Curtis Battery Charger 1620S User Manual

manual  
1620  
S W I T C H M O D E  
BATTERY CHARGER  
Applicable to 230VAC units only  
Before charging, read  
instructions carefully!  
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CONTENTS  
1. MODEL ENCODEMENT ............................. page 1  
2. TEChNICAL SPECIFICATIONS.................. page 1  
3. INSTALLATION ............................................. page 7  
4. OPERATION................................................... page 8  
5. TROUBLEShOOTING ................................. page 9  
6. MAINTENANCE...........................................page 10  
Curtis 1620 Manual  
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MODEL ENCODEMENT  
1620uv-www/xx/yy-zzz  
1620  
u
v
- www / xx  
/
yy  
- zzz  
Series  
Number  
Model Cooling Sealing  
Input  
Output  
Output  
Current  
Voltage  
Voltage  
1
2
F
S
120  
24  
20  
001  
Fan  
cooled  
Sealed 120VAC  
24VDC 20 Amps Consult Factory  
for  
230  
230VAC  
additional options  
TECHNICAL SPECIFICATIONS  
2.1 Electrical  
Input:  
Voltage:  
120VAC models  
100-132VAC  
230VAC models  
180-264VAC  
Frequency Range: 57-63Hz  
Input Current:  
47-63Hz  
12Arms max. @ 100VAC/60Hz  
4.5Arms max. @ 180VAC/50Hz  
Output Voltage:  
Output Current:  
Output Max. Power:  
24VDC, nominal  
0-20A  
580W  
2.2 Mechanical  
Case:  
Aluminum alloy, black finish  
Polycarbonate, black  
292L x 165.0W x 73.0h  
2.8kg  
End caps:  
Dimensions (mm):  
Weight:  
2.3 Connections  
AC Power Inlet:  
Programming Port:  
IEC 320/C14  
Molex 39-01-2040 For use with Curtis  
Instruments’ Model 1311 handheld programmer only.  
Pin  
1
Function  
Rx  
2
SEC_RTN  
Tx  
3
4
+12V  
Motor Controller Inhibit:  
DC Power Output:  
Molex 39-01-4030 60mA max. current.  
Pin  
1
Function  
See wiring diagram 1  
No connection  
See wiring diagram 1  
2
3
2 x M5 studs (max torque 2.2Nm).  
Pin  
+
Function  
B+ output  
B– output  
page 1  
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J2-1  
J2-2  
J2-3  
100V max., 60mA max.  
Wiring diagram 1.  
2.4 Environmental  
Operating temperature:  
Storage temperature:  
humidity:  
0°C to +50°C  
-40°C to +85°C  
95% non-condensing at 38°C  
SAEJ1378, 55g pulse at 9-13ms  
5g rms, 5-500 hz, 2 hrs. per axis  
IP-54, including fan  
Shock:  
Vibration:  
Protection:  
2.5 Compliance  
Radiated Emissions:  
Conducted Emissions:  
EN50082-1-1997  
ESD:  
FCC Part 15, Class A  
FCC Part 15, Class A  
EN55011, Class A  
EN55011, Class A  
X
EN61000-4-2:1995  
EN61000-4-3:1995 +  
A1:1998  
Radiated Immunity:  
Electrical fast transient:  
Surge Immunity:  
Conducted Immunity:  
Power Frequency Magnetic Field:  
Voltage dips and sags:  
harmonics:  
Voltage fluctuations (flicker)  
Safety  
EN61000-4-4:1995  
EN61000-4-5:1995  
EN61000-4-6:1996  
EN61000-4-8:1993  
EN61000-4-11:1995  
EN61000-3-2:2000  
EN61000-3-3:1995  
EN60335-1:1995  
EN60335-2-29:1997  
2.6 Battery Types  
This charger is suitable for use with all 24V, 12 cell, rechargeable lead acid  
batteries with capacities of approximately 200Ah.  
2.7 Charge Cycle Profile  
The Model 1620 charger provides three different charge profiles: IVa (Off Mode,  
see Figure 1), I VI a (Equalize Mode, see Figure 2) and IV V (Float Mode, see  
1
2
1 2  
Figure 3).  
For definitions of the variables mentioned in this section, refer to Table 1.  
page 2  
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2.7.1 – End of Charge Mode  
Figure 1. Charge profile for End of Charge Mode  
Figure 1 defines the charge profile for the End of Charge Mode. As long as the  
battery voltage (V) is above Undervoltage Lockout Level (Vuvlo), charging will  
start after short delay of about 6 seconds. For battery voltage between Vuvlo and  
Vlv, charge current will be limited to lower value (Ilv) in order to prevent gassing  
damage to the batteries. Good batteries will quickly increase voltage above Vlv  
and the 1620 will increase current to Constant Current value (Icc).  
