MANUAL
1604/1608
SWITCH MODE
BATTERY CHARGERS
for Lead-Acid Batteries
Before charging, read
instructions carefully!
CONTENTS
1. MODEL ENCODEMENT.............................. page 1
2. TECHNICAL SPECIFICATIONS .................. page 2
3. INSTALLATION.............................................. page 4
4. OPERATION .................................................. page 5
5. TROUBLESHOOTING .................................. page 9
6. MAINTENANCE .......................................... page 9
MODEL ENCODEMENT
Model1
Input
Output
Output
Series
Voltage 2 Voltage 3
Series 4 Number 5
1604CS
-
-
-
-
-
-
AVS
AVS
AVS
AVS
AVS
AVS
/
/
/
/
/
/
12
24
12
24
12
24
/
/
/
/
/
/
04
04
08
08
08
08
-
-
-
-
-
-
xxx
xxx
xxx
xxx
xxx
xxx
1
1604FV
1608FS
1
1604CS: Convection cooled, sealed to IP-54
1604FV: Fan cooled, protected to IP-31
1608FS: Fan cooled, electronics sealed to IP-54, fan protected to IP-31
2
3
AVS: Auto Voltage Select, operates at 120VAC or 230VAC automatically
12: 12VDC
24: 24VDC
4
5
04: 4A
08: 8A
Series Number: Identifies charger features, consult Curtis
page 1
Curtis 1604/08 Manual
TECHNICAL SPECIFICATIONS
2.1 Electrical
Nominal Operating Voltage
12V / 24V, 4A Chargers
12V, 8A Chargers
24V, 8A Chargers
120VAC
230VAC
120VAC
230VAC
120VAC
230VAC
Input Voltage (VAC)
90 - 132
180 - 264
90 - 132
180 - 264
105 - 132
210 - 264
Operating Frequency (Hz)
Input Current (A rms, max.)
47 - 63
1.0 @
90V/60Hz
2.0 @
0.5 @
180V/50Hz
1.0 @
2.0 @
90V/60Hz
1.0 @
180V/50Hz
N/A
N/A
12VDC nominal outputs
24VDC nominal outputs
2
4.0 @
105V/60Hz
2.0 @
210V/50Hz
N/A
N/A
90V/60Hz
180V/50Hz
Input Leakage
(µA, max.)
<500 @
120V/60Hz
<500 @
230V/50Hz
<500 @
120V/60Hz
<500 @
230V/50Hz
<500 @
120V/60Hz
<500 @
230V/50Hz
Output Power (W, nom./max.)
12VDC nominal outputs
24VDC nominal outputs
48 / 67.5
96 / 135
4.0
96 / 125
192 / 240
8.0
Output Current (A, max.)
Output Voltage (VDC, nom./range)
12VDC nominal outputs
24VDC nominal outputs
12 / 6.0 - 15.0
24 / 12.0 - 30.0
2.2 Mechanical
Case:
Aluminum alloy, black finish
Polycarbonate, black
End caps:
Dimensions (mm max.):
1604CS & 1604FV:
1608FS:
160 L x 96 W x 52 H
160 L x 140 W x 52 H
Weight (kg) 1604/1608:
1.0/1.5
2.3 Connections
AC Power Inlet:
DC Power:
IEC 320/C14 Male on cable
ITT Cannon XLR-3-12C Male Plug or equivalent on cable
Pin Function
1
2
3
B+
B-
Motor Controller Charging Indicator
Programming Port: Molex 39-01-2040 with four female crimp terminals
(Molex 39-00-0056). Use with Curtis Model 1311 Hand
Held Programmer only.
Pin Function
1
2
3
4
Rx
SEC_RTN
Tx
+12V
Output Adapters:
P/N 17604348-1 for use with
Model 1288 Motor Controller
P/N 17604348-2 for use as
ISO-7176 compliant Off-board Charger
Pin
1
Function
Pin
Function
Motor Controller
1
2
3
B+
B-
B- (inhibit)
Charging Indicator
2
3
4
5
6
B+
N/C
N/C
B-
N/C
Charge Indicator: Low impedance capable of sinking 60 mA DC to B-.
Remote LED: Some models come with a wire harness for remote LED capability.
