Cotek CX1215, CX1280, CX1235, CX1250, CX1225 User Manual

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Page 1

CX-SERIES

ADVANCED BATTERY

CHARGER

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Table of Content

1. IMPORTANT SAFETY INFORMATION ............................................................................ 2

1-1 General Safety Precautions ................................................................................................. 2

1-2 Battery Precautions .............................................................................................................. 2

2. FEATURES ........................................................................................................................ 3

2-1 Battery Charging Curve ........................................................................................................ 3

2-2 Specification ......................................................................................................................... 5

2-3 Mechanical Drawings ........................................................................................................... 6

3. PRODUCT DESCRIPTION .............................................................................................. 10

3-1 Configurations .................................................................................................................... 10

3-2 S1 Dip Switch Setting ......................................................................................................... 11

3-3 Charging Status LED Indicator ........................................................................................... 11

3-4 Failure Indicator ................................................................................................................. 12

3-5 Pin Assignment of CN2 – For Alarms Signal & Fan Control ............................................... 12

3-6 Pin Assignment of CN3 – For Temperature sensor & Remote control ............................... 12

3-7 Pin Assignment of CN4 – For Remote control) .................................................................. 12

3-8 Pin Assignment of ESB Connectors - For CX1215/1225/1235) ......................................... 13

3-9 Temperature Compensation .............................................................................................. 13

3-10 Rescue Battery Curve: ................................................................ ................................ ..... 14

3-11 Battery Charger Selection (Reference only) ..................................................................... 14

3-12 Battery Voltage setting suggestion ................................................................................... 15

4. INSTALLING THE COTEK ADVANCED CHARGER ..................................................... 15

4-1 Battery charger connection diagram .................................................................................. 16

5. TROUBLE SHOOTING ................................................................................................... 19

6. WARRANTY STATEMENT ............................................................................................. 19

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1. Important Safety Information

WARNING!

BEFORE INSTALLING OR USING CX-SERIES BATTERY CHARGER, YOU NEED TO READ FOLLOWING SAFETY INFORMATION CAREFULLY.

1-1 General Safety Precautions

1-1-1. For indoor use, do not expose CX-Series Battery Charger to water, mist, snow, or

dust. To reduce the risk of fire, do not cover or obstruct the ventilation enclosure.

1-1-2. To avoid the risk of fire and electric shocks, make sure that existing wiring is in

good electrical condition and not undersized. 1-1-3. Do not charge non-rechargeable batteries. 1-1-4. Disconnect the AC Grid before making or breaking the connections to the battery. 1-1-5. Only the AC cord with IEC socket is allowed to plug to the battery charger. 1-1-6. Never charge a frozen battery. 1-1-7. If the AC cord is damaged do not attempt to use. It must be replaced or repaired

by a qualified person. 1-1-8. Corrosive substances may escape from the battery during charging and damage

delicate surfaces. Please store and charge in a suitable area.

1-2 Battery Precautions

1-2-1. If battery acid contacts your skin or clothing, wash it out with soap and water

immediately. 1-2-2. If battery acid contacts your eyes, wash it out with cold running water for at least

20 minutes and get medical attention immediately. 1-2-3. Never smoke or make a spark or flame in the vicinity of the battery or the engine. 1-2-4. Do not drop metals on the battery.

The resulting sparks or short-circuits on the battery or other electrical parts may

cause an explosion. 1-2-5. Remove personal metal items such as rings, bracelets, necklaces, and watches

when operating with lead-acid batteries. It may cause short circuit and very high

temperature, which can melt metal items.

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2. Features

 Universal AC input with active PFC  Compatible with Lead Acid, Li-ion, Gel and AGM batteries  Support remote controller CR-1 as optional accessory.  Voltage / temperature compensation  2 stage fan speed control (Sleep mode)  Output power OK signal  Output alarm signal  High efficiency and high reliability  Built-in battery rescue function  Built-in Engine Start Battery (ESB) output function  Protection Short Circuit / Over Voltage / Over Temperature / Brown-out Protection  Withstand 2G vibration test

2-1 Battery Charging Curve

2-1-1 Bulk Stage (Constant Current)

At the beginning of the charging process, the flat battery is charged at constant current (maximum charge current) until the battery voltage reaches the set charging voltage (Refer to 3-2 charging mode setting).

