary from less  
than 1 hour to 10 hours.  
4.1.4 When charging is complete both the yellow and green lights will remain  
on and the charger will be in standby mode. The charger is now ready to  
be disconnected from AC power or from the battery. Note: if the charger  
is disconnected from the battery and connected to another battery with  
out removing AC power it resets itself over a three minute period.  
During this reset, the yellow light will flash briefly and the charger will  
return to standby mode prior to beginning a charge cycle.  
4.2. Programming the Charger  
The Model 1604 or 1608 charger has a number of parameters that can be  
programmed by the user, using a Curtis 1311 handheld programmer. These  
programming variables allow the charger's performance characteristics to fit the  
needs of the individual application. To use the 1311 refer to the 1311 instruction  
manual, Curtis P/N 53028.  
While programming can be performed when the charger is connected to the  
batteries or when charging, it is recommended that the charger be disconnected  
from power and from the batteries prior to commencing programming.  
Connecting the programmer to the charger while charging will result in the  
immediate termination of the charge cycle. The charger will remain in standby as  
long as the programmer is connected.  
There are two Program menu options - Basic Settings and Top Off Settings.  
There are four options under the Basic Settings. They are described in the following  
order. They are listed in the text by the names that appear on the programmer's  
Program Menu: (bold text indicates default settings)  
- Constant Voltage  
- Amp hour Capacity  
- End of Charge Mode  
- Fan Modulation  
Constant Voltage (CV, see figures 1, 2, 3 and 4)  
Constant voltage defines the battery voltage at which point the charger changes  
from constant current mode to constant voltage mode. Three Constant Voltage set-  
points are available:  
Option  
Setpoint (VDC)  
Battery Chemistry  
12VDC charger 24VDC charger  
1
2
14.0  
14.3  
28.0  
28.6  
Gel  
AGM, Gel, SLA, VRLA  
3
14.6  
29.2  
special applications as required by the  
battery manufacturer  
page 5  
Curtis 1604/08 Manual  
Amp hour Capacity  
Amp hour Capacity is the storage capacity of the battery, as defined by the  
battery's manufacturer. Selecting the appropriate amp hour capacity determines  
the longest period of time the charger will charge before automatically shutting  
off. If the charger is still charging at this point, it provides an error code to the  
operator. Refer to Section 5, Troubleshooting, to correct this error. Three Amp  
hour Capacity setpoints are available:  
Option  
Amp hour rating  
(4A / 8A charger)  
Charge Cycle Timer (t , see Fig. 1, 2, 3 and 4)  
c
(hours)  
1
2
3
60 / 100  
100 / 200  
200 / 400  
16  
24  
48  
End of Charge Mode  
End of Charge Mode defines how the charger terminates the charge cycle. There are  
three End of Charge Modes:  
Option  
Mode  
Notes  
1
End of Charge Charge Profile: IVa  
(see Figure 1)  
Charger goes into standby upon reaching End of Charge  
current. Charge will automatically restart if the standby  
voltage falls below 12.9V (12V charger) 25.7V (24V charger),  
and automatically self terminates. This compensates for battery  
self-discharge over long periods of time. This mode is recommended  
for daily use or for long term storage.  
2
Equalize  
Charge Profile: I1VI2a if previous mode was End of Charge  
I1V1I2V2 if previous mode was Float.  
(see Figure 2  
and Figure 4)  
After constant voltage terminates, charger adjusts its output  
current to 1.5A/3A (4A/8A charger). The current is held  
for either 3 hours or until the battery reaches 15.8V (12V  
charger) or 30.5V (24V charger). The Equalize cycle automatically  
reverts to the previous mode of charge termination after  
the completion of 1 cycle. Check the battery manufacturer’s  
recommendation regarding the frequency at which batteries  
should be equalized.  
3
Float  
Charge Profile: IV1V2  
(see Figure 3)  
After constant voltage terminates, the charger reduces the  
output current to 0.25A (24V charger), and cycles on and off  
automatically to maintain an average battery voltage of (float  
voltage, FV) 13.3V (12V charger) or 26.6VDC (24V charger).  
This will continue until AC power is recycled. This mode of  
charging is recommended for daily use or for short term  
storage conditions to maintain battery health.  
