Curtis 1620 User manual

Specifications subject to change without notice
©2002 CURTIS INSTRUMENTS,INC. 53033 REV B 9/03
is a registered trademark of Curtis Instruments, Inc.
MMAANNUUAALL
MODEL
1620
SWITCH MODE
BATTERY CHARGER
Before charging, read
instructions carefully!
Applicable to 230VAC units only
CURTIS INSTRUMENTS, INC.
200 Kisco Avenue, Mt. Kisco, NY 10549 • Tel: [phone] • FAX [phone]
www.curtisinst.com

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
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
Read the Operating Instructions carefully before using the Model 1620 charger.
1. 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.
2. 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.
3. WARNING – Explosive gases may result from charging. Provide adequate ventilation during charging.
Prevent flames or sparks.
4. 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.
5. WARNING – If safe operation of the charger can no longer be ensured, stop and secure it against
operation.
6. WARNING – If the supply cord is damaged, it must be replaced by a qualified person in order to avoid
hazard.
7. WARNING – Never charge a frozen battery.
8. WARNING – To reduce the risk of injury, charge only lead acid or gel cell type batteries. Do not attempt
to charge any other type of chargeable or non-rechargeable battery; these batteries may burst, causing
personal injury and damage.
9. 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.
10. CAUTION –
It is recommended that you disconnect the AC power cord before connecting or disconnectin g
the charger to the battery.
11. CAUTION – Not intended for outdoor use.
12. CAUTION – Charger surface may be hot while plugged in and for a period of time thereafter.
13. CAUTION – Units with fans 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.
14. CAUTION – If charger failure or malfunction may cause personal injury or material damage, use
additional safety measures such as limit switches, guards, etc.
15. 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.
16. 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.
17. CAUTION – Never plug a 120VAC only charger into a receptacle not rated for 120VAC nominal.
18. 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.
19. This charger was manufactured and tested according to the applicable technical standards referenced
herein. It complies with safety regulations as shipped from the factory.
20. 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.

2.4 Environmental
Operating temperature: 0°C to +50°C
Storage temperature: -40°C to +85°C
Humidity: 95% non-condensing at 38°C
Shock: SAEJ1378, 55g pulse at 9-13ms
Vibration: 5g rms, 5-500 Hz, 2 hrs. per axis
Protection: IP-54, including fan
2.5 Compliance
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 four different charge profiles: IVa (Off Mode,
see Figure 1), I1VI2a (Equalize Mode after Off Mode, see Figure 2), IV1V2(Float
Mode, see Figure 3), and I1V1I2V2(Equalize Mode after Float Mode, see Figure 4).
For definitions of the variables mentioned in this section, refer to Table 1.
Curtis 1620 Manual page 2
MODEL ENCODEMENT
TECHNICAL SPECIFICATIONS
2.1 Electrical
2.2 Mechanical
Case: Aluminum alloy, black finish
End caps: Polycarbonate, black
Dimensions (mm): 289L x 165.0W x 73.0H
Weight: 2.8kg
2.3 Connections
AC Power Inlet: IEC 320/C14
Programming Port: Molex 39-01-2040 For use with Curtis
Instruments' Model 1311 handheld programmer only.
PinFunction
1 Rx
2 SEC_RTN
3 Tx
4 +12V
Motor Controller Inhibit: Molex 39-01-4030 Capable of sinking up to 60mA
DC to ground.
PinFunction
1 See wiring diagram
2 No connection
3 See wiring diagram
DC Power Output: 2 x M5 studs
PinFunction
+B+ output
–B– output
Curtis 1620 Manual
page 1
1
2
1620uv-www/xx/yy-zzz
1620 u v - www / xx / yy - zzz
Model Cooling Sealing Input Output Output Series
Voltage Voltage Current Number
FS120 24 20 001
Fan Sealed 120VAC 24VDC 20 Amps Consult Factory
cooled for
230 additional options
230VAC
Input: 120VAC models 230VAC models
Voltage: 100-132VAC 180-264VAC
Frequency Range: 57-63Hz 47-63Hz
Input Current: 12Arms max. @ 100VAC/60Hz 4.5Arms max. @ 180VAC/50Hz
Output Voltage: 24VDC, nominal
Current: 0-20A
Max. Power: 480W
Radiated Emissions: FCC Part 15, Class A EN55011, Class A
Conducted Emissions: FCC Part 15, Class A EN55011, Class A
EN50082-1-1997 — X
ESD: — EN61000-4-2:1995
Radiated Immunity: — EN61000-4-3:1995 +
A1:1998
Electrical fast transient: — EN61000-4-4:1995
Surge Immunity: — EN61000-4-5:1995
Conducted Immunity: — EN61000-4-6:1996
Power Frequency Magnetic Field: — EN61000-4-8:1993
Voltage dips and sags: — EN61000-4-11:1995
Harmonics: — EN61000-3-2:2000
Voltage fluctuations (flicker) — EN61000-3-3:1995
Safety — EN60335-1:1995
EN60335-2-29:1997

