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 Page
1. Model Encodement 2 !
2. Technical Specifications
2.1 Electrical 4
2.2 Mechanical 5
2.3 Environmental 6
3. Installation 7
4. Operation 12
5. Troubleshooting 14
6. Maintenance 15

!
1. MODEL ENCODEMENT
802RB wwww x
Voltage Reset type/level
12 B = 2.09 VPC
2436
2448
3648
7280

2
y zzzz
Discharge profile 001O
G = 1.97 VPC at Full O = Curtis
1.75 VPC at Empty logo
N = 2.04 VPC at Full
1.73 VPC at Empty

3
!
 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 18/25 25/35
24/48 18/25 25/35
36/48 18/25 25/35
72/80 18/25 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.

Panel Cutout
52mm, 21/16” diameter

5
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

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 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.

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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
!
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.

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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 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.

9
!
Table 1. Hour Meter Control Lines & Impedance
Specifications
Model Low Voltage High Voltage Min. Impedance
Maximum Minimum HRM+ HRM-
12 VDC 3.0 VDC 8.0 VDC 24 kΩ 12 kΩ
24/36 VDC 5.0 VDC 15.0 VDC 80 kΩ 20 kΩ
24/48 VDC 5.0 VDC 15.0 VDC 80 kΩ 20 kΩ
36/48 VDC 7.0 VDC 22.0 VDC 120 kΩ 30 kΩ
72/80 VDC 15.0 VDC 45.0 VDC 240 kΩ 60 kΩ
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
10
On
!
 !
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

12
!
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.

13
!
5. Troubleshooting
The following checklist should help you to
troubleshoot any problems with the instrument.
Problem Possible Causes
No display Terminals not connected or
improper voltage
Stays at FULL Instrument voltage does not
match battery voltage,
B+ connected to the wrong
terminal
Will not reset 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