Fuel Gauge & Hour Meter

SOLID STATE BATTERY

‘FUEL’ GAUGE & HOUR METER

M O D E L 8 0 3

D E S C R I P T I O N

Curtis Model 803 combines in one instrument a completely

solid state battery discharge indicator, an LCD hour meter

and lift lockout, housed in a 52mm case. Void of moving

parts, this combination instrument is exceptionally reliable

even in severe operating environments.

A P P L I C A T I O N

Model 803 is a combination gage ideally suited for

electrically powered vehicles.

F E A T U R E S

‘Fuel’ Gauge Features

• Multicolor 10-bar LED displays state of charge

(5 green, 3 yellow, 2 red LEDs).

• Flashing red LED signals “energy reserve” alarm at 70%

discharged.

• Double flashing red LEDs signal “empty” alarm at 80%

discharged.

• Normally closed relay opens at 80% discharge for lift

lockout. This unique holding relay will only lock out at the

end of a lift cycle.

• Recognizes improperly charged battery.

• Keyswitch activated LED display (Fuel gage

electronics are energized as long as they remain

connected to the battery).

• Wide range adjustable discharge profile.

• Dual reset methods in each gage: Open Circuit Reset for

vehicles that exchange batteries and Charge Tracking

Reset for vehicles whose batteries remain connected to the

gage during recharge.

Hour Meter Features

• Monitors use-time throughout the equipment’s lifespan.

• Records and displays up to 99,999.9 hours on its LCD, rol s

over and continues to count and display.

• Hour meter LCD remains on as long as bat ery

is connected.

• Stores latest total in EEPROM nonvolatile memory, without

need of power.

• Operates and displays in temperatures from -40˚C

to +65˚C under harsh conditions of vibration, shock,

moisture and dust.

System Voltages

Available in single voltages from 12 VDC to

80 VDC, or in dual voltage of 24/36, 36/48,

24/48 or 72/80 VDC. Operating range is

± 25% of nominal voltage.

CURTIS INSTRUMENTS, INC.

200 KISCO AVENUE

MT. KISCO, NY 10549 USA

TEL (914) 666-2971

FAX (914) 666-2188

CURTIS INSTRUMENTS, (UK) LTD.

5 UPPER PRIORY STREET

NORTHAMPTON NN1 2PT, ENGLAND

TEL 44 (0) 1604-629755

FAX 44 (0) 1604-629876

CURTIS INSTRUMENTS INDIA

PRIVATE LTD.

1199, GHOLE ROAD

PUNE 411004, INDIA

TEL 91 (0) 20-5531288

FAX 91 (0) 20-5539192

M O D E L 8 0 3

T E C H N I C A L S P E C I F I C AT I O N S

Hour meter accuracy: +0.1%

Operating temperature: -40°C to +65°C

Shock & vibration: Meets SAE J 1378

Humidity: 95% RH (non-condensing) at +38°C

LCD character height: 5 mm

Mating connector: Molex 8 pin, 39-01-2085

Discharge range: Empty from 1.57 volts/cel to1.93 volts/cel

Reset levels: Open circuit reset(OCR)at 2.09 volts/cel

Charge Tracking Reset(CTR) tracks bat ery recharge

M O D E L N U M B E R D E S C R I P T I O N

803 RB 2448 B C J 3zzO

CASE STYLE VOLTAGE RESET TYPE DISCHARGE OUTPUT OEM

/LEVEL PROFILE CODE

RB=Round (52mm) 12 B =CTR/OCR (3zzO) C=Adjustable (2zzO and 1zzO

Contact rating=3 Amps

w/black bezel 2436 =HVR/OCR (1zzO/2zzO) 1.57vpc to are earlier versions)

when continuously closed,

2448 where 1.93vpc O= Curtis logo

3648 OCR=2.09vpc at empty 1 Amp when opening.

7280 HVR=2.35vpc K=N.C. relay

Y=N.O. relay

contact rating=1 Amp

D I M E N S I O N S m m

"U" Clamp for

.76 to6.35

MNOP

DISCHARGE

Thumbnut 4mm

Washer 4mm

51.46 Max

43.62 Max

Panel Thickness

Black Bezel

Fuel Gage "LED"

2 Red, 3 Yellow, 5 Green

Bar Height 5mm

0 1/2 1

- +

88888.8 / 1
10

CONNECTOR PINOUT

Pin No.Relay Option J

1HRM (–)

2*Keyswitch

3Relay ARM (+)

42.46 Max

57.75 Max

8.89 Max

Hour Meter "LCD"

Character Height

5mm

4Relay N.C. (–)

5Common (B–)

6HRM (+)

7B+ Low

8B+ High

* Keyswitch turns on “fuel gage” display and

enables the hour meter. To accumulate time

in the hour meter one or both of the HRM+

and HRM– inputs must be connected.

