manual
1620
S W I T C H M O D E
BATTERY CHARGER
Applicable to 230VAC units only
Before charging, read
instructions carefully!
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
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
Curtis 1620 Manual
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
Curtis 1620 Manual
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
Curtis 1620 Manual
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
Curtis 1620 Manual
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
Curtis 1620 Manual
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
Curtis 1620 Manual
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
Curtis 1620 Manual
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
Curtis 1620 Manual
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
Curtis 1620 Manual
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
Curtis 1620 Manual
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
Curtis 1620 Manual
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
Curtis 1620 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.
53033 REV E 12/07
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