2.7.2- Equalize Mode after End of Charge Mode
Figure 2. Charge profile for Equalize Mode after End of Charge Mode
Only flooded lead-acid (FLA) batteries require equalization. In order to prevent dam-
age to the battery, the charger will go through the equalization process once, automati-
cally returning to the charge profile being utilized immediately before the equaliza-
tion. The Model 1620 provides the option of equalizing batteries, without need for
separate power sources, in order to extend battery life.
Figure 2 defines the charge profile for the Equalize Mode if the previous charge
profile was Off Mode. Battery equalization is recommended periodically (every 3,
6 or 12 months) or when the specific gravity of the battery acid drops below a
certain level – review the battery manufacturers’ recommendations. After going
through bulk charge and Constant Voltage modes, the charger will reduce its out-
put current 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
2.7.1 – 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.
Curtis 1620 Manual
page 3

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 connected.
Curtis 1620 Manual
page 5
2.7.4- Equalize Mode after Float Mode
Figure 4. Charge profile for Equalize Mode after Float Mode
Only flooded lead-acid (FLA) batteries require equalization. In order to prevent dam-
age to the battery, the charger will go through the equalization process once, automati-
cally returning to the charge profile being utilized immediately before the equaliza-
tion. The Model 1620 provides the option of equalizing batteries, without need for
separate power sources, in order to extend battery life.
Figure 4 defines the charge profile for the Equalize Mode if the previous charge
profile was Float Mode. This profile behaves similarly to the Equalize Mode
(after Off Mode) except that after the equalization stage the charger will immedi-
ately enter standby. It will then behave as described in the Float mode – reactivat-
ing after the battery voltage drops 0.4V below Vfloat.
Curtis 1620 Manual page 6

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 (+) 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.
Curtis 1620 Manual page 8
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.
Curtis 1620 Manual
page 7
Flash Pattern Mode Charge Status
Yellow on, Green on Standby Indicator 1 Charge done, ready to use.
Yellow on, Green blinks1Charging Charging normally.
Yellow and Green blink1together Standby Indicator 2 Charge cycle has not started,
refer to troubleshooting section.
Yellow and Green blink alternately Programming 1311 programmer connected to the unit.
Yellow blinks1, Green on Standby Indicator 3 End of Charge (Veoc) voltage reached.
Charge done, ready to use.
Yellow blinks1, Green off Error Charge cycle stopped,
refer to troubleshooting section.
Yellow blinks2once, Error Charge cycle stopped,
2 seconds off, repeats, Green off refer to troubleshooting section.
Yellow blinks2twice, Error Charge cycle stopped,
2 seconds off, repeats, Green off refer to troubleshooting section.
No indicators on Off/Error Charger is unplugged, otherwise
refer to troubleshooting section.
1– 0.5s on, 0.5s off
2– 0.5s on
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 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.
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.
3
4

