KOP3 Battery Charger. User's Manual

Transcription

1 KOP3 Battery Charger User's Manal 24V / 125A 48V / 62.5A

2 1.Introdction KOP3 battery chargers are modern flly atomatic devices sitable not only for charging bt also for maintaining and monitoring the batteries. The charger stores data abot charging times and Ah charged. This data may be accessed for frther analysis. The device is protected against reverse polarity and short circit, has adjstable time limitations for every charging phase, battery temperatre monitoring and compensation and crrent redction at elevated ambient temperatres. Yor battery charger was factory programmed for a specific battery type. Make sre the charging profile sits yor battery type. To change the charging profile for a specific battery type, parameters can only be programmed with a PC software package and a programming interface. The programming parameters allow the charger's profile to sit the battery type. Up to five charging phases can be programmed with separate vales for charging voltages, crrents, charging times, temperatre compensation and other control fnctions. Please contact yor dealer for frther information. When programming the charging profile always follow the battery manfactrer's recommendations. Please read the operating and safety instrction careflly before sing or installing the KOP3 battery charger! 2. Start of the charging process Establish a safe connection between the battery and the charger first. Then plg the mains connector. When removing the connection, remove the mains plg from the mains first, before disconnecting the battery. The charger type is shown first after the charger has been connected to the mains and then the measred vales as the battery voltage see the following page. The charging time depends on battery size and state of charge. If the battery was only slightly loaded, then the charging process will complete faster. At higher ambient temperatres or when exposed to strong snlight, the charging crrent is redced and the charging time increased accordingly. The charger can remain connected to the battery permanently. The power consmption is less than 0.5 ma. 2

3 The pictres below illstrate the vales shown on the charger display. In the first row the battery voltage and the battery crrent are shown. The battery voltage indicates the voltage at the battery terminals and not the otpt voltage of the charger. This vale is exact only if the voltage drop compensation parameter has been set correctly. Main screen The charging crrent may be smaller as the charger nominal vale if a lower vale has been programmed or if the charging power or the mains crrent are at their limits or if cooling is insfficient and the overheating protection is active. The symbol after the displayed nmber shows that the corresponding vale has reached the limit. In the bottom line is the info icon [ ]. By pressing on the info it can be switched between the three screens (see the pictres on the left side). The bottom row shows the crrent charging phase on the left and the total charging time in hors and mintes on the right side. Secondary screen The abbreviation SN is for serial nmber of the charger. Firmware and Revision show the version and revision of charger firmware in the left colmn and of display firmware in the right colmn. Toching of the English or German national flag switches between the langages for displaying warnings and error messages. Info screen The crrent and voltage vales depend on battery state of charge, on charger parameters (p to five charging phases can be set), environment temperatre, mains voltage and battery temperatre if temperatre compensation has been enabled with charger parameters. If the charging crrent is lower than the parameter vale for one of these reasons, then the charging time is increased accordingly. 3

4 3. Meanings of the vales shown on the display Batt. temp. Battery temperatre in ºC This vale is displayed only if the temperatre sensor is connected. When the battery temperatre monitoring and battery temperatre compensation have been nlocked with the charger parameters, then the measred vale is also checked for validity. Charg. temp. Charger temperatre in ºC Internal temperatre of the charger power stage in ºC Charge The charged Ah (Ampere-hors) After the completion of charging the vale of the charged Ah is displayed ntil a new battery is connected or charging is restarted for the same battery. BMS BMS limit in % If a battery management system is connected then it's reqest for crrent redction (percentage of nominal crrent) is shown ( OFF means charging is blocked or no connection to the BMS). Iac Line crrent in A (crrent from the mains socket) This crrent is limited to 14.7 A by charger firmware. It can be higher as 14.7 A dring fast load or mains changes only. Iac Max Crrent vale of line crrent limitation when the BMS inpt is sed to choose/select the maximm line crrent limit. Power Charging power in W = Charging crrent x Battery voltage The power otpt (total power) of the charger is not the same as the charging power. It also incldes losses at the cables, fses and plgs. The voltage drops are compensated by the charger. The charger otpt power limit incldes losses of the varios voltage drops. Therefore, the maximm achievable charging power can be somewhat smaller than 3000 W in practice since the total charger otpt is limited to 3000 W and not to the battery charging power. A charging power of less than 3000 W can also be cased by a low spply voltage (limit of the line crrent). Ucomp. Compensation of the charging voltage in V This vale indicates for how mch the voltage measred inside of the charger is higher than the voltage at the battery terminals. The crrent charging phase After the charging has been completed and the charger has trned off the text "END" text appears on the display. If the message "Charging completed" appears, althogh still charging and the charging phase is displayed, then the trickle charging phase has been started. The trickle charging is for battery charge maintenance and for some battery types for cell eqalization. Phase 4