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2-1-2 Absorption Stage (Constant Voltage)

The absorption charging duration will depend on the battery status. Before moving to absorption stage, charger will wait for two minutes then charging at

constant voltage until the battery is fully charged. Once the battery is fully charged or the charging current is below 6.25% of the rated

charging current for 15 minutes, then the absorption stage ends.

2-1-3 Float Stage

After absorption stage, the battery charger switches to float stage, maintains the battery at 100% charge without overcharging or damaging the battery. This means the charger can be left connected to the battery continuously.

2-1-4 Recondition stage

Every 12 days, the battery charger switches back to Bulk stage for 85 minutes in order to revive the battery. This prevents any fatigue symptoms such as sulphation.

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2-2 Specification

Model

CX1215

CX1225

CX1235

CX1250

CX1280

CX2415

CX2425

CX2440

Output

Battery Type

Lead Acid / Li-ion / Gel / AGM

Standard Boost Charge Voltage

14.4V / 14.7V (Select by S1 DIP switch)

28.8V / 29.4V

(Select by S1 DIP switch )

Standard Float Charge Voltage

13.8V / 13.5V (Select by S1 DIP switch)

27.6V / 27V

(Select by S1 DIP switch)

Main Rated Current

15A

25A

35A

50A

80A

12.5A

25A

40A

Main Output

1 2 2 3 3 2 3

ESB Output

1 1 1

ESB Output Voltage / Current

13.8V/2A

Battery Charging Mode

3-stage charging capability IUOU

Isolation Type

Use active power MOSFET on each output terminal

Single Output Current Limit

15A

25A

35A

40A

12.5A

25A

40A

Input

Voltage Range

90~264VAC

Frequency Range

47~63Hz

Power Factor (Typ.)

PF > 0.92 at full load

Efficiency (Typ.) at 230Vac

87%

90%

Protection

Short Circuit

Current is reduced to < 1A continued 30sec., will operate 30 seconds then turn off

Over Voltage

17.5V ±1%, protection type: shut down output (recovery after resetting AC power ON)

35V ±1%, protection type: shut

down output

( recovery after resetting AC

power ON )

Over Temperature Charger Over Temperature 100 ±5°C detected by heat sink

52±5°C (Optional temperature sensor)

Auto recovery after heat sink temperature goes down to 50±5°C

Function

Alarm Signal

NC. / NO. Relay contact output (Please reference Alarms signal & Fan control)

Temperature Compensation

-10mv / 0.5°C with COTEK temperature sensor

Sleep Mode

By Remote Controller and S1-4 DIP switch (Please refer to section 3-2)

Remote Controller

Support COTEK Remote Controller CR-1 ( Please refer to section 3-6 and 3-7)

Environment

Working Temp.

-20~50°C (refer to output load de-rating curve)

Working Humidity

20~90% RH non-condensing

Temp. Coefficient

±0.03% (0~50°C)

Vibration

10~500Hz, 2G 10min. / 1cycle period for 60min. each along X, Y, Z axes.

Safety

EMC

Safety Standards

Certified EN 60335-1, EN60335-2-29

Withstand Voltage

I/P-O/P: 4242VDC, I/P-FG: 1768VDC, O/P-FG: 700VDC

Isolation Resistance

I/P-O/P: 100M Ohms / 500VDC

EMI Conduction & Radiation

EN 55022; EN 55024; EN 61204-3; EN 55014-1; EN 55014-2

Harmonic Current

EN 61000-3-2; EN 61000-3-3; EN 61204-3; EN 61000-6-1; EN 61000-6-3

EMS Immunity

IEC 61000-4-2, 3, 4, 5, 6, 8, 11; ENV 50204

Others

Dimension (WxHxD) (Unit: mm)

183x72x243.4

183x72

x263.4

213x76.5

x272.4

213x76.5

x312.4

183x72

x243.4

213x76.5

x272.4

213x76.5

x312.4

Packing (Unit: kg)

1.6

1.7

1.9

3.1

4.0

1.6

2.9

3.9

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2-3 Mechanical Drawings

Model: CX1215/1225/1235/2415

Unit: mm

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Model: CX1250/1280/2425/2440

Unit: mm

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2-3-1 CX1215/1225/1235/2415 (Front Panel)

Front panel

①

AC Inlet (IEC)

⑥

Status LED

②

ESB connector

⑦

CN2

③

DC output -

⑧

TEMP/CN3

④

DC output +

⑨

CN4

⑤

Dip Switch 1 (S1)