Contact your local Curtis sales office for details.
page 2
Curtis 1604/08 Manual
2.4 Environmental
Operating Range: -10˚C to + 50˚C
Storage Range:
Humidity:
Shock:
-40˚C to + 85˚C
95% RH (non-condensing) at 35˚C
SAE J1378, 55g
Vibration:
Protection:
5g rms, 5-500 Hz, 2 hours per axis
1604CS: IP54
1604FV: IP31 (horizontal mounting)
1608FV: IP54 (Electronics) IP31 (Fan)
2.5 Compliance
1604CS
1604FV
1608FS
UL 1012
UL 1012
UL1012
CAN/CSA-C22.2 No.107.2
EN60335-1
CAN/CSA-C22.2 No.107.2
EN60335-1
CAN/CSA-C22.2 No.107.2
EN60335-1
EN60335-2-29
EN55011
EN60335-2-29
EN55011
EN60335-2-29
EN55011
EN61000-3-3
EN61000-4-2
EN61000-4-3
EN61000-4-4
EN61000-4-5
EN61000-4-6
EN61000-4-8
EN61000-4-11
ENV 50204
EN61000-3-3
EN61000-4-2
EN61000-4-3
EN61000-4-4
EN61000-4-5
EN61000-4-6
EN61000-4-8
EN61000-4-11
ENV 50204
EN61000-3-3
EN61000-4-2
EN61000-4-3
EN61000-4-4
EN61000-4-5
EN61000-4-6
EN61000-4-8
EN61000-4-11
ENV 50204
2.6 Battery Types
All chargers are intended for use with lead acid or gel cell batteries only, for their
respective voltages.
2.7 Charge Cycle Profile
Models 1604 and 1608 use a multi-stage charge cycle, dependent upon battery
geometry, with software programmable set points.
1. Constant Current Mode: Output current is 4.0A max for the 4A models or
8.0A max for the 8A models. Current is held constant until the constant
voltage is reached. Output current is reduced during the Constant Current
Mode if the charger should begin to overheat.
2. Constant Voltage Mode: Output voltage shall be held at an average voltage of
approximately 14.3V for 12V chargers or 28.6V for 24V chargers. The charger
will hold the voltage to within 100mV of this value, reducing the current
gradually until the charging ends. Charging ends when the current falls below
0.5A or the charger remains in Constant Voltage Mode for more than 4 hours.
The charger will shut down and remain in standby.
page 3
Curtis 1604/08 Manual
3. Restart: If the battery self-discharges below 12.9V for 12V batteries or below
25.7V for 24V batteries while the charger is in standby, the charger cycles into a
constant current of 1.0A (4A models)/2.0A (8A models) until the constant
voltage setpoint is reached. The unit will regulate and terminate as in Constant
Voltage Mode.
2.8 Indication Lights
The charger features built in diagnostics. Refer to the table below to interpret the
flashing of the yellow and green indicator lights. Flashing of the yellow indicator
means that the charging cycle has ended early and the battery may not be fully
charged. Refer to the Troubleshooting section to correct these faults.
Flash Pattern
Indication
Yellow on
AC power present
Green on
Charge complete
Green blinking
Charging
Yellow & Green on simultaneously
Yellow & Green blink simultaneously
Yellow blinks 1X
Yellow blinks 2X
Yellow blinks 3X
Charger in standby mode
No battery/reverse polarity
Not reaching constant voltage setpoint
Not reaching 24V within 2 hours
Charge current/voltage does not normalize
Battery voltage too high (over 32V)
Charger over temperature
Yellow blinks 4X
Yellow blinks 5X
INSTALLATION
•
•
Charger should be securely mounted on a flat surface.
The power cord to the IEC 320/C14 connector should be of the appropriate
gauge to carry a 10A current @ 120VAC, or a 5A current @ 230VAC for
the cable’s length, to meet the requirements of applicable electrical codes.
3
•
•
A minimum of 30mm clearance should be provided at each end of the
charger for vented models.
The charger should not be installed in locations which restrict air flow.
page 4
Curtis 1604/08 Manual
OPERATION
4.1. Charging the Battery
Note: If a DC output adapter is used, connect the adapter to the charger output
connector prior to supplying AC power to the charger.
4.1.1 Ensure that the charger is either unplugged from AC power or is in
standby mode.