5 4. Mechanical installation The following things mst be considered dring the installation: a. Ensre the distance from the walls or other objects Ensre the distance from the walls or other objects. Leave enogh space (at least 10 cm) between the cooling openings and other objects or walls, so that the air can circlate well. b. Avoid the heat bild-p Despite very high efficiency qite a lot of heat arises. Therefore, the charger mst only be installed in places with enogh air exchange. Otherwise, the air temperatre rises in the vicinity of the device and the charging crrent may be redced or the device may trn off. c. Horizontal monting Mont the charger on a flat srface (from the top) as shown on the image. The device can withstand higher stress de to vibration and shock in the horizontal position. d. Vertical monting The cables and terminals mst be on the lower side so that the fan moves the hot air p - as shown on the image. IMPORTANT: The charger shold be monted vertically in applications sch as electric vehicles, since high shock and vibrations are common in sch applications and it can withstand better in sch position. IMPORTANT: Observe the additional warnings (see the table). Do not make any holes on the chassis, as components can be damaged. Mont the charger on a flat srface. 5

6 5. Connections CAN/BMS S /BM CAN 1 Mini-XLR 5p PTC AY REL 3 PTC 1 Mini-XLR 3p BAT+ BAT 2 Max. 5 A RELAY Phoenix MSTBV 230 V NO C NC Pinot of the PTC connector 1 2 GND SER-OUT 3 PTC Connected to the battery mins internally Serial otpt (commnication with KOP-USB or KOPPROT) PTC connection for battery temperatre measrement The signals on the PTC connector are not galvanically separated from the battery. Pinot of the CAN/BMS connector 1 BMS-IN V GND2 CAN-H CAN-L Cathode of the optocopler for the BMS PWM inpt (anode connected to +12 V throgh a 1k0 resistor). Crrent throgh the optocopler diode min. 1 ma Power spply for the external display (max.100 ma) Grond connection for the external display Commnication with the display or other devices (no CAN Bs termination resistor in the charger) All signals and the 12 V power spply are galvanically separated from the mains (230 V) and from the battery. RELAIS connection NO C NC 6 Normally open max. 5 A continos/switching crrent Common Normally closed

7 6. Fnctions of the charger software (standard version) a. Mains crrent limiter Most sockets are protected between 10 A and 16 A on the mains side. Very few sockets tolerate a continos crrent of more than 15 A. To avoid overheating with excessive mains crrent, it is limited to max A (see the description below for frther crrent limit selection with the BMS inpt). Comment: For 230 V mains voltage and fll otpt power the charger needs approx A from the socket. At low mains voltage, the mains crrent wold increase at the same power, bt this wold be redced to max A. In the short term, the crrent can also be somewhat higher than 14.7 A in the case of very fast mains voltage flctations. If the mains voltage drops below approx. 180 Vac, the KOP3 charger is switched off. After the mains voltage rises again, the charging is restarted where it was interrpted. b. BMS inpt The selection of the mains crrent limitation is the standard fnction of this inpt. If this inpt is connected to grond (GND), the mains crrent is limited to 8.7 A, if not, then the mains crrent is limited to 14.7 A. Other vales on reqest. A plg with the preassembled switch can be ordered as an option. Special software versions are to be ordered if the BMS inpt is sed for commnication with the battery management system. Contact Piktronik for the description of the BMS PWM interface. c. CAN Bs The standard firmware version spports the external display. For spport of special fnctions, like E.g. commnication with the BMS, please contact Piktronik. d. Relay otpt This is switched on when 230 V is connected. Other software options for relay otpt on reqest. If other fnctions are reqired, the charger software can also be changed later via the PTC connector with the KOP-USB programming adapter. NOTE: The charger has very low power consmption. Therefore, depending on the fnction, the display can remain switched on for more than 20 seconds after the mains plg has been disconnected. 7

8 7. Technical characteristics KOP3-24V KOP3-48V Nominal voltage / crrent 24 V 48 V Charging crrent 125 A 62.5 A Minimal starting voltage 10.5 V 13.0 V 10.5 V to 33.6 V 24.0 V to 62.0 V 91% 92% Charger type Adjstable charging voltage range Typ. efficiency Power factor > 0.95, typ at fll power and 230 V Mains voltage 180 V V / Hz Mains crrent max. 15 A Standby power consmption from the battery < 0.5 ma Otpt power max W Dimensions (L x W x H) 380 x 265 x 95 mm 6.3 kg Weight incl.mains cable Protection grade Approvals 6.6 kg IP20 (IP21 with horizontal monting) EN Class B, EN , EN , EN , EN , EN , EN , EN , EN , EN Trobleshooting Isse Remedy Display on the device does not trn on after connection to the mains socket Check the mains connection. Check if the mains voltage is present. Charging does not start Check the warning or the error message shown on the display. The list of possible errors is shown on the following page. Battery voltage is too low The battery voltage is lower than the minimm vale at which the charger is allowed to start. The battery voltage at the start of the charge mst be higher than half of the "Max. Voltage" parameter in the first charge phase and higher than the "Minimm start voltage" parameter. 8

