Manual - Curtis Instruments

Manual - Curtis Instruments
Manual
Curtis Models 1622, 1626, and 1627
Battery Charger
Curtis Instruments, Inc.
200 Kisco Avenue
Mt. Kisco, NY 10549
www.curtisinstruments.com
Read Instructions Carefully!
Specifications are subject to change without notice.
© 2017 Curtis Instruments, Inc. ® Curtis is a registered trademark of Curtis Instruments, Inc.
© The design and appearance of the products depicted herein are the copyright of Curtis Instruments, Inc.
53100 Rev A 1/17
1.0 IMPORTANT SAFETY AND OPERATING INSTRUCTIONS
TABLE OF CONTENTS
Save these instructions. This manual contains important safety and operating instructions for the
1622,1626, and 1627 Industrial Battery Chargers. Read this information in its entirety before using
your charger. For technical support, please contact the manufacturer or distributor of your vehicle or
machine, as their version of this charger may require unique operating instructions.
1.0 Important Safety and Operating Instructions........................................1
Safe Operating Instructions....................................................................2
2.0 Understanding the Battery Charger.......................................................3
WARNING
Only use the charger with a charging profile that is appropriate to the specific battery type. Other
usage may cause personal injury and damage. Lead acid batteries may generate explosive hydrogen
gas during normal charging. Keep sparks, flames, and smoking materials away from batteries. Do not
operate charger in an enclosed area or an area with restricted ventilation. Never charge a frozen or
non-rechargeable battery. Observe all battery manufacturers’ precautions (e.g. maximum charge rates
and if cell caps should be removed while charging).
3.0 Charging Profiles.....................................................................................4
4.0 Identifying Charger Serial Number.........................................................5
Table 1 Charger Error & Fault Codes.............................................................6
DANGER
There is risk of electric shock. Connect the charger power cord to an AC outlet that has been properly
installed and grounded in accordance with all local codes and ordinances. A grounded AC outlet is
required to reduce the risk of electric shock—do not use ground adapters or modify the plug. Do not
touch uninsulated portions of the output connector or uninsulated battery terminals. Disconnect the
AC supply before making or breaking the connections to the battery. Do not open or disassemble
the charger. Do not operate the charger if the AC supply cord or DC output cord is damaged or if the
charger has received a sharp blow, been dropped, or is damaged in any way. Refer all repair work to
the manufacturer, or qualified personnel. The charger is not intended for use by individuals (including
children) with reduced physical, sensory, or mental capabilities. Nor should individuals whor lack
experience and/or knowledge of electrical systems and battery charging use the charger, unless they
have been given supervision or instruction concerning use of the charger by a person responsible for
their safety. Supervise children to ensure they do not play with the charger.
Figure A
Models 1622, 1626 and 1627
Battery Chargers
Curtis Models 1622, 1626, and 1627 Manual
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Curtis Models 1622, 1626, and 1627 Manual
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2.0 UNDERSTANDING THE BATTERY CHARGER
SAFE OPERATING INSTRUCTIONS
• The charger has up to 25 selectable charging profiles stored in its internal memory to charge
batteries. These profiles are specific to each manufacturer and model of battery. Your equipment
supplier or charger distributor is responsible for ensuring the active charge profile matches the
battery pack charging requirements. Contact them with any questions about which profile to
select for each battery pack.
1. When you first plug the charger into AC power, the AC Power Indicator illuminates solid blue to
indicate AC power is present.
Solid blue = AC power available
2. The Battery Charging Indicator has 4 states as follows:
Flashing green = Low state of charge
Solid green = High state of charge
• The charger may become hot during charging. Use hand protection to safely handle the charger
during charging.
Flashing green = High state of charge
Solid green = Charge completed
• To maintain safe operations, the unit automatically reduces its output power if the temperature
rises above set thresholds or if the AC input voltage is too low. The charger also reduces output
power if it detects the battery pack is damaged.
3. The Fault/Error/USB Indicator indicates faults, errors, and USB activity as follows:
• If power is interrupted, and then returns, the charger starts and continues to operate without
hazard to the user, or damage to the batteries.
Solid red = Charger fault
See display panel for details
• Unplug the charger from both AC and DC sources when cleaning, moving or conducting any
maintenance or repair on the charger. No user- serviceable parts are inside. Do not remove the
cover due to the risk of electrical shock.
