CURTIS 802 Fuel Gage/Hour Meter User manual

MODEL 802

“FUEL” GAGE/HOUR METER

®

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Read Instructions Carefully !

Safety Instructions

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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.

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Note the safety instructions marked with this warning symbol in this manual.

TABLE OF CONTENTS

1. Model Encodement

2. Technical Specifications

2.1 Electrical

2.2 Mechanical

2.3 Environmental

3. Installation

4. Operation

5. Troubleshooting

6. Maintenance

Page

2

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7

12

4

5

6

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1. MODEL ENCODEMENT

802RB wwww

Voltage

12

2436

2448

3648

7280

x

Reset type/level

B = 2.09 VPC

2

y

Discharge profile

G = 1.97 VPC at Full

1.75 VPC at Empty

N = 2.04 VPC at Full

1.73 VPC at Empty

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001O

O = Curtis logo

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2. TECHNICAL SPECIFICATIONS

2.1 Electrical

Operating Range

± 25% of nominal voltage

Operating Current

Voltage (volts) Nominal Current (mA) Maximum Current (mA)

12 35 58

24/36

24/48

18/25

18/25

25/35

25/35

36/48

72/80

18/25

18/25

25/35

25/35

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2.2 Mechanical

Display

Battery state-of-charge: 10-bar, tri-color LED

Hour Meter: 6-digit LCD, 5mm high

Hour Meter Range & Resolution

99,999.9 Hours

Hardware Kit

Mounting bracket, thumbnuts or M4 Hex nuts (2), lock washers (2), Quick Connect connectors (5).

No connectors in bulk shipments.

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Panel Cutout

52mm, 2 1 /

16

” diameter

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2.3 Environmental

Temperature

Operating:

Storage:

-40°C to +65°C

-50°C to +90°C

Humidity

95% RH (Non Condensing) at 38°C

Shock &

Vibration

Meets SAE J 1378

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3. INSTALLATION

The Model 802 fits into a dash-panel cutout measuring 2

1

/

16

” (52 mm).

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Terminal Assignment

(see diagram on page 9)

Terminal 1 = High Battery +

Single voltage models: Terminal 1 connects to battery +;

Connection is made as close as possible to the battery to prevent voltage drops that will cause errors in discharge indicator readings. The connection is made before vehicle’s keyswitch so that the keyswitch does not take power from Terminal 1. Terminal 5 is left open.

Dual voltage models: Terminal 1 connects to battery + when vehicle voltage is the higher of the 2 voltage ranges of the Model 802., Terminal 5 is left open.

Terminal 2 = Battery –

Terminal 2 connects to battery – as close to the battery as possible.

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Terminal 3 = Hour Meter +

Terminal 3 connects to a high voltage as defined in Table 1 to activate the hour meter. By connecting Terminal 3 to a low

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voltage or leaving it open gives control of the hour meter to the Hour Meter (–) input. See Tables 1 & 2.

Terminal 4 = Hour Meter –

Terminal 4 connects to a low voltage as defined in Table 1 to activate the hour meter. Leaving Terminal 4 open or connecting it to a high voltage gives control of the hour meter to the Hour Meter (+) input. See Tables 1 & 2.

Terminal 5 = Low Battery +

Single voltage models: Terminal 5 remains open.

Dual voltage models: Terminal 5 connects to battery + when vehicle voltage is the lower of the 2 voltage ranges of Model 802, Terminal 1 is left open. Connect as close as possible to battery to prevent voltage drops that will cause error in discharge indicator readings. The discharge indicator uses Terminal 5 for its battery stateof-charge measurements. The voltage is not to be switched by the vehicle keyswitch.

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Terminal 6 = Keyswitch

The keyswitch, Terminal 6, turns on and off the LED display of the battery discharge indicator. Monitoring of the battery continues when this terminal is turned off and the display is not lit. The hour meter display is unaffected by this terminal, although it cannot accumullate more time as long as the keyswitch terminal is not energized. The control inputs HRM (+) and HRM (–) are enabled by the keyswitch. Terminal 6 is connected to the vehicle’s keyswitched battery + line.

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Table 1. Hour Meter Control Lines & Impedance

Specifications

Model Low Voltage High Voltage Min. Impedance

Maximum Minimum HRM+ HRM-

12 VDC

24/36 VDC

3.0 VDC 8.0 VDC

5.0 VDC 15.0 VDC

24 k Ω 12 k Ω

80 k Ω 20 k Ω

24/48 VDC

36/48 VDC

5.0 VDC 15.0 VDC 80 k Ω 20 k Ω

7.0 VDC 22.0 VDC 120 k Ω 30 k Ω

72/80 VDC 15.0 VDC 45.0 VDC 240 k Ω 60 k Ω

Table 2. Hour Meter Control Logic

Ter. 4 (HRM-) Ter. 3 (HRM+) Hour Meter Status

High Low Off

High Open Off

Open Low Off

Open Open Off

Low High On

Low Low On

Low Open On

High High On

Open High On

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NOTE: Fuses and Wires

Regulations may require that Model 802 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.

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4. OPERATION

Display

The Curtis Model 802 combines in one instrument a completely solid state LED battery state-of-charge indicator, and a LCD hour meter.

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.

Here, the LED flashes indicating “energy reserve” (70% discharged).

The left most 2 LEDs flash indicating “empty” (80% depth of discharge).

LCD Hour Meter

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Reset type/level

(after or during recharge)

CTR = Charge Tracking Reset

If the gage is connected to the battery during recharge, the gage will track the battery charge level.

OCR = Open Circuit Reset

If the gage is disconnected from the battery during recharge, the gage 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.

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5. Troubleshooting

The following checklist should help you to troubleshoot any problems with the instrument.

Problem

No display

Possible Causes

Terminals not connected or improper voltage

Stays at FULL

Will not reset

Instrument voltage does not match battery voltage,

B+ connected to the wrong terminal

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

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6. Maintenance

Model 802 Series is not serviceable in the field. Defective units returned to the factory within the warranty period (see inside backcover) will be replaced without charge.

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Guarantee - Curtis Instruments’ products and/or components are guaranteed 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 proper 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 component. 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 consequential damages or loss of profits or other damages. Returned defective 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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CURTIS INSTRUMENTS, INC.

200 Kisco Avenue, Mt. Kisco, NY 10549

Tel. (914) 666-2971 • FAX (914) 666-2188

53005 REV B 7/01