Note: In addition to a “U” clamp and thumbnuts/washers shown in the drawing, individual y

packed units are provided with a mating connector and female pins. Bulk packed

units are provided with a “U” clamp and hex nuts/washers only.

WA R R A N T Y Two year limited warranty from time of delivery.

is a trademark of Curtis Instruments, Inc.

Specifications subject to change without notice.©Curtis Instruments, Inc. 2004

50024 REV C 4/04

SOLID STATE BATTERY

‘FUEL’ GAUGE & HOUR METER

M O D E L 8 0 2

D E S C R I P T I O N

Model 802 is a combination battery ‘fuel’ gauge and solid

state hour meter housed in a single 52mm diameter case.

Void of moving parts, this two-in-one unit provides exceptional

reliability even in severe operating conditions.

A P P L I C A T I O N

Model 802’s dual voltage feature makes it ideal for material

handling applications, including forklift truck manufacturers

and parts dealers trying to ease their stocking requirements.

These high quality gauges are also advantageous on sweep-

er/scrubbers, aerial lift platforms and personnel carriers.

F E A T U R E S

‘Fuel’ Gauge Features

• Multicolor 10-bar LED displays state of charge (5 green,

3 yellow, 2 red LEDs).

• Flashing red LED signals “energy reserve” alarm at 70%

discharged.

• Double flashing red LEDs signal “empty” alarm at 80%

discharged.

• Recognizes improperly charged battery.

• Keyswitch activated LED display (Fuel gauge electronics

are energized as long as they remain connected to the

battery).

• Dual reset methods in each gauge: Open Circuit Reset

for vehicles that exchange batteries and Charge Tracking

Reset for vehicles whose batteries remain connected to the

gauge during recharge.

Hour Meter Features

• Monitors use-time throughout the equipment’s lifespan.

• Records and displays up to 99,999.9 hours on its LCD,

rolls over and continues to count and display.

• Hour meter LCD remains on as long as battery is

connected.

• Stores latest total in EEPROM nonvolatile memory, without

need of power.

• Operates and displays in temperatures from -40˚C

to +65˚C under harsh conditions of vibration, shock,

moisture and dust.

Hour Meter Features

• Monitors use-time throughout equipment’s lifespan.

• Records and displays up to 99999.9 hours on LCD,

rolls over and continues to count and display.

• Stores latest total in EEPROM nonvolatile memory, without

need of external power or internal battery.

• Operates and displays in temperatures from -40˚C

to +65˚C under harsh conditions of vibration, shock,

moisture and dust.

• Accuracy of +0.1% throughout its operating

temperature range.

• Flashing hour-glass icon signals hour-meter

accumulation of time.

System Voltages

Available in single voltages from 12 VDC to 80 VDC, or

in dual voltage of 24/36, 36/48, 24/48 or 72/80 VDC.

Operating range is ± 25% of nominal voltage.

CURTIS INSTRUMENTS, INC.

200 KISCO AVENUE

MT. KISCO, NY 10549 USA

TEL (914) 666-2971

FAX (914) 666-2188

CURTIS INSTRUMENTS, (UK) LTD.

5 UPPER PRIORY STREET

NORTHAMPTON NN1 2PT, ENGLAND

TEL 44 (0) 1604-629755

FAX 44 (0) 1604-629876

CURTIS INSTRUMENTS INDIA

PRIVATE LTD.

1199, GHOLE ROAD

PUNE 411004, INDIA

TEL 91 (0) 20-5531288

FAX 91 (0) 20-5539192

M O D E L 8 0 2

T E C H N I C A L S P E C I F I C A T I O N S

Note: The following data covers both ‘fuel’ gauge and hour meter.

Current consumption:

Weight:

65mA maximum @ 48 V nom.

Less than 3.5 oz

Operating temperature:-40°C to +65°C

Storage temperature:

Shock:

Vibration:

Humidity:

-50°C to +90°C

SAE J1378 55g

SAE J1378 20g

95% RH (non-condensing) at 38°C

M O D E L N U M B E R D E S C R I P T I O N

802RBwwxxBG or 802RBwwxxBN

ww= lower of the two voltages for dual voltage units, or none for single voltage units.

xx = voltage of single voltage unit or higher of the two voltages for dual voltage units.

Discharge profile:

BG = for electric vehicles that have a discharge profile ranging from 1.97 to 1.75 volts per cell.

BN = for electric vehicles that have a discharge profile ranging from 2.04 to 1.73 volts per cell.

