Curtis 803 User manual
MODEL 803
“FUEL”GAUGE/HOUR METER
!*&)26758(7.326&5*+800<!
®
CURTIS INSTRUMENTS, INC.
200 Kisco Ave.
Mount Kisco, New York 10549
914-666-2971
www.curtisinstruments.com
53002 REV E 3/13
###" Page
1. Model Encodement 2
2. Technical Specifications
2.1 Electrical 4
2.2 Mechanical 6
2.3 Environmental 7
3. Installation 8
4. Operation 16
5. Troubleshooting 18
6. Maintenance 19
7. Safety 20
8. Warranty 21
#
! 9999 :;<====
Voltage
12
24
1224
2436
2448
3648
7280
Reset level
(See page 17)
Discharge profile
C = Adjustable
(See Table 3)
Output
J = N.C. holding relay
Contact rating =
3 Amps
when continuously
closed, 1 Amp
when opening
K = N.C. relay
Y = N.O. relay
Contact rating =
1 Amp
3zzO
O = Curtis
logo
B+ HIGH (Pin 8) Current B+ LO (Pin 7) Current
Model
Voltage
Output
Option
I Nominal
@B+=Nom
I Maximum
@B+=Max
I Nominal
@B+=Nom
I Maximum
@B+=Max
Dual
Voltage
Untis
12/24V G/Z 26mA@24V 39mA@30V 61mA@12V 120mA@15V
24/36V J 34mA@36V 48mA@45V 27mA@24V 42mA@30V
24/36V K/Y 49mA@36V 67mA@45V 33mA@24V 52mA@30V
24/48V J 34mA@48V 48mA@60V 27mA@24V 42mA@30V
24/48V K/Y 47mA@48V 64mA@60V 33mA@24V 52mA@30V
36/48V J 35mA@48V 48mA@60V 29mA@36V 42mA@45V
36/48V K/Y 44mA@48V 60mA@60V 34mA@36V 50mA@45V
72/80V J 30mA@80V 40mA@100V 28mA@72V 38mA@90V
72/80V K/Y 33mA@80V 45mA@100V 29mA@72V 41mA@90V
#" #"
0*(75.(&0
Operating Range
± 25% of nominal voltage
B+ HIGH (Pin 8) Current B+ LO (Pin 7) Current
Model
Voltage
Output
Option
I Nominal
@B+=Nom
I Maximum
@B+=Max
I Nominal
@B+=Nom
I Maximum
@B+=Max
Single
Voltage
Untis
12V J 35mA@12V 59mA@15V N/A N/A
24V K/Y 34mA@24V 53mA@30V N/A N/A
*(-&2.(&0
Display
Battery state-of-charge: 10-bar, tri-color LED
our Meter: 6-digit LCD, 5mm high
Resolution
Hour Meter
99,999.9 ours
ardware Kit
Mounting bracket, thumbnuts or M4 ex nuts (2),
lock washers (2), mating connector Molex
No. 39-01-2085, w/pins No. 39-00-0039, no
connectors in bulk shipments.
Panel Cutout
52mm, 2 1/16” diameter
29.5321*27&0
Temperature
Operating: –40°C to +65°C
Storage: –50°C to +90°C
umidity 95% R (Non Condensing) at 38°C
Shock & 2.2 G, 20-200 z; 20 minute period;
Vibration X,Y,Z, 13 cycles each
"##
The Model 803 Installation Kit includes a
pre-assembled mating connector with
5” terminated wires.
Ask for Curtis Part Number 15369002.
The Model 803 fits into a dash-panel cutout measuring
2 1/16” (52 mm).
Terminal Assignment (see diagram on page 13)
.235&77*5<
Single voltage models: Pin 8 to battery +; Pin 7, open.
Dual voltage models: When vehicle voltage is the higher
voltage of the 2 operating voltages, Pin 8 connects to
battery +; Pin 7, open. When vehicle voltage is the lower
of the 2 operating voltages, Pin 7 connects to battery +,
Pin 8, open.
The discharge indicator uses Pin 7 or 8 for its battery
state-of-charge measurements. Connection are to be
made as close as possible to battery to prevent voltage
drops that will cause errors in discharge indicator
readings. The connection is not to be switched by
the vehicle’s keyswitch.
.2&77*5<>
Connect to battery ground as close to battery
as possible.
.2*<6:.7(-
The keyswitch turns on and off the LED display of the
battery discharge indicator. Monitoring of the battery
continues when Pin 2 is turned off and the display
is not lit.
The hour meter display is unaffected by Pin 2, although
it cannot accumulate more time as long as the
keyswitch pin is not energized. The control inputs RM
(+) and RM (–) are enabled by the keyswitch. Pin 2
is connected to the vehicle’s keyswitch.
.26385*7*5327530
In normal operation, Pin 1 or 6 is connected and the
other is left open. Only one of these pins is connected
when using normal hour meter function. It is possible to
OR the hour meter between the two inputs so that it
accumulates the total time either system is on. our
meter control logic is detailed in Table 2.
.2385*7*5
RM (+) (for use with a switched positive voltage)
Pin 6 connects to a high voltage as defined in Table 1
to activate the hour meter. Leaving Pin 6 open or
connecting it to a low voltage gives control of the hour
meter to the our Meter (–) input. See Table 2.
.2385*7*5>
RM (–) (for use with a switched ground)
Pin 1 connects to a low voltage level as defined in
Table 1 to activate the hour meter. Leaving Pin 1 open
or connecting it to high voltage gives control of the hour
meter to the our Meter (+) input.