This is beginning of a bulk charge, which typically returns 80% of the charge. At  
the end of bulk charging, battery voltage has reached Constant Voltage level (Vcv)  
and the charger will maintain the voltage by reducing the current (I) gradually.  
When the current drops to Icv, charging will stop, at which point the charger has  
returned 105-110% of the Ampere-hours discharged.  
If the battery is not used, its voltage will slowly drop due to self-discharging.  
When battery voltage reaches Restart Voltage (Vrst), the 1620 will turn back on  
and fully charge battery again.  
page 3  
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2.7.2- Equalize Mode after End of Charge Mode  
Figure 2. Charge profile for Equalize Mode  
Figure 2 defines the charge profile for the Equalize Mode. After going through  
bulk charge and Constant Voltage modes, the charger will reduce its output cur-  
rent to Top-Off Current (Ito) until one of the two possible outcomes occurs:  
(1) Battery voltage rises to Equalize Voltage (Vequ) or  
(2) Equalize Time-Out (Tto) is reached.  
Once one of these two possibilities occur, charging will stop and the 1620 will set itself  
to Off Mode; the charger remains in standby until restart voltage (Vrst) is reached.  
page 4  
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2.7.3 - Float Mode  
Figure 3. Charge profile for Float Mode  
Figure 3 defines the charge profile for the Float Mode. In this mode of operation,  
batteries are maintained at full charge. In addition to maintaining full charge, the  
charger can support a load current – as long as the combined load current and  
battery charging requirements do not exceed the output current defined in the  
Constant Current setpoint (Icc, default value of 20A in the Basic Mode).  
In this mode of operation, the charger will go through bulk charge and Constant  
Voltage modes as previously described. It then goes into standby until the battery  
voltage drops 0.4V below the Float Voltage (Vfloat, default value of 26.8VDC in  
Basic Mode) setpoint. The charger will then reactivate and maintain float voltage  
as long as the current requirement is above 2A. If current drops to 2A, the charger  
will again enter standby mode. The charger will continue this cycle of standby/  
reactivation until power is removed or until the Model 1311 programmer is con-  
nected.  
page 5  
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2.8 Indication Lights  
The charger features built in diagnostics. Refer to the table below to interpret the  
flashing of the green and yellow indicator lights.  
Flash Pattern  
Mode  
Charge Status  
Yellow on, Green on  
Standby Indicator 1  
Charge done, ready to use.  
1
1
Yellow on, Green blinks  
Charging  
Charging normally.  
Yellow and Green blink together  
Standby Indicator 2  
Charge cycle has not started,  
refer to troubleshooting section.  
1311 programmer connected to the unit.  
End of Charge (Veoc) voltage reached.  
Charge done, ready to use.(200s delay)  
Charge cycle stopped,  
refer to troubleshooting section.  
Charge cycle stopped,  
refer to troubleshooting section.  
Charge cycle stopped,  
Yellow and Green blink alternately  
Programming  
Standby Indicator 3  
1
Yellow blinks , Green on  
1
Yellow blinks , Green off  
Error  
2
Yellow blinks once,  
Error  
2 seconds off, repeats, Green off  
2
Yellow blinks twice,  
Error  
2 seconds off, repeats, Green off  
No indicators on  
refer to troubleshooting section.  
Charger is unplugged, otherwise  
refer to troubleshooting section.  
Off/Error  
1
2
– 0.5s on, 0.5s off  
– 0.5s on  
page 6  
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INSTALLATION  
3.1 Unit should be securely mounted to a flat surface.  
3.2 The power cord to the IEC 320/C14 connector should be of the appropriate  
gauge to carry a 15A current, for the cable’s length, to meet the requirements  
of applicable electrical codes. The power cord must meet IEC requirements  
with a minimum cross section of 1.5mm.  
3
3.3 The wires between the charger output and the battery should be of the  
appropriate gauge to carry a 20A current, for the cable’s length, to meet the  
requirements of applicable electrical codes. An inline fuse (32V min. 30A  
max.) is recommended to protect against accidental battery short circuit.  
3.4 A minimum of 30mm clearance should be provided at each vented end of  
the charger.  
3.5 Charger should not be installed in locations which restrict airflow to the  
unit.  
3.6 The circuit supplying power to the charger should be rated at a minimum of  
15A for a 120VAC circuit, or for 5A for a 230VAC circuit.  
page 7  
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OPERATION  
4.1 Charging the battery  
4.1.1 If using the motor speed controller inhibit, and a Curtis motor controller  
is present, connect the Motor Controller Inhibit connector to the  
appropriate connector on the motor speed controller.  
