Curtis 1620S User's Manual
Contents
1. VANUA L 1620 SWITCH MODE BATTERY CHARGER Applicable to 230VAC units only Before charging read instructions carefully 11 CAUTION Charger surface may be hot while plugged in and for a period of time thereafter 13 IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS Read the Operating Instructions carefully before using the Model 1620 charger WARNING Failure to install and operate the charger in accordance with these instructions may result in damage to the charger or injury to the operator WARNING Never place the charger directly above or below the battery being charged Gases or fluids from the battery will corrode and damage the charger Locate the charger as far away from the battery as the output cable allows WARNING Explosive gases may result from charging Provide adequate ventilation during charging Prevent flames or sparks WARNING Do not attempt to open the charger There is risk of electric shock even if the charger is unplugged No user serviceable components inside WARNING If safe operation of the charger can no longer be ensured stop and secure it against operation WARNING If the supply cord is damaged it must be replaced by a qualified person in order to avoid hazard WARNING Never charge a frozen battery WARNING To reduce the risk of injury charge only lead acid or gel cell type batteries Do not attempt to charge any oth2. 4 21VDC 5VDC 0 1VDC Vuvlo Equalize Voltage 29 33V 31VDC 0 1VDC Float Voltage Vfloat 25 30V 26 8V 0 1VDC Low Voltage Timeout 1 10hrs 1 hour jaca Maximum Charge Time 2 36hrs 16 hours 1 hour 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 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 Viv and less than 1 Battery voltage maintained by charger during bulk charge This voltage is maintained by continuously dropping the output current until Veoc is reached 5 Current used to recover deeply discharged batteries
3. shipped from the factory Be sure to read and understand all of the battery manufacturer s instructions such as removing or not removing cell caps or recommended rate of charging prior to using this charger Warranty Two Year Limited Warranty see terms of sale for specifics All specifications subject to change without notice CONTENTS 1 1 2 TECHNICAL SPECIFICATIONS page 1 3 INSTALLATION tenter ebbe t istae reris page 7 4 OPERATION a P TH Ry ees page 8 5 TROUBLESHOOTING page 9 6 page 10 Curtis 1620 Manual MODEL ENCODEMENT 1620uv www xx yy zzz 1620 u v Model Cooling Sealing F 5 Sealed cooled www xx yy 222 Input Output Output Series Voltage Voltage Current Number 120 24 20 001 120VAC 24VDC 20 Amps Consult Factory for 230 additional options 230VAC TECHNICAL SPECIFICATIONS 2 1 Electrical Input 120VAC models 230VAC models Voltage 100 132VAC 180 264VAC Frequency Range 57 63Hz 47 63Hz Input Current Output Voltage Output Current Output Max Power 2 2 Mechanical Case End caps Dimensions mm Weight 2 3 Connections AC Power Inlet Programming Port Motor Controller Inhibit DC Power Output 12Arms 100VAC 60Hz 4 5Arms max 180VAC 50Hz 24VDC nominal 0 20A 580W Alumin
4. this current is used when the battery voltage is greater than or equal to Vuvlo and less than Vlv Current used to Equalize the batteries 1 Charger goes into soft overvoltage mode from which it recovers when battery voltage drops below Vrst Current at which the charger transitions to EoC mode enter stand by mode 1 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 Vev and then Battery voltage at which the charger switches from to Ice Battery voltage below which the charger will not turn on Used when EoC Mode is EQUALIZE The voltage at which the EQUALIZE mode is ended unless the mode ends by reaching Tto 1 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 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 1hr 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 Curtis 1620 Manual page 12 CURTIS CURTIS INSTRUMENTS INC
5. 200 Kisco Avenue Mt Kisco 10549 Tel 914 666 2971 FAX 914 666 2188 www curtisinst com Ke CURTIS is a registered trademark of Curtis Instruments Inc Specifications subject to change without notice 2005 CURTIS INSTRUMENTS INC 53033 REV E 12 07
6. 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 Yellow on Green on Yellow on Green blinks Yellow and Green blink together Yellow and Green blink alternately Yellow blinks Green Yellow blinks Green off Yellow blinks once 2 seconds off repeats Green off Yellow blinks2 twice 2 seconds off repeats Green off No indicators on 1 _ 0 5s 0 55 off 2 0 55 on Standby Indicator 1 Charging Standby Indicator 2 Programming Standby Indicator 3 Error Error Error Off Error Charge Status Charge done ready to use Charging normally Charge cycle has not started refer to troubleshooting section 1311 programmer connected to the unit End of Charge 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 refer to troubleshooting se
7. ction Charger is unplugged otherwise refer to troubleshooting section Curtis 1620 Manual page 6 3 1 3 2 3 3 3 4 3 9 3 6 INSTALLATION Unit should be securely mounted to a flat surface 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 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 A minimum of 30mm clearance should be provided at each vented end of the charger Charger should not be installed in locations which restrict airflow to the unit 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 1 2 Connect the terminal of the charger to the terminal of the battery 4 1 3 Connect the ter