Note: For detail description on item 5 (Dip Switch S1), please refer to section 3-2

2-3-2 CX1215/1225/1235/2415 (Rear Panel)

Rear panel

①

Power Switch

②

Fan

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2-3-3 CX1250/1280/2425/2440 (Front Panel)

Front panel

①

AC Inlet (IEC)

⑤

Status LED

②

DC output -

⑥

CN2

③

DC output +

⑦

TEMP/CN3

④

Dip Switch 1 (S1)

⑧

CN4

Note: For detail description on item 4 (Dip Switch S1), please refer to section 3-2

2-3-4 CX1250/1280/2425/2440 (Rear Panel)

Rear panel

①

Power Switch

②

Fan

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3. Product Description

Below models are available with COTEK Advanced Battery Charger CX Series:

3-1 Configurations

3-1-1 Standard Accessory

Number

A B C

Description

Copper Bus

Screw

AC Power Cable

Diagram

Quantity

per

CX1215

CX1225

CX1235

CX1250

CX1280

CX2415

CX2425

CX2440

A x 1pcs

1pcs x x

1pcs x x B x x x

1pcs

1pcs C x

2pcs

3pcs

2pcs

3pcs

1pcs

3-1-2 Optional Accessory

Number A B

Description

Ring Terminal

Battery Temp Sensor

Remote

Diagram

Number

CX1215

CX1225

CX1235

CX1250

CX1280

CX2415

CX2425

CX2440

2pcs

3pcs

5pcs

3pcs

5pcs

1pcs

Model

No. of supply battery

Support ESB (Engine Start battery)

CX1215

Yes

CX1225 /CX1235 2 Yes

CX1250 /CX1280 3 No

CX2415

CX2425 /CX2440 3 No

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3-2 S1 Dip Switch Setting

Status

1 2 3 4 12V / 24V CC/CV

12V / 24V Float

CC turn to CV

voltage

ON X OFF X 14.4V / 28.8V

---

OFF

OFF X 14.7V / 29.4V

---

Float voltage

OFF X ---

13.5V / 27.0V

OFF

OFF X ---

13.8V / 27.6V

Power Mode

(Current limit

output voltage)

OFF

13.2V / 26.4V

OFF

13.8V / 27.6V

OFF

14.4V / 28.8V

Remote

ON X ---

---

Fan force ON/OFF

X X X

---

X X X

OFF

---

X: Not Applicable

---: By Default setting

3-2-1 Default setting

3-3 Charging Status LED Indicator

Charging status

LED Status

Bulk-1

Orange fast

Bulk-2

Orange slow

Absorption-1

Orange solid

Absorption-2

Green solid

Float

Green flash

LED color change by the status change

Model

12V Series

24V Series

CC/CV

14.4V

28.8V

Float

13.8V

27.6V

Power Mode

Off

Remote

Off

Fan

Full Speed

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3-4 Failure Indicator

Failure status

LED Status

Description

Input or Output

Red solid Output current is reduced to <1A

AC I/P unstable

Output FUSE blown

Temperature

Red fast Battery over heat (the indicator is available only when

COTEK temperature sensor is connected)

Battery under heat ( the indicator is available only when COTEK temperature sensor is connected)

Charger over heat (Heat Sink)

Battery voltage

Red slow Battery over voltage

Battery under voltage or output under voltage in C.C. mode.

Fan abnormality

Red light flash twice

Fan abnormality

ESB Failure

Red light slow ones

ESB no output / output short

3-5 Pin Assignment of CN2 – For Alarms Signal & Fan Control

Normally closed

Normally open

COM

Sleep mode control

GND

4-5 Short

Sleep mode on

4-5 Open

Sleep mode off

3-6 Pin Assignment of CN3 – For Temperature sensor & Remote control

R_VCC

GND

TEMP

BAT-

DATA I/O

BAT+

3-7 Pin Assignment of CN4 – For Remote control)

R_VCC

BAT-

NC.

BAT-

DATA I/O

BAT+

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3-8 Pin Assignment of ESB Connectors - For CX1215/1225/1235)

VCC

GND

3-9 Temperature Compensation

CX12xx Series model

CX24xx Series model

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3-10 Rescue Battery Curve:

In case of battery over discharge (when battery voltage lower than 10V), CX battery charger will reduce the charging current to prevent further damage on the battery. The following curve is only applicable for Lead-acid & AGM battery.

