Cotek CX1215 User manual

CX-SERIES
ADVANCED BATTERY
CHARGER

1
Table of Content
1. IMPORTANT SAFETY INFORMATION............................................................................ 2
1-1 General Safety Precautions ................................................................................................. 2
1-2 Battery Precautions.............................................................................................................. 2
2. FEATURES........................................................................................................................ 3
2-1 Battery Charging Curve........................................................................................................ 3
2-2 Specification......................................................................................................................... 5
2-3 Mechanical Drawings........................................................................................................... 6
3. PRODUCT DESCRIPTION.............................................................................................. 10
3-1 Configurations.................................................................................................................... 10
3-2 S1 Dip Switch Setting......................................................................................................... 11
3-3 Charging Status LED Indicator........................................................................................... 11
3-4 Failure Indicator ................................................................................................................. 12
3-5 Pin Assignment of CN2 –For Alarms Signal & Fan Control............................................... 12
3-6 Pin Assignment of CN3 –For Temperature sensor & Remote control............................... 12
3-7 Pin Assignment of CN4 –For Remote control) .................................................................. 12
3-8 Pin Assignment of ESB Connectors - For CX1215/1225/1235) ......................................... 13
3-9 Temperature Compensation .............................................................................................. 13
3-10 Rescue Battery Curve:..................................................................................................... 14
3-11 Battery Charger Selection (Reference only)..................................................................... 14
3-12 Battery Voltage setting suggestion................................................................................... 15
4. INSTALLING THE COTEK ADVANCED CHARGER..................................................... 15
4-1 Battery charger connection diagram .................................................................................. 16
5. TROUBLE SHOOTING ................................................................................................... 19
6. WARRANTY STATEMENT............................................................................................. 19

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1. Important Safety Information
WARNING!
BEFORE INSTALLING OR USING CX-SERIES
BATTERY CHARGER, YOU NEED TO READ
FOLLOWING SAFETY INFORMATION CAREFULLY.
1-1 General Safety Precautions
1-1-1. For indoor use, do not expose CX-Series Battery Charger to water, mist, snow, or
dust. To reduce the risk of fire, do not cover or obstruct the ventilation enclosure.
1-1-2. To avoid the risk of fire and electric shocks, make sure that existing wiring is in
good electrical condition and not undersized.
1-1-3. Do not charge non-rechargeable batteries.
1-1-4. Disconnect the AC Grid before making or breaking the connections to the battery.
1-1-5. Only the AC cord with IEC socket is allowed to plug to the battery charger.
1-1-6. Never charge a frozen battery.
1-1-7. If the AC cord is damaged do not attempt to use. It must be replaced or repaired
by a qualified person.
1-1-8. Corrosive substances may escape from the battery during charging and damage
delicate surfaces. Please store and charge in a suitable area.
1-2 Battery Precautions
1-2-1. If battery acid contacts your skin or clothing, wash it out with soap and water
immediately.
1-2-2. If battery acid contacts your eyes, wash it out with cold running water for at least
20 minutes and get medical attention immediately.
1-2-3. Never smoke or make a spark or flame in the vicinity of the battery or the engine.
1-2-4. Do not drop metals on the battery.
The resulting sparks or short-circuits on the battery or other electrical parts may
cause an explosion.
1-2-5. Remove personal metal items such as rings, bracelets, necklaces, and watches
when operating with lead-acid batteries. It may cause short circuit and very high
temperature, which can melt metal items.

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2. Features
Universal AC input with active PFC
Compatible with Lead Acid, Li-ion, Gel and AGM batteries
Support remote controller CR-1 as optional accessory.
Voltage / temperature compensation
2 stage fan speed control (Sleep mode)
Output power OK signal
Output alarm signal
High efficiency and high reliability
Built-in battery rescue function
Built-in Engine Start Battery (ESB) output function
Protection Short Circuit / Over Voltage / Over Temperature / Brown-out Protection
Withstand 2G vibration test
2-1 Battery Charging Curve
2-1-1 Bulk Stage (Constant Current)
At the beginning of the charging process, the flat battery is charged at constant current
(maximum charge current) until the battery voltage reaches the set charging voltage (Refer
to 3-2 charging mode setting).