4
4.1.2 Connect the charger output connector to the vehicle/battery connector.
4.1.3 Plug the AC line cord into a nearby outlet. Turn on wall switch (if used).
The yellow light will illuminate to indicate that AC power is present.
After several seconds the green light will flash to indicate that charging is
in process. If no lights are illuminated, or if the yellow light flashes,
refer to the Troubleshooting section. Charge time may vary from less
than 1 hour to 10 hours.
4.1.4 When charging is complete both the yellow and green lights will remain
on and the charger will be in standby mode. The charger is now ready to
be disconnected from AC power or from the battery. Note: if the charger
is disconnected from the battery and connected to another battery with
out removing AC power it resets itself over a three minute period.
During this reset, the yellow light will flash briefly and the charger will
return to standby mode prior to beginning a charge cycle.
4.2. Programming the Charger
The Model 1604 or 1608 charger has a number of parameters that can be
programmed by the user, using a Curtis 1311 handheld programmer. These
programming variables allow the charger's performance characteristics to fit the
needs of the individual application. To use the 1311 refer to the 1311 instruction
manual, Curtis P/N 53028.
While programming can be performed when the charger is connected to the
batteries or when charging, it is recommended that the charger be disconnected
from power and from the batteries prior to commencing programming.
Connecting the programmer to the charger while charging will result in the
immediate termination of the charge cycle. The charger will remain in standby as
long as the programmer is connected.
There are two Program menu options - Basic Settings and Top Off Settings.
There are four options under the Basic Settings. They are described in the following
order. They are listed in the text by the names that appear on the programmer's
Program Menu: (bold text indicates default settings)
- Constant Voltage
- Amp hour Capacity
- End of Charge Mode
- Fan Modulation
Constant Voltage (CV, see figures 1, 2, 3 and 4)
Constant voltage defines the battery voltage at which point the charger changes
from constant current mode to constant voltage mode. Three Constant Voltage set-
points are available:
Option
Setpoint (VDC)
Battery Chemistry
12VDC charger 24VDC charger
1
2
14.0
14.3
28.0
28.6
Gel
AGM, Gel, SLA, VRLA
3
14.6
29.2
special applications as required by the
battery manufacturer
page 5
Curtis 1604/08 Manual
Amp hour Capacity
Amp hour Capacity is the storage capacity of the battery, as defined by the
battery's manufacturer. Selecting the appropriate amp hour capacity determines
the longest period of time the charger will charge before automatically shutting
off. If the charger is still charging at this point, it provides an error code to the
operator. Refer to Section 5, Troubleshooting, to correct this error. Three Amp
hour Capacity setpoints are available:
Option
Amp hour rating
(4A / 8A charger)
Charge Cycle Timer (t , see Fig. 1, 2, 3 and 4)
c
(hours)
1
2
3
≤60 / ≤100
≤100 / ≤200
≤200 / ≤400
16
24
48
End of Charge Mode
End of Charge Mode defines how the charger terminates the charge cycle. There are
three End of Charge Modes:
Option
Mode
Notes
1
End of Charge Charge Profile: IVa
(see Figure 1)
Charger goes into standby upon reaching End of Charge
current. Charge will automatically restart if the standby
voltage falls below 12.9V (12V charger) 25.7V (24V charger),
and automatically self terminates. This compensates for battery
self-discharge over long periods of time. This mode is recommended
for daily use or for long term storage.
2
Equalize
Charge Profile: I1VI2a if previous mode was End of Charge
I1V1I2V2 if previous mode was Float.
(see Figure 2
and Figure 4)
After constant voltage terminates, charger adjusts its output
current to 1.5A/3A (4A/8A charger). The current is held
for either 3 hours or until the battery reaches 15.8V (12V
charger) or 30.5V (24V charger). The Equalize cycle automatically
reverts to the previous mode of charge termination after
the completion of 1 cycle. Check the battery manufacturer’s
recommendation regarding the frequency at which batteries
should be equalized.
3
Float
Charge Profile: IV1V2
(see Figure 3)
After constant voltage terminates, the charger reduces the
output current to 0.25A (24V charger), and cycles on and off
automatically to maintain an average battery voltage of (float
voltage, FV) 13.3V (12V charger) or 26.6VDC (24V charger).