3-11 Battery Charger Selection (Reference only)

 12 Volt Battery

COTEK Model

Battery capacity range

Estimated charging time

CX1215

50~80Ah

6~24

CX1225

80~125Ah

6~24

CX1235

125~175Ah

6~24

CX1250

175~250Ah

6~24

CX1280

250~400Ah

6~24

The above suggested battery charger selection is based on battery capacity multiply

0.2~0.3. Example: 100Ah battery * 0.2 / 0.3 = 20A~30A in this case please select CX1225.

 24 Volt Battery

COTEK Model

Battery capacity range

Estimated charging time

CX2415

50~80Ah

6~24

CX2425

80~125Ah

6~24

CX2440

125~200Ah

6~24

The above suggested battery charger selection is based on battery capacity multiply

0.2~0.3. Example: 100Ah battery * 0.2 / 0.3 = 20A~30A in this case please select CX2425.

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3-12 Battery Voltage setting suggestion

 GEL TYPE (Max. Voltage of 14.1 / 28.2 Volt)  AGM TYPE (Max. Voltage of 14.4 / 28.8 Volt)  Lead-Acid (Max. Voltage of 14.8 / 29.6 Volt)

4. Installing the COTEK Advanced Charger

When selecting the installation location, observe the following instructions:

 The battery charger can be installed horizontally or vertically.  Do not install the charger in following situations:

 In wet environment  In dusty environment  In the vicinity of combustible materials  In areas where there is a danger of explosions

 The place of installation must be well ventilated. A ventilation system must be

available for installation in small, enclosed space. The clearance around the device must be at least 25cm.

 The charger must be installed on a level and sufficiently sturdy surface.  Do not install the charger above batteries, because they can emit corrosive sulphur

fumes that will damage the device.

 For ambient temperatures higher than 40 ℃ (such as in engine or heating

compartments, or direct sunlight), the heat from the charger under load can lead to reduced output.

 The air inlet on the underside and the air outlet on the back of charger must remain

clear.

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4-1 Battery charger connection diagram

Model: CX1215

Single output charging

CX1215

15A MAX

Model: CX1225/CX1235/2415

I1 + I2

CX-1225

25A MAX

CX-1235

35A MAX

CX-2415

12.5A MAX

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I1 or I2

CX-1225

25A MAX

CX-1235

35A MAX

CX-2415

12.5A MAX

Model: CX1250/CX1280/2425/2440

I1+I2+I3

CX-1250

50A MAX

CX-1280

80A MAX

CX-2425

25A MAX

CX-2440

40A MAX

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I1+I2

CX-1250

50A MAX

CX-1280

80A MAX

CX-2425

25A MAX

CX-2440

40A MAX

I3 Single output

charging

CX-1250

40A MAX

CX-1280

40A MAX

CX-2425

25A MAX

CX-2440

40A MAX

Single output

charging

CX-1250

40A MAX

CX-1280

40A MAX

CX-2425

25A MAX

CX-2440

40A MAX

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5. Trouble Shooting

LED display

Cause

Remedy

Red, slowly flashing

Battery under voltage or battery overload

Check the battery. Switch the battery charger off and on again.

Defective battery

Replace the battery

Overheating

Improve the ventilation of the battery charger or battery. Make sure that no ventilation openings are covered. If necessary, reduce the ambient temperature.

Red, permanently lit

Short circuit or reversed polarity

Connect the battery charger with the correct polarity. Rectify the short circuit. Check if the fuse has blown and replace it if necessary.

Red, double flash

Fan fault

Check the fan for dirt or damage.

Red, slow double flash

Fault at the starter battery connection

Check the starter battery connection for a short circuit.

6. Warranty Statement

We guarantee this product against defects in materials and workmanship for a period of 24 months from the date of purchase. Please contact your local COTEK authorized distributor for RMA (Return material Authorization) service. Please note that COTEK is only responsible for ensuring our products are operational before delivery. This warranty will be considered void if the unit has been misused, altered, or accidentally damaged. COTEK is not liable for anything that occurs as a result of the user’s fault.

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No. 33, Sec. 2, Renhe Rd., Daxi Township, Taoyuan County 33548, Taiwan

Phone：+886-3-3891999 FAX：+886-3-3802333

http：// www.cotek.com.tw

Update: 2014.07