4
4.1.2 Connect the (–) terminal of the charger to the (–) terminal of the battery.  
4.1.3 Connect the (+) terminal of the charger to the (+) terminal of the battery.  
4.1.4 Plug the charger into an appropriate AC power source.  
4.1.5 Charging is complete when a steady green indicator light is seen next to the  
battery symbol on the charger. Unplug the charger from the wall and  
disconnect the charger from the battery, removing the connection to the (+)  
terminal first.  
4.2 Programming Options  
Curtis chargers do not use the 1311’s Monitor, Faults, or Functions Menus. The  
Information and Programmer Setup Menus operate as described 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.  
The 1620 offers two levels of programmability, Basic and Advanced. The pro-  
gram features are accessed by connecting a Curtis Model 1311 handheld pro-  
grammer to the Programming port. Programming in Basic Mode involves setting  
battery type (Flooded or Sealed Lead-Acid) and End of Charge Mode (charge  
profile), while Advanced Mode offers flexibility of changing the most important  
parameters of the charger for optimum charging of almost any Lead-Acid based  
battery. Of course, selecting the Factory Default option restores the charger set-  
tings to the default values it left the factory with. This option can be invoked at  
any time.  
Variable parameters, limits, default settings, accuracy and descriptions are listed  
in Table 1.  
4.3 Programming the charger  
Note 1: Connecting the Model 1311 handheld programmer to the charger will  
cause the charger to enter standby mode while connected. The charger will reset  
and resume normal operation upon removal of the 1311.  
Note 2: The Model 1311 handheld programmer is available with different con-  
nectors. Be sure to use a 1311 with the 4 pin Molex connector. Conact a Curtis  
sales office for assistance.  
4.3.1 Attach the programmer to the 4-pin Molex connector, between the  
indicators. The yellow and green indicators will blink on and off  
simultaneously, indicating that the charger is in programming mode.  
4.3.2 Configure the programmable parameters defined in Section 4.2.  
4.3.3 Once the programmable parameters have been defined, disconnect the  
1311 programmer from the charger. The charger will reset and resume  
normal operation.  
page 8  
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TROUBLESHOOTING  
The following checklist should help you to troubleshoot any problems with the  
charger. Make sure to observe all safety instructions provided on the unit and in  
this manual.  
5
Flash Pattern  
Indication  
Solution  
Yellow and Green  
No battery  
or reverse polarity  
Battery may be disconnected from  
charger or connected back wards.  
1
blink together  
Battery may be severely discharged.  
Lower Vulvo in the software setting.  
Battery damaged. Replace battery.  
1
Yellow blinks ,  
Charger overvoltage  
Battery may have been disconnected  
before the end of charge; reconnect the  
Green off  
3
battery and reset the charger . (or wait 200  
seconds).  
Battery manufacturer’s rated voltage may  
exceed charger’s rating. Verify rated battery  
voltage.  
2
Yellow blinks once,  
Not reaching VCV  
within Tcmax.  
Battery manufacturer’s rated capacity may  
exceed charger’s rating. Increase Tcmax,  
2seconds off, repeats,  
Green off  
3
increase Icc, or reset the charger .  
Battery may be damaged or old.  
Replace battery.  
2
Yellow blinks twice,  
Not reaching Vlv  
Battery manufacturer’s rated capacity may  
exceed charger’s rating. Increase Tlv, decrease  
2 seconds off, repeats, within Tlv  
Green off  
3
Vlv, increase Ilv, or reset the charger .  
Battery may be damaged or old.  
Replace battery.  
No indicators on  
damaged charger  
No power or  
Charger may be unplugged. Check for  
AC power. Charger may be damaged.  
Consult manufacturer for repair or return.  
1
2
3
– 0.5s on, 0.5s off  
– 0.5s on  
– Resetting the charger: Remove and restore power to the charger. Charger may  
be damaged if operation does not resume after AC power is recycled (light  
should go off approx. 20sec after power is removed and then charger can be  
restarted). Alternately, connect the Model 1311 handheld programmer to the  
charger until it has completed its boot up phase, then disconnect the programmer.  
page 9  
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MAINTENANCE  
Excess dirt or grime may be removed from the unit by wiping it with a cloth  
dampened with water.  
Although Curtis chargers are equipped with a fan designed to last the life of the  
charger, exposure to harsh environments – such as dusty condition, grease, chemi-  
cals, etc. – may impair the effectiveness of the fan. If the operation of the fan is  
noticeably degraded, Curtis recommends an immediate replacement of the fan  
with Curtis Part Number 17603351, 1620 Fan Assembly.  
6
6.1  
Replacing the fan:  
6.1.1. Disconnect the charger from power and from the battery.  
6.1.2. Remove the fanguard by simultaneously pushing in the retaining clips  
on either side of the fan and gently pulling the fan guard away.  