.2!*0&<
Pin 3 connects in series with the lift coil circuit (or
the circuit to be switched at empty). For holding relay
(J), Pin 3 must be electrically closer to battery +
than Pin 4
.2!*0&<
Pin 4 also connects in series with the circuit to be
switched at empty.
HRM HRM+ & Keyswitch
Enabled Disabled Enabled Disabled
Model VLResistance VHResistance VHVL
Single
Voltage
Untis
12V <1.5V <1.8kOhm >5V >6.8kOhm >8.5V <2.5V
24V <2.3V <5.5kOhm >7.5V >20kOhm >8.5V <2.5V
Dual
Voltage
Untis
12/24V <1.7V <4.4kOhm >5.5V >20kOhm >8.5V <2.5V
24/36V <2.3V <5kOhm >7.5V >20kOhm >8.5V <2.5V
24/48V <2.3V <5kOhm >7.5V >20kOhm >8.5V <2.5V
36/48V <2.3V <3.2kOhm >7.5V >20kOhm >8.5V <2.5V
72/80V <3.3V <5.8kOhm >11V >20kOhm >11.5V <3.5V
#&'0*385*7*5327530.2*"4*(.+.(&7.326
#&'0*385*7*53275303,.(
.2!> .2! 385*7*5"7&786
igh Low Off
igh Open Off
Open Low Off
Open Open Off
Low igh On
Low Low On
Low Open On
igh igh On
Open igh On
#: Fuses and Wires
Regulations may require that the Model 803 be
fused. If installing a fuse, use a 10A fuse wired with
1.5mm or equivalent wire. The voltage drop across the fuse,
its holder, and connectors must be less than 1% of the
nominal system voltage.
Discharge Adjustments
Table 3 lists the voltages per cell under load that correspond
to an empty indication on the gauge (lockout point).
#&'0*.6(-&5,*)/8671*27"*77.2,6
"*77.2,$307*00&7147<
K 1.57
L 1.63
M 1.68
N 1.73 (factory setting)
O 1.78
P 1.82
Q 1.84
R 1.86
S 1.89
T 1.91
U 1.93
CURTIS Model 803 Rear View
Connections for Typical Model 803 Application
Vehicle system voltage is the higher of the two operating
voltages of a dual voltage unit. our meter measures
“keyswitch on” time.
Reset type/level (after or during recharge)
CTR = Charge Tracking Reset
If the gauge is connected to the battery during recharge,
the gauge will track the battery charge level.
For standard “B” profile, CTR Full = 2.35 vpc and
CTR Empty = 2.10 vpc.
OCR = Open Circuit Reset
If the gauge is disconnected from the battery during
recharge, the gauge will retain the last indication. It will
advance to full when reconnected only if the battery voltage
is above the OCR level. For standard (“B”) reset, OCR =
2.09 VPC*.
*VPC = volts per cell.
!#
Display
The Curtis Model 803 combines in one instrument a
completely solid state LED battery state-of-charge
indicator, an LCD hour meter, and lift lockout.
Only when battery is properly charged is right
most LED lit. As battery’s state-of-charge decreases,
successive LEDs
light up, one at
a time.
ere, the LED flashes
indicating “energy
reserve” (70% discharged).
The left most 2 LEDs flash
indicating “empty” (80%
depth of discharge). At this
point, lift lockout occurs.
385*7*5
1
1
#538'0*6-337.2,
The following checklist should help you to
troubleshoot any problems with the instrument.
53'0*1 366.'0*&86*6
No display Terminals not connected or
improper voltage
Stays at FULL Instrument voltage does not
match battery voltage,
B+ connected to the wrong
terminal
Will not reset Instrument voltage does not
match battery voltage, or battery
not fully charged
Resets w/o charging battery Not connected directly to
battery terminals
EMPTY too soon B+ connected to wrong terminal,
or instrument voltage does not
match battery voltage, or
terminals not directly connected
to battery
&.27*2&2(*
Model 803 Series is not serviceable in the field. Units returned
to the factory within the warranty period (see inside backcover)
will be replaced without charge.
37*6
This equipment is intended to be used on battery
powered industrial vehicles such as Lift Trucks
(Forklifts), Pallet Trucks, and Scrubbers.
If the equipment is used in a manner not specified
by the manufacturer, the protection provided by the
equipment may be imparied.
Direct Current
Reinforced Insulation
"&+*7<26758(7.326
This instrument was manufactured and tested
according to the applicable technical standards. It complies with
all the safety regulations as shipped from the factory.
Installation and startup must be performed by skilled personnel.
Failure to install and operate the unit in accordance with these
instructions may result in damage or injury.
If safe operation of the instrument can no longer be ensured,
stop and secure it against accidental operation.
If instrument failure or malfunction may cause personal injury or
material damage, use additional safety measures such as limit
switches, guards, etc.
Read the Operating Instructions carefully before startup.
Note the safety instructions marked with this
warning symbol in this manual.
%&55&27<
Curtis Instruments’ products and/or components are guaran-
teed against defects in workmanship and material for a period
of two years, or as defined in the individual product literature,
from date of shipment from our factory, when applied in a prop-
er application within specified ratings. This guarantee is limited
to repair or replacement F.O.B. our factory. There is no further
warranty or implied representation, guarantee, promise or
agreement as to any Curtis Instruments product and/or compo-
nent. Curtis Instruments, Inc., cannot assume responsibility or
accept invoices for unauthorized repairs to its products and/or
components, even though defective. In no case will Curtis
Instruments’ responsibility extend to products, components or
equipment not of its manufacture. Under no circumstances
shall Curtis Instruments, Inc., be liable for any special or con-
sequential damages or loss of profits or other damages.
Returned goods will not be accepted unless identified by a
Curtis Return Material Authorization (RMA).
All specifications are subject to
change without notice.
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