4
2-1-2 Absorption Stage (Constant Voltage)
The absorption charging duration will depend on the battery status.
Before moving to absorption stage, charger will wait for two minutes then charging at
constant voltage until the battery is fully charged.
Once the battery is fully charged or the charging current is below 6.25% of the rated
charging current for 15 minutes, then the absorption stage ends.
2-1-3 Float Stage
After absorption stage, the battery charger switches to float stage, maintains the battery at
100% charge without overcharging or damaging the battery. This means the charger can
be left connected to the battery continuously.
2-1-4 Recondition stage
Every 12 days, the battery charger switches back to Bulk stage for 85 minutes in order to
revive the battery. This prevents any fatigue symptoms such as sulphation.

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2-2 Specification
Model
CX1215
CX1225
CX1235
CX1250
CX1280
CX2415
CX2425
CX2440
Output
Battery Type
Lead Acid / Li-ion / Gel / AGM
Standard Boost Charge
Voltage
14.4V / 14.7V (Select by S1 DIP switch)
28.8V / 29.4V
(Select by S1 DIP switch )
Standard Float Charge
Voltage
13.8V / 13.5V (Select by S1 DIP switch)
27.6V / 27V
(Select by S1 DIP switch)
Main Rated Current
15A
25A
35A
50A
80A
12.5A
25A
40A
Main Output
1
2
2
3
3
2
3
3
ESB Output
1
1
1
--
--
--
--
--
ESB Output Voltage /
Current
13.8V/2A
13.8V/2A
13.8V/2A
--
--
--
--
--
Battery Charging Mode
3-stage charging capability IUOU
Isolation Type
Use active power MOSFET on each output terminal
Single Output Current Limit
15A
25A
35A
40A
40A
12.5A
25A
40A
Input
Voltage Range
90~264VAC
Frequency Range
47~63Hz
Power Factor (Typ.)
PF > 0.92 at full load
Efficiency (Typ.) at 230Vac
87%
87%
87%
87%
87%
90%
90%
90%
Protection
Short Circuit
Current is reduced to < 1A continued 30sec., will operate 30 seconds then turn off
Over Voltage
17.5V ±1%, protection type: shut down output
(recovery after resetting AC power ON)
35V ±1%, protection type: shut
down output
( recovery after resetting AC
power ON )
Over Temperature
Charger Over Temperature 100 ±5°C detected by heat sink
52±5°C (Optional temperature sensor)
Auto recovery after heat sink temperature goes down to 50±5°C
Function
Alarm Signal
NC. / NO. Relay contact output (Please reference Alarms signal & Fan control)
Temperature Compensation
-10mv / 0.5°C with COTEK temperature sensor
Sleep Mode
By Remote Controller and S1-4 DIP switch (Please refer to section 3-2)
Remote Controller
Support COTEK Remote Controller CR-1 ( Please refer to section 3-6 and 3-7)
Environment
Working Temp.
-20~50°C (refer to output load de-rating curve)
Working Humidity
20~90% RH non-condensing
Temp. Coefficient
±0.03% (0~50°C)
Vibration
10~500Hz, 2G 10min. / 1cycle period for 60min. each along X, Y, Z axes.
Safety
&
EMC
Safety Standards
Certified EN 60335-1, EN60335-2-29
Withstand Voltage
I/P-O/P: 4242VDC, I/P-FG: 1768VDC, O/P-FG: 700VDC
Isolation Resistance
I/P-O/P: 100M Ohms / 500VDC
EMI Conduction & Radiation
EN 55022; EN 55024; EN 61204-3; EN 55014-1; EN 55014-2
Harmonic Current
EN 61000-3-2; EN 61000-3-3; EN 61204-3; EN 61000-6-1; EN 61000-6-3
EMS Immunity
IEC 61000-4-2, 3, 4, 5, 6, 8, 11; ENV 50204
Others
Dimension (WxHxD)
(Unit: mm)
183x72x243.4
183x72
x263.4
213x76.5
x272.4
213x76.5
x312.4
183x72
x243.4
213x76.5
x272.4
213x76.5
x312.4
Packing (Unit: kg)
1.6
1.7
1.9
3.1
4.0
1.6
2.9
3.9

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2-3 Mechanical Drawings
Model: CX1215/1225/1235/2415
Unit: mm

7
Model: CX1250/1280/2425/2440
Unit: mm

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2-3-1 CX1215/1225/1235/2415 (Front Panel)
Front panel
①
AC Inlet (IEC)
⑥
Status LED
②
ESB connector
⑦
CN2
③
DC output -
⑧
TEMP/CN3
④
DC output +
⑨
CN4
⑤
Dip Switch 1 (S1)
Note: For detail description on item 5 (Dip Switch S1), please refer to section 3-2
2-3-2 CX1215/1225/1235/2415 (Rear Panel)
Rear panel
①
Power Switch
②
Fan