6.1.3. Unplug the fan assembly, noting the fan orientation, air flow direction,  
and wire routing.  
6.1.4. Remove the fan assembly.  
6.1.5. Replace with new fan assembly , being sure to match the orientation  
and airflow direction of the previous fan, and plug the fan in. Route  
the fan wires as previously located to avoid pinching the wires.  
6.1.6. Replace fan guard and push until a click is heard. Verify both retaining  
clips have fully engaged.  
page 10  
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Table 1. Programming Parameters  
Programming mode  
BASIC MODE2  
Description  
Programming  
Limits  
Default Value  
Increment  
Battery Type  
1 or 2  
1
1
1
1
End of Charge  
1, 2, or 3  
ADVANCED MODE  
Constant Current (Icc)  
10-20A  
20A  
0.5A  
Constant Voltage Level  
(Vcv)  
26-30V  
2-10A  
29V  
6A  
0.1VDC  
0.5A  
Low Voltage Current  
(Ilv)  
Top-off current (Ito)  
2-10A  
6A  
0.5A  
0.1V  
End of charge ("soft"overvoltage)  
29-35V  
31VDC  
(Veoc)  
EoC Threshold (Icv)  
Restart Voltage (Vrst)  
2-20A  
4A  
0.5A  
0.1V  
22-28v  
26VDC  
Bulk Charge Threshold (Vlv)  
0-26VDC  
4-21VDC  
24VDC  
5VDC  
0.1VDC  
0.1VDC  
Low Voltage Lockout  
(Vuvlo)  
Equalize Voltage (Vequ)  
Float Voltage (Vfloat)  
29-33V  
25-30V  
31VDC  
26.8V  
0.1VDC  
0.1VDC  
Low Voltage Timeout (Tlv)  
Equalize Timeout ( Tto)  
1-10hrs  
0-5hrs  
1 hour  
2 hours  
16 hours  
1 hour  
1 hour  
1 hour  
Maximum Charge Time  
2-36hrs  
(Tcmax)  
1 Accuracy is calculated as percentage of the maximum setting.  
2 Items in bold are as they appear in the display of the 1311 handheld programmer.  
page 11  
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Accuracy*  
Definition  
1-FLA: Float voltage is set to 26.8V, Constant voltage set to 29V.  
2-SLA: Float voltage set to 27.6V, Constant voltage to 29.4V  
1-OFF: Charger goes into standby. Charger will cycle to recharge the battery as  
determined by Vrst and enter standby at the end of the charge cycle.  
2-EQUALIZE: Charger adjusts its output current to Ito, and drives the battery to Vequ.  
It has the time allotted by Tto to do this or a fault will occur.  
3-FLOAT: Charger goes into standby upon entering EoC Mode, and remains in standby  
until the battery reaches Vfloat. At this point the charger turns on and maintains Vfloat  
until power is recycled.  
+/- 3%  
Current used to charge the batteries during normal (bulk charge) operation. This current  
is used when the battery voltage is greater than, or equal to Vlv, and less than Vcv.  
+/- 1%  
+/- 5%  
Battery voltage maintained by charger during bulk charge. This voltage is maintained by  
continuously dropping the output current, until Veoc is reached.  
Current used to recover deeply discharged batteries; this current is used when the battery  
voltage is greater than or equal to Vuvlo, and less than Vlv.  
+/- 5%  
+/- 1%  
Current used to Equalize the batteries.  
Charger goes into "soft" overvoltage mode, from which it recovers when battery voltage  
drops below Vrst.  
+/- 3%  
+/- 1%  
Current at which the charger transitions to EoC mode.  
Used when EoC Mode is EQUALIZE or OFF; the battery voltage at which charger  
automatically turns on and recharges the battery. Charger must be in stand by mode when  
this voltage is detected; the charger will charge the battery until it reaches Vcv and then  
enter stand by mode.  
+/- 1%  
+/- 1%  
Battery voltage at which the charger switches from Ilv to Icc.  
Battery voltage below which the charger will not turn on.  
+/- 1%  
+/- 1%  
Used when EoC Mode is EQUALIZE. The voltage at which the EQUALIZE mode is  
ended, unless the mode ends by reaching Tto.  
Used when EoC Mode is FLOAT. Once the battery voltage drops to this set point, the  
charger will turn on and stay on, maintaining this battery voltage.  
+/- 5min  
+/- 5min  
+/- 1hr  
If battery does not reach Vlv within this timeout period, an error is indicated.  
Used when EoC Mode is EQUALIZE. Number of hours charger is kept at equalization  
current, unless the mode is ended by reaching Vequ.  
The maximum amount of time the charger has to complete a charge cycle and enter  
standby mode. Failure to complete charge in the allotted time will result in a fault mode.  
page 12  
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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.  
53033 REV E 12/07  
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