Flashing amber = External error condition; Caution
See display panel for details
• Do not expose the charger to oil, dirt, mud or direct heavy water spray when cleaning the vehicle
or machine.
Flashing green = USB port active
Solid green = Safe to remove USB flash drive
See the error display for the code and error description in the Charger Error & Fault Codes Table.
• If the detachable AC input power cord set or DC output cord is damaged, do not use the charger
until they are replaced with cord sets appropriate to your region and application.
4. The Charging Output Indicator means that the charger output is active, and there is a potential risk
of electric shock.
• When mated with a sealed AC cord, the charger meets IP66 specifications, making it dust-tight
and protected against powerful water jets. If a cord set with an unsealed connector is used, the
plug and connector must be periodically inspected to ensure the contacts are clean and dry.
5. The Charge Profile / Error Display shows one of four possible codes to indicate different conditions:
• F codes: a condition has caused charging to stop. Re-insert AC power to reset the
charger to clear the error.
• E codes: an error condition has caused charging to stop. Re-insert AC power to reset the
charger to clear the error.
• P codes: the charger profile selection is active.
-- If this charger is provided with an AC cord set and the power plug does not match the power
outlet, contact the equipment manufacturer, distributor, or Curtis Instruments for the correct
AC cord set terminating with a 3-prong plug suitable for your region’s grounded power outlet.
-- In North America (and other 120V AC regions), the AC cord must be a 3-conductor UL Listed/
CSA approved detachable cord set at least 1.8m in length (≥ 6 feet), minimum 16AWG and
rated SJT; terminated with 250V, 13A or greater connector.
-- In Japan, the AC cord must be a 3-conductor PSE approved detachable AC cord set
terminated with 100V, 15A or greater connector.
• USB codes: the USB interface is active, and the USB flash drive should not be removed.
When the E, F, and P codes appear, the letter is followed by three numbers and a period to
indicate different conditions (e.g., E-0-0-4). See the Charger Error & Fault Codes Table for details on
these conditions and solutions.
6. The Select Charge Profile button is used to select a charge profile from the profiles that are stored on
the charger. Up to 25 charge profiles can be stored. See Selecting A Charge Profile for instructions.
-- In 220-240 VAC regions, the AC cord must be a 3-conductor safety approved cord set, with
1.5mm² conductors(min.), rated appropriately for industrial use. The cord must be terminated
on one end with a grounding
type input plug appropriate
for use in the country of
destination and both plug and
connector should be rated
250V, 10A, or greater.
7. The USB Host Port allows data to be transferred to and from the charger using a standard USB
flash drive, including the downloading of charge tracking data and updating of the charger’s
software and / or charge profiles.
• Extension cords must be 3-wire
cord no longer than 30m (100’) at
10 AWG or 7.5m (25’) at 16 AWG,
per UL guidelines.
3.
Fault / Error / USB Indicator
2.
Battery Charging Indicator
1.
AC Power Indicator
7.
USB Host Port
4.
Charging Output Indicator
5.
Charge Profile / Error Display
6.
Select Charge Profile Button
Only use compatible IEC320 C13 cables, as shown above
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Curtis Models 1622, 1626, and 1627 Manual
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3.0 CHARGING PROFILES
3. Press and release the Select Charge Profile button to advance through the charge profiles. The
selected charging profile will be displayed up to three times (e.g. “P-0-1-1” for Profile 11).*
The charger has up to 25 selectable charging profiles stored in its internal memory to charge batteries.
These profiles are specific to each manufacturer and model of battery. Your equipment supplier or
charger distributor is responsible for ensuring the active charge profile matches the battery pack
charging requirements. Contact them with any questions about the default profile, the other profiles on
the charger, and which profile to select for each battery pack.
Selecting A Charge Profile
1. Disconnect AC input from the charger, or from the wall outlet. Wait 30 seconds for the input relay to open.
* The process will time out and the profile will remain unchanged if there is 15 seconds of inactivity.
A profile number is allowed to display three times, or if AC power is cycled.