Fan Modulation - Default setting: Off  
Fan Modulation can be turned on or off. If fan modulation is set to Off, the fan runs  
at full speed whenever the charger is charging. This maximizes charger power output  
over all operating conditions. If fan modulation is set to On, the speed of the fan is  
proportional to the temperature of the charger. This mode of operation is quieter.  
page 6  
Curtis 1604/08 Manual  
Top Off Settings - Default setting: Off  
Charge profile with the Top Off settings enabled looks similar to the Equalize  
end of charge mode (End of charge option 2). The difference is that in the Top  
Off mode the following parameters can be adjusted:  
- Top Off Time, ranging from 0 to 5 hours;  
- Top Off Voltage, ranging from 28 to 32.4 Volts;  
- Top Off Current, ranging from 0.5 to 4.5 Amperes.  
The Top Off mode is enabled by setting the Top Off Time to a value higher  
than zero. The charger enters the Top Off mode at the end of the main charge  
cycle (after the constant voltage part) and sets the output current to the value  
defined by the Top Off Current setting. The Top-Off mode will finish when:  
(1) preset Top Off Time expires or (2) battery voltage reaches the Top Off  
Voltage setting, whichever happens first.  
At the end of the Top Off mode, the charger continues according to the End of  
Charge Mode settings - stands by and awaits for the restart voltage or contin-  
ues the float mode.  
To program the charger:  
Curtis chargers do not use the 1311's Monitor, Faults, or Functions Menus. The  
Information and Programmer Setup Menus operate as describe in the 1311's  
instruction manual with the exception of the Serial Number submenu in the  
Information Menu – this field is filled with a default value of 12345678.  
4.2.1. Disconnect the charger from the AC outlet and battery.  
4.2.2. Attach the programmer to the 4-pin Molex connector on the charger  
(near the light indicators). Depending on the specific 1311 being used,  
a different connector cable may be required to connect to the charger.  
Contact a Curtis sales office for assistance.  
4.2.3. Apply AC power to the charger. The yellow and green light indicators  
will alternately blink, indicating that the charger is in programming mode.  
4.2.4. Configure the programmable parameters described above.  
4.2.5. Once the programmable parameters have been defined, disconnect the  
1311 programmer from the charger and follow the charger installation  
instructions.  
V/I  
CV  
V
I
tc  
t
Figure 1. End of Charge Profile  
page 7  
Curtis 1604/08 Manual  
V/I  
CV  
V
I
tc  
Figure 2. End of Charge Profile with Equalize  
t
V/I  
V
CV  
FV  
I
tc  
t
Figure 3. Float Profile  
V/I  
V
I
CV  
FV  
tc  
Figure 4. Float Profile with Equalize  
t
page 8  
Curtis 1604/08 Manual  
TROUBLESHOOTING  
Problem  
Possible Causes & Solutions  
Lights do not turn on.  
No power. Plug the unit in.  
No power. If the outlet is damaged, try another  
outlet on another circuit.  
5
Yellow light blinks 1x  
Yellow light blinks 2x  
Yellow light blinks 3x  
Battery manufacturer’s rated capacity may  
exceed charger's rating.  
Battery may be damaged or old.  
Battery manufacturer’s rated capacity may  
exceed charger's rating.  
Battery may be damaged or old.  
Battery manufacturer's rated capacity may  
exceed charger's rating.  
Battery may be damaged or old.  
Unit may be damaged if operation does not  
resume after AC power is removed and reapplied.  
Yellow light blinks 4x  
Yellow light blinks 5x  
Battery voltage exceeds charger specified  
operating range.  
Charger overheated. Remove power, wait ten  
minutes and then reapply power.  
Yellow & Green lights  
blink simultaneously  
Battery may not be connected to the charger.  
Battery may be severely discharged (<6VDC).  
Battery connections may be reversed.  
Yellow & Green lights  
alternately blink  
Charger is in the program mode. Handheld  
programmer is connected to the charger.  
Disconnect the programmer from the charger.  
MAINTENANCE  
Cleaning:  
Excess dirt or grime may be removed from the unit by wiping it with a cloth  
dampened with water.  
6
page 9  
Curtis 1604/08 Manual  
CURTIS INSTRUMENTS, INC.  
200 Kisco Avenue, Mt. Kisco, NY 10549 • Tel: (914) 666-2971 • FAX (914) 666-2188  
is a registered trademark of Curtis Instruments, Inc.  
Specifications subject to change without notice  
© 2005 CURTIS INSTRUMENTS, INC.  
53031 REV F 7/05  

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