Reset voltage:

If power is broken to the battery ‘fuel’ gauge during charging, the unit will reset at 2.09 volts per

cell. If the battery ‘fuel’ gauge remains connected during charging, the gauge will track the battery

from 2.10 volts per cell to 2.35 volts per cell.

D I M E N S I O N S M M

"U" CLAMP FOR .76 TO 6.35

PANEL THICKNESS

T H U M B N U T 4 M M

WA S H E R 4 M M

S E E N OT E 2 . 0

52.07 MAX

LABEL

55.37 MAX

BLACK BEZEL

B + HI

B + LOW

9.02 MAXETI (+)

ENABLE

FUEL GAGE "LED" 2 RED.

3 YELLOW. 5 GREEN.

BAR HEIGHT 5mm

HOUR METER "LCD"

CHARACTER HEIGHT 5mm

012

COMMON

(B-)

KEYSWITCH

ETI (-)

ENABLE

W A R R A N T Y Two year limited warranty from time of delivery.

is a trademark of Curtis Instruments, Inc.

Specifications subject to change without notice.©Curtis Instruments, Inc. 2007

88888.810

58.42 MAX

50025 REV C 6/07

MODEL 802

“FUEL” GAGE/HOUR METER

Read Instructions Carefully!

Safety Instructions

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.

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

1. MODEL ENCODEMENT

802RB

wwww

Voltage

2436

2448

3648

7280

Reset type/level

B = 2.09 VPC

Discharge profile

G = 1.97 VPC at Full

1.75 VPC at Empty

N = 2.04 VPC at Full

1.73 VPC at Empty

zzzz

001O

O = Curtis

logo

2. TECHNICAL SPECIFICATIONS

2.1 Electrical

Operating Range

± 25% of nominal voltage

Operating Current

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

24/36

24/48

36/48

72/80

18/25

25/35

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.

Panel Cutout

52mm, 21/16” diameter

2.3 Environmental

Temperature

Operating:-40°C to +65°C

Storage:-50°C to +90°C

Humidity 95% RH (Non Condensing) at 38°C

Shock &

Vibration Meets SAE J 1378

3. INSTALLATION

The Model 802 fits into a dash-panel cutout

measuring 21/16” (52 mm).

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.

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

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 state-

of-charge measurements. The voltage is not to be

switched by the vehicle keyswitch.

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 accumu-

llate 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.

Table 1. Hour Meter Control Lines & Impedance

Specifications

Model Low VoltageHigh Voltage Min. Impedance

Maximum Minimum HRM+ HRM-

12 VDC3.0 VDC8.0 VDC24 kΩ12 kΩ

24/36 VDC5.0 VDC 15.0 VDC80 kΩ20 kΩ

24/48 VDC5.0 VDC 15.0 VDC80 kΩ20 kΩ

36/48 VDC7.0 VDC 22.0 VDC 120 kΩ30 kΩ

72/80 VDC 15.0 VDC 45.0 VDC 240 kΩ60 kΩ

Table 2. Hour Meter Control Logic

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

High

Open

Low

High

Open

Low

Open

Low

Open

High

Low

Open

High

Off

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.

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

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.

5. Troubleshooting

The following checklist should help you to

troubleshoot any problems with the instrument.

Problem

No display

Stays at FULL

Will not reset

Possible Causes

Terminals not connected or

improper voltage

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 batteryNot 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

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.

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.

CURTIS INSTRUMENTS, INC.

200 Kisco Avenue, Mt. Kisco, NY 10549

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

53005 REV B 7/01

MODEL 802

“FUEL” GAGE/HOUR METER

Read Instructions Carefully!

Safety Instructions

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.

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

1. MODEL ENCODEMENT

802RB

wwww

Voltage

2436

2448

3648

7280

Reset type/level

B = 2.09 VPC

Discharge profile

G = 1.97 VPC at Full

1.75 VPC at Empty

N = 2.04 VPC at Full

1.73 VPC at Empty

zzzz

001O

O = Curtis

logo

2. TECHNICAL SPECIFICATIONS

2.1 Electrical

Operating Range

± 25% of nominal voltage

Operating Current

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

24/36

24/48

36/48

72/80

18/25

25/35

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.

Panel Cutout

52mm, 21/16” diameter

2.3 Environmental

Temperature

Operating:-40°C to +65°C

Storage:-50°C to +90°C

Humidity 95% RH (Non Condensing) at 38°C

Shock &

Vibration Meets SAE J 1378

3. INSTALLATION

The Model 802 fits into a dash-panel cutout

measuring 21/16” (52 mm).

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.

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

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