CX Series User’s Manual Advanced Converter / Charger
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Table of Content 1. 2. 3. IMPORTANT SAFETY INFORMATION 1 1-1. General Safety Precautions 1 1-2. Battery Precautions 2 FEATURES 3 2-1. Battery Charging Curve 4 2-2. Specification 6 2-3. Mechanical Drawings 9 PRODUCT DESCRIPTION 13 3-1. Configurations 13 3-2. S1 Setting 14 3-3. Charging Status LED Indicator 15 3-4. Failure Indicator 15 3-5. Pin Assignment of CN2 – For Alarms Signal & Fan Control 16 3-6. Sleep Mode 16 3-7.
. INSTALLING CONVERTER / CHARGER 21 4-1. Battery charger connection diagram 23 5. TROUBLE SHOOTING 26 6. WARRANTY STATEMENT 27 6-1. Warning 27 6-2.
1.Important Safety Information Warning! Before installing or using CX series power converter, 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.
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. 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.
2.
2-1.Battery Charging Curve 14.4 / 28.8 V 13.8 / 27.6 V 12.8 / 25.6 V 9.6 / 19.2 V 0V Current BULK(CC) ABSORPTION(CV) FLOAT RECONDITION FLOAT Maintain the battery at 100% charge condition PER-CHARGE Return amps = 6.25% of rated current Reconditioning the battery Stay at 13.8V / 27.6V 2 Weeks FLOAT 0.25 hours~24 hours Maintain the battery at 100% charge condition 14.4V / 28.
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). 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.
2-2.Specification Model Battery Type Standard Boost Charge Voltage Standard Float Charge Voltage Main Rated Current Output CX1235 CX1250 CX1280 80A 14.4V / 14.7V (Select by S1 DIP switch) 13.8V / 13.5V (Select by S1 DIP switch) 15A 25A 35A 50A 1 2 2 3 3 ESB Output 1 1 1 -- -- 13.8V/2A 13.8V/2A 13.
Model Battery Type Standard Boost Charge Voltage Standard Float Charge Voltage Main Rated Current Output CX2415 27.6V / 27V (Select by S1 DIP switch) 12.5A 25A Main Output 2 3 3 ESB Output -- -- -- -- -- -- Current Battery Charging Mode 3-stage charging capability IUOU Isolation Type Use active power MOSFET on each output terminal Single Output Current Limit 12.5A 90~264VAC (Refer to 2-2-1 de-rating curve) Frequency Range 47~63Hz Power Factor (Typ.) PF > 0.
Charging current (%) 2-2-1. Charging Current vs. Ambient Temperature De-rating Curve 100% Normal 80% 40% S1 pin4 ON or CN2 pin4-5 Short 20% CR1 Sleep mode 10% -20°C 40°C 50°C Ambient Temperature Charging current vs. Ambient Temperature Figure 2. Charging current vs. Ambient temperature de-rating curve Charging current (%) 2-2-2. Charging Current vs. Input Voltage Temperature De-rating Curve 100% 50% 90 110 130 230 250 270 AC Voltage (V) Charging current vs. Input voltage Figure 3.
2-3.Mechanical Drawings CX1280, CX2440 CX1250, CX2425 CX1235 CX1215, CX1225, CX2415 C A E B D F Figure 4. Mechanical Drawings Model A (mm) B (mm) C (mm) D (mm) E (mm) F (mm) CX1215 243 54.2 135.0 183 6.5 72 CX1225 243 54.2 135.0 183 6.5 72 CX1235 263 56.7 150.0 183 6.5 72 CX1250 272 60.2 152.0 213 6.5 77 CX1280 312 65.2 182.0 213 6.5 77 CX2415 243 54.2 135.0 183 6.5 72 CX2425 272 60.2 152.0 213 6.5 77 CX2440 312 65.2 182.0 213 6.
2-3-1. CX1215 / 1225 / 1235 / 2415 (Front Panel) 6 7 8 9 3 2 5 4 1 Figure 5. CX1215 front panel 6 7 8 9 3 2 5 4 1 Figure 6.
2-3-2. CX1215 / 1225 / 1235 / 2415 (Rear Panel) 2 1 Figure 7. CX1215/1225/1235/2415 rear panel Front panel AC Inlet (IEC) ① Status LED ② 2-3-3. CX1250 / 1280 / 2425 / 2440 (Front Panel) 5 6 7 8 4 3 2 1 Figure 8.
2-3-4. CX1250 / 1280 / 2425 / 2440 (Rear Panel) 2 1 Figure 9.
3.Product Description Below models are available with COTEK Advanced Battery Charger CX Series: Model No. of supply battery CX1215 CX1225 / CX1235 CX1250 / CX1280 CX2415 CX2425 / CX2440 1 2 3 2 3 Support ESB (Extra Second Battery) Yes Yes No No No 3-1. Configurations 3-1-1.
Number A B C CX 1215 CX 1225 CX 1235 CX 1250 CX 1280 CX 2415 CX 2425 CX 2440 2pcs 1pcs 1pcs 3pcs 1pcs 1pcs 3pcs 1pcs 1pcs 5pcs 1pcs 1pcs 5pcs 1pcs 1pcs 3pcs 1pcs 1pcs 5pcs 1pcs 1pcs 5pcs 1pcs 1pcs 3-2. S1 Setting 3-2-1.