This will continue until AC power is recycled. This mode of
charging is recommended for daily use or for short term
storage conditions to maintain battery health.
Fan Modulation - Default setting: Off
Fan Modulation can be turned on or off. If fan modulation is set to Off, the fan runs
at full speed whenever the charger is charging. This maximizes charger power output
over all operating conditions. If fan modulation is set to On, the speed of the fan is
proportional to the temperature of the charger. This mode of operation is quieter.
page 6
Curtis 1604/08 Manual
Top Off Settings - Default setting: Off
Charge profile with the Top Off settings enabled looks similar to the Equalize
end of charge mode (End of charge option 2). The difference is that in the Top
Off mode the following parameters can be adjusted:
- Top Off Time, ranging from 0 to 5 hours;
- Top Off Voltage, ranging from 28 to 32.4 Volts;
- Top Off Current, ranging from 0.5 to 4.5 Amperes.
The Top Off mode is enabled by setting the Top Off Time to a value higher
than zero. The charger enters the Top Off mode at the end of the main charge
cycle (after the constant voltage part) and sets the output current to the value
defined by the Top Off Current setting. The Top-Off mode will finish when:
(1) preset Top Off Time expires or (2) battery voltage reaches the Top Off
Voltage setting, whichever happens first.
At the end of the Top Off mode, the charger continues according to the End of
Charge Mode settings - stands by and awaits for the restart voltage or contin-
ues the float mode.
To program the charger:
Curtis chargers do not use the 1311's Monitor, Faults, or Functions Menus. The
Information and Programmer Setup Menus operate as describe 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.
4.2.1. Disconnect the charger from the AC outlet and battery.
4.2.2. Attach the programmer to the 4-pin Molex connector on the charger
(near the light indicators). Depending on the specific 1311 being used,
a different connector cable may be required to connect to the charger.
Contact a Curtis sales office for assistance.
4.2.3. Apply AC power to the charger. The yellow and green light indicators
will alternately blink, indicating that the charger is in programming mode.
4.2.4. Configure the programmable parameters described above.
4.2.5. Once the programmable parameters have been defined, disconnect the
1311 programmer from the charger and follow the charger installation
instructions.
V/I
CV
V
I
tc
t
Figure 1. End of Charge Profile
page 7
Curtis 1604/08 Manual
V/I
CV
V
I
tc
Figure 2. End of Charge Profile with Equalize
t
V/I
V
CV
FV
I
tc
t
Figure 3. Float Profile
V/I
V
I
CV
FV
tc
Figure 4. Float Profile with Equalize
t
page 8
Curtis 1604/08 Manual
TROUBLESHOOTING
Problem
Possible Causes & Solutions
Lights do not turn on.
No power. Plug the unit in.
No power. If the outlet is damaged, try another
outlet on another circuit.
5
Yellow light blinks 1x
Yellow light blinks 2x
Yellow light blinks 3x
Battery manufacturer’s rated capacity may
exceed charger's rating.
Battery may be damaged or old.
Battery manufacturer’s rated capacity may
exceed charger's rating.
Battery may be damaged or old.
Battery manufacturer's rated capacity may
exceed charger's rating.
Battery may be damaged or old.
Unit may be damaged if operation does not
resume after AC power is removed and reapplied.
Yellow light blinks 4x
Yellow light blinks 5x
Battery voltage exceeds charger specified
operating range.
Charger overheated. Remove power, wait ten
minutes and then reapply power.
Yellow & Green lights
blink simultaneously
Battery may not be connected to the charger.
Battery may be severely discharged (<6VDC).
Battery connections may be reversed.
Yellow & Green lights
alternately blink
Charger is in the program mode. Handheld
programmer is connected to the charger.
Disconnect the programmer from the charger.
MAINTENANCE
Cleaning:
Excess dirt or grime may be removed from the unit by wiping it with a cloth
dampened with water.
6
page 9
Curtis 1604/08 Manual
CURTIS INSTRUMENTS, INC.
200 Kisco Avenue, Mt. Kisco, NY 10549 • Tel: (914) 666-2971 • FAX (914) 666-2188
is a registered trademark of Curtis Instruments, Inc.
Specifications subject to change without notice
© 2005 CURTIS INSTRUMENTS, INC.
53031 REV F 7/05
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