5
Curtis 1620 Manual page 10
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.
1– 0.5s on, 0.5s off
2
– 0.5s on
3–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.
Curtis 1620 Manual
page 9
Flash Pattern Indication Solution
Yellow and Green No battery Battery may be disconnected from
blink1together or reverse polarity charger or connected back wards.
Battery may be severely discharged.
Lower Vulvo in the software setting.
Battery damaged. Replace battery.
Yellow blinks1, Charger overvoltage Battery may have been disconnected
Green off
before the end of charge; reconnect the
battery and reset the charger2.
Battery manufacturer's rated voltage may
exceed charger's rating. Verify rated battery
voltage.
Yellow blinks2once, Not reaching VCV Battery manufacturer’s rated capacity may
2seconds off, repeats, within Tcmax. exceed charger's rating. Increase Tcmax,
Green off increase Icc, or reset the charger3.
Battery may be damaged or old.
Replace battery.
Yellow blinks2twice, Not reaching Vlv Battery manufacturer’s rated capacity may
2 seconds off, repeats, within Tlv exceed charger's rating. Increase Tlv, decrease
Green off Vlv, increase Ilv, or reset the charger3.
Battery may be damaged or old.
Replace battery.
No indicators on No power or Charger may be unplugged. Check for
damaged charger AC power. Charger may be damaged.
Consult manufacturer for repair or return.
6MAINTENANCE
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, chemicals,
etc. – may impair the effectiveness of the fan. If the operation of the fan is notice-
ably degraded, Curtis recommends an immediate replacement of the fan with
Curtis Part Number 17603351, 1620 Fan Assembly.
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.

Curtis 1620 Manual page 12
Curtis 1620 Manual
page 11
Programming mode Description Programming
Limits
Default Value Increment Accuracy* Definition
BASIC MODE2Battery Type 1 or 2 1 1 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
End of Charge 1, 2, or 3 1 1 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. An EQUALIZE cycle is
completed only once. Once the cycle is complete, it changes to the previous setting for
EoC Mode until the next time the EQUALIZE mode is selected.
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.
ADVANCED MODE Constant Current (Icc) 10-20A 20A 0.5A +/- 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.
Constant Voltage Level
(Vcv)
26-30V 29V 0.1VDC +/- 1% Battery voltage maintained by charger during bulk charge. This voltage is maintained by
continuously dropping the output current, until Veoc is reached.
Low Voltage Current
(Ilv)
2-10A 6A 0.5A +/- 5% 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.
Top-off current (Ito) 2-10A 6A 0.5A +/- 5% Current used to Equalize the batteries.
End of charge ("soft" overvoltage)
(Veoc)
29-35V 31VDC 0.1V +/- 1% Charger goes into "soft" overvoltage mode, from which it recovers when battery voltage
drops below Vrst.
EoC Threshold (Icv) 2-20A 4A 0.5A +/- 3% Current at which the charger transitions to EoC mode.
Restart Voltage (Vrst) 22-28v 26VDC 0.1V +/- 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 Vcv and then
enter stand by mode.
Bulk Charge Threshold (Vlv) 0-26VDC 24VDC 0.1VDC +/- 1% Battery voltage at which the charger switches from Ilv to Icc.
Low Voltage Lockout
(Vuvlo)
4-21VDC 5VDC 0.1VDC +/- 1% Battery voltage below which the charger will not turn on.
Equalize Voltage (Vequ) 29-33V 31VDC 0.1VDC +/- 1% Used when EoC Mode is EQUALIZE. The voltage at which the EQUALIZE mode is
ended, unless the mode ends by reaching Tto.
Float Voltage (Vfloat) 25-30V 26.8V 0.1VDC +/- 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.
Low Voltage Timeout (Tlv) 1-10hrs 1 hour 1 hour +/- 5min If battery does not reach Vlv within this timeout period, an error is indicated.
Equalize Timeout ( Tto) 0-5hrs 2 hours 1 hour +/- 5min Used when EoC Mode is EQUALIZE. Number of hours charger is kept at equalization
current, unless the mode is ended by reaching Vequ.
Maximum Charge Time
(Tcmax)
2-36hrs 16 hours 1 hour +/- 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.
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.
Table 1. Programming Parameters