3-3. Charging Status LED Indicator Charging status Bulk-1 Bulk-2 Absorption-1 Absorption-2 Float LED Status Orange fast Orange slow Orange solid Green solid Green flash LED color change by the status change 3-4. Failure Indicator Failure status LED Status Input or Output Red solid Temperature Red fast Battery voltage Red slow Fan abnormality ESB Failure Red light flash twice Red slow every 2 sec.
3-5. Pin Assignment of CN2 – For Alarms Signal & Fan Control 1 2 3 4 5 Normally closed Normally open COM Sleep mode control GND 4-5 Short 4-5 Open Sleep mode on Sleep mode off 3-6.
3-8. Pin Assignment of CN4 – For Remote control 1 R_VCC 2 BAT- 3 NC. 4 BAT- 5 DATA I/O 6 NC. 3-9. Pin Assignment of ESB Connectors – For CX1215/1225/1235 + VCC - GND 3-10. Temperature Compensation CX12XX series model 15.0 14.7VDC Charging voltage in V 14.5 14.2VDC 14.0 13.8VDC 13.5 Abs orp tion Flo 12Volt system: -10mV / 0.5oC at 13.4VDC -3.33mV / oC per cell 13.0 12.5 Battery voltage 12.
CX24XX series model 30.0 29.4VDC Charging voltage in V 29.0 28.4VDC 28.0 27.6VDC 27.0 Abs orp tion Flo 24Volt system: -20mV / 0.5oC at 26.8VDC -3.33mV / C per cell o 26.0 25.0 Battery voltage 24.0 U Rer 20oC o 52 C -30 -20 -10 0 5 10 20 30 40 50 60 Temperature compensation characteristic (charge voltage versus temperature) Battery temperature oC ※ In the CV=29.4V and float=27.6V situation. Please follow this rule in other situations. Figure 11.
3-12. Battery Charger Selection (Reference only) y 12 Volt Battery COTEK Model Battery capacity range CX1215 CX1225 CX1235 CX1250 CX1280 50~80Ah 80~125Ah 125~175Ah 175~250Ah 250~400Ah Estimated charging time 6~24 6~24 6~24 6~24 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.
3-14. Fan speed duty description The fan determined by load and heat sink temperature. 1. Fan speed 100%: comply with one of the following conditions a. Load 75% 50% and heat sink temperature 50 b. Load c. Heat sink temperature 75 2. Fan speed duty 50%: 67.5 a. Heat sink temperature or b. Set CX to sleep mode by setting DIP4 (Refer to 3-2) when 1. a, b, or c applies 3. Fan speed duty 0%: a. Load < 75% and heat sink temperature < 35 or b.
4.Installing Converter / Charger When selecting the installation location, observe the following instructions: y The battery charger can be installed horizontally or vertically. y Do not install the charger in following situations: In wet environments In dusty environments In the vicinity of combustible materials In areas where there is a danger of explosions y The place of installation must be well ventilated. A ventilation system must be available for installations in small, enclosed space.
Notice! Before drilling any holes, make sure that no electrical cables or other parts of the vehicle can be damaged by drilling, sawing and filing.
4-1. Battery charger connection diagram Model CX1215 Description Connection diagram 15A MAX Remote Control 12V Battery Fuse Voltage CX1225 CX1235 I1+I2 CX1225 25A MAX Fuse Fuse Temp. Sensor I1 32V, Fuse Current DC LOAD Extra Second Battery 23A I2 CX1235 35A MAX Fuse Fuse Temp.
Model CX2415 Description Connection diagram I1 I1+I2 12.5A MAX I2 Fuse Temp. Sensor Remote Control 24V Battery 32V, Fuse Current Fuse Voltage CX1225 CX1235 I1 or I2 CX1225 25A MAX I1 23A I2 CX1235 35A MAX Fuse Fuse Fuse 12V Battery Temp.
Model CX2415 Description Connection diagram I1 or I2 12.5A MAX I1 I2 Fuse Fuse 24V Battery 24V Battery Fuse Voltage CX1250 CX1280 I1+I2+I3 CX1250 50A MAX I1 Remote Control 32V, Fuse Current I2 DC LOAD 23A I3 Fuse CX1280 80A MAX Temp. Sensor Temp.
Model CX2425 CX2440 Description Connection diagram I1+I2+I3 CX2425 25A MAX I1 I3 Fuse CX2440 40A MAX I2 Temp. Sensor Remote Control 24V Battery CX2425 Fuse Voltage CX2440 Fuse Voltage 32V, Fuse Current 32V, Fuse Current DC LOAD 40A 80A 5.
6.Warranty Statement 6-1. Warning Warning! Do not open or disassemble the Converter / Charger. Attempting to do so may cause risk of electrical shock or fire. 6-2. Warranty We guarantee this product against defects in materials and workmanship for a period of 24 months from the date of purchase. In case you need to repair or replace any defective power inverters, please contact COTEK local distributor. This warranty will be considered void if the unit has been misused, altered, or accidentally damaged.
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