8. cturer for repair or return 1 0 55 on 0 5s off 2_ 0 5s on 3 Solution Battery may be disconnected from charger or connected back wards Battery may be severely discharged Lower Vulvo in the software setting Battery damaged Replace battery Battery may have been disconnected before the end of charge reconnect the battery and reset the charger or wait 200 seconds Battery manufacturer s rated voltage may exceed charger s rating Verify rated battery voltage Battery manufacturer s rated capacity may exceed charger s rating Increase increase Icc or reset the charger s Battery may be damaged or old Replace battery Battery manufacturer s rated capacity may exceed charger rating Increase Tlv decrease Vly increase or reset the charger Battery may be damaged or old Replace battery Charger may be unplugged Check for 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 e
9. er type of chargeable or non rechargeable battery these batteries may burst causing personal injury and damage WARNING To protect the operator from serious injury and the battery from damage Curtis recommends using a fast blow fuse rated for a minimum of 32V and a maximum of 30A between the battery and the charger CAUTION It is recommended that you disconnect the AC power cord before connecting or disconnecting the charger to the battery CAUTION Not intended for outdoor use CAUTION Units must have at least 30mm of clearance on the vented ends of the charger Do not restrict ventilation to the charger in any way Failure to do so may result in degradation of charge performance CAUTION If charger failure or malfunction may cause personal injury or material damage use additional safety measures such as limit switches guards etc CAUTION Failure to install and use the charger in accordance with these instructions may impair the protection provided by the charger and may void the manufacturers warranty CAUTION Never plug a 120VAC only charger into a receptacle not rated for 120VAC nominal These chargers are suitable for use with all 24V 12 cell rechargeable lead acid gel cell batteries ONLY It is intended for use with batteries rated up to 200 amp hours This charger was manufactured and tested according to the applicable technical standards referenced herein It complies with safety regulations as
10. ing 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 Curtis 1620 Manual page 4 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
11. ith 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 VI5a Equalize Mode see Figure 2 and IV V Float Mode see Figure 3 For definitions of the variables mentioned in this section refer to Table 1 Curtis 1620 Manual page 2 2 7 1 End of Charge Mode t T cmax Thy 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 Vly charge current will be limited to lower value 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 8096 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 discharg
12. minal 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 4 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
13. quipped 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 1 6 1 1 6 1 2 6 1 3 6 1 4 6 1 5 6 1 6 Replacing the fan Disconnect the charger from power and from the battery Remove the fanguard by simultaneously pushing in the retaining clips on either side of the fan and gently pulling the fan guard away Unplug the fan assembly noting the fan orientation air flow direction and wire routing Remove the fan assembly 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 Replace fan guard and push until a click is heard Verify both retaining clips have fully engaged Curtis 1620 Manual page 10 Table 1 Programming Parameters Limits ADVANCED MODE Constant Current Icc 10 20A 0 5A Constant Voltage Level 26 30V 29V 0 1VDC Vcv Low Voltage Current 2 10A GA 0 5A Ilv S o Rd in End of charge soft overvoltage 29 35V 31VDC 0 1V Veoc iii i Restart Voltage Vrst 22 28 26VDC 0 1V Bulk Charge Threshold 0 26VDC 24VDC 0 1VDC Low Voltage Lockout
14. 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 Curtis 1620 Manual page 8 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 Flash Pattern Indication Yellow and Green No battery blink together or reverse polarity Yellow blinks Green off Charger overvoltage Yellow blinks once Not reaching VCV 2seconds off repeats within Tcmax Green off Yellow blinks twice Not reaching Vlv 2 seconds off repeats within Tlv Green off No indicators on No power or damaged charger AC power Charger may be damaged Consult manufa
15. um alloy black finish Polycarbonate black 292L x 165 0W x 73 0H 2 8kg IEC 320 C14 Molex 39 01 2040 For use with Curtis Instruments Model 1311 handheld programmer only Pin Function 1 Rx 2 SEC RTN 3 Tx 4 12V Molex 39 01 4030 60mA max current Pin Function 1 See wiring diagram 1 2 No connection 3 See wiring diagram 1 2 x M5 studs max torque 2 2Nm Pin Function B output output page 1 Curtis 1620 Manual ree 2 2 2 3 100V max 60mA max Wiring diagram 1 2 4 Environmental Operating temperature Storage temperature Humidity Shock Vibration Protection 2 5 Compliance Radiated Emissions Conducted Emissions EN50082 1 1997 ESD Radiated Immunity Electrical fast transient Surge Immunity Conducted Immunity Power Frequency Magnetic Field Voltage dips and sags Harmonics Voltage fluctuations flicker Safety 2 6 Battery Types FCC Part 15 Class A FCC Part 15 Class A 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 EN55011 Class A EN55011 Class A X EN61000 4 2 1995 EN61000 4 3 1995 1 1998 N61000 4 4 1995 N61000 4 5 1995 N61000 4 6 1996 61000 4 8 1993 N61000 4 11 1995 N61000 3 2 2000 NG61000 3 3 1995 60335 1 1995 EN60335 2 29 1997 Ei pj pn p p Bp pnm pj This charger is suitable for use w
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