4. Once the desired charging profile is displayed, press and hold the Select Charge Profile button
for 10 seconds to confirm selection and exit Profile Selection Mode. When the charge profile is
confirmed, the Error Indicator and Battery Charging Indicator lights turn off, while the blue AC Power
Indicator remains illuminated. At this point, the button can be released.
5. Press the Select Charge Profile button to verify the desired profile has been selected.
In some circumstances, the charging profile output will be altered to maintain safe operations. The
unit automatically reduces its output power if the temperature rises above set thresholds, or if the
AC input voltage is too low. The charger also reduces output power if it detects the battery pack
is damaged. If power is interrupted, and then returns, the charger starts and continues to operate
without hazard to the user, or damage to the batteries.
4.0 IDENTIFYING CHARGER SERIAL NUMBER
The charger’s serial number is printed on the front of the charger. This is the number to provide when
requesting technical support.
2. While reconnecting AC input, press and hold the Select Charge Profile button. Hold the button
(approximately 10 seconds) through the light check function until the Error Indicator is on (in
amber) and the Battery Charging Indicator (in green) starts flashing.
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Table 1 Charger Error & Fault Codes
Code
Description
Solution
E-00-1
E-02-1
Battery high voltage
Possible causes: wrong battery voltage for charger; other charger also
attached; resistive battery.
Possible solutions: check the battery voltage and cable connections; check
battery size and condition.
This error will automatically clear once the voltage is in range.
E-00-2
E-02-2
Battery low voltage
Possible causes: battery disconnected, battery over discharged.
Possible solutions: check the battery voltage and cable connections; check
battery size and condition.
This error will automatically clear once the voltage is in range.
E-00-3
Charge timeout caused by
battery pack not reaching
required voltage within safe
time limit (charge profile
dependent)
Possible causes: charger output reduced due to high temperatures, poor
battery health, very deeply discharged battery and/or poorly connected
battery.
Possible solutions: operate at lower ambient temperature. Replace battery
pack. Check DC connections. This error will clear once the charger is reset
by cycling DC or AC.
E-00-4
Battery could not meet
minimum voltage (charge
profile dependent)
Possible causes: check for shorted or damaged cells.
Possible solutions: replace battery pack. Check DC connections. This error will
automatically clear once the charger is reset by cycling DC or AC.
E-00-7
Battery amp hour limit
exceeded
Possible causes: poor battery health, very deeply discharged battery, poorly
connected battery, and/or high parasitic loads on battery while charging.
Possible solutions: replace battery pack. Check DC connections. Disconnect
parasitic loads. This error will automatically clear once the charger is reset
by cycling DC or AC.
E-00-8
Battery temperature is out
of range
Possible battery temperature sensor error. Check temperature sensor and
connections. Reset charger. This error will clear once the condition has been
corrected.
E-01-2
Reverse polarity error
Battery is connected to the charger incorrectly. Check the battery
connections. This error will clear once the condition has been corrected.
E-01-6
E-01-8
E-02-6
USB operation failed
(software)
Software upgrade failure or script operation failure. Ensure the USB flash
drive is properly formatted and reinsert the USB flash drive.
E-01-7
USB operation failed
(hardware)
Remove and reinsert the USB drive. If condition persists, cycle AC and retry
by reinserting the USB drive.
E-02-3
High AC voltage error
(>270 VAC)
Connect charger to an AC source that provides stable AC between 85-270
VAC/45-65 Hz. This error will clear once the condition has been corrected.
E-02-4
Charger failed to initialize
The charger has failed to turn on properly. Disconnect AC input and battery
for 30 seconds before retrying.
E-02-5
Low AC voltage oscillation
error
AC source is unstable. Could be caused by undersized generator and/or
severely undersized input cables. Connect charger to an AC source that
provides stable AC between 85-270 VAC/45-65 Hz. This error will clear once
the condition has been corrected.
F-0-0-1, F-0-0-2
F-0-0-3, F-0-0-4
F-0-0-6
Internal charger fault. Remove AC and battery for minimum 30 seconds and
retry charger. If it fails again, please contact the manufacturer of your vehicle
or machine.
This is a Class A product complying with United States Federal Communications Commission, Code of Federal Regulations; 47CFR part 15. In a domestic
environment, this product may cause radio interference, in which case the user may be required to take adequate measures.
Curtis Models 1622, 1626, and 1627 Manual
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