9 9.Error list Error nmber and description 1 Charger temperatre sensor or cooling fan failed 2 Charging time limit has been exceeded 3 Battery temperatre sensor failed or not connected or shorted 4 Charger temperatre dring the charging process too high 5 Battery voltage too high at the start of the charging 6 Battery temperatre too low dring charging 7 Battery temperatre too high dring charging 8 Charger disconnected from the battery dring charging 9 Incorrect parameter checksm 10 Problems with the crrent measrement 11 Incorrect parameter vales Internal problem with the power measrement or no release signal from the power stage The charging crrent measrement is otside of the tolerances or the otpt is overloaded at very low otpt voltage Problem with the crrent control If an error appears on the display (on a red backgrond), the error information is displayed with a nmber with text description - e.g. " ". Please provide that error nmber when the spplier or manfactrer is contacted. 10. Accessories for KOP3 Chargers Order code Description CKOP Cable 16 mm2 Radox 2 m long for KOP3-48V CKOP Cable 25 mm2 Radox 2 m long for KOP3-24V and KOP3-48V KOP-DIS1-6,0 External display with 6 m cable and 5p Mini-XLR plg The display shows the same information as the bilt-in display. CKOP-T3,6 Battery temperatre sensor with Mini-XLR plg (3.6 m long) Other lengths and versions on reqest. G Mini XLR plg - 3 pin version G Mini XLR plg - 5 pin version G Mating connector to the relay socket CK3-CURR-SW Cable with 5p Mini-XLR plg and switch for the selection of mains crrent limitation Other mains/battery plgs, cable lengths and cable versions on reqest. 9

10 11. General information Read the manal thoroghly. The charger mst be sed with the original cables only. Do not change, shorten, extend or short circit the cables. Remove the mains plg from the mains first before breaking the battery connection. Only rechargeable batteries can be sed. Do not connect any non- rechargeable batteries (like dry-cell batteries) to the charger. The charger mst be sed for the correct battery type only. Do not install the charger inside motor-homes, campers or caravans. Check the charger for cable, hosing and connector damages before se. Do not operate the charger when damaged. There are no ser serviceable parts inside. Refer servicing to qalified service personnel. Do not expose the charger to rain, moistre, direct snlight or dst. Always disconnect the mains after charging and generally when the device is not in se. Dring the trickle charge the charger remains attached to the mains. Observe the warnings on the last page of this manal. 10

11 12. Warnings COOLING Do not cover the charger hosing and protect it from direct snlight or other heat sorces. The charging crrent is redced at elevated ambient temperatres and the charging time increases accordingly. The bilt-in fan mst be able to cool the electronics well. The fan speed depends on ambient temperatre and charging crrent. CONNECTION Otpt crrents are very high. Select the correct wire/cable size, se ferrles for wire ends, keep contact points clean and properly connect the otpt terminals. FUSES The fse in the charger is not a sfficient protection for the battery cable from the battery to the charger. A corresponding fse mst be located in the immediate vicinity of the battery terminal. MAINS The line crrent is limited to 14.7 A by the charger firmware. Please CONNECTION check if the wall socket and the mains fse meet this crrent. BATTERY TYPE / SIZE Use this charger for the pre-set battery type and size only, otherwise the battery may not be flly charged or the battery can be damaged or it's life can be redced. LITHIUM BATTERIES Lithim batteries are very sensitive to overcharging and overheating. The charger can reglate only the total voltage, bt can not recognize states of individal cells. Therefore, the charger shold only be sed together with a battery management system. LEAD-ACID BATTERY GASSES Lead-acid batteries prodce hydrogen-oxygen gases, which can be explosive, and slfric acid that can case severe brns. Make sre the working area is well-ventilated. Cigarettes or any open fires or sparks may case an explosion. Keep all ignition sorces away from the battery. ACIDS Battery acid can damage yor eyes and skin. In the event of an accident, flsh with water and seek medical help immediately. Use proper personal protective devices when handling a damaged or leaking battery. Treat the material sed to clean p the battery acid spill as hazardos waste. Batteries contain hazardos materials. Among others, lead and TOXIC SUBSTANCES antimony are toxic sbstances. Waste lead-acid and many other battery types are hazardos waste and mst be treated according to the Battery Disposal Reglations. 11

12 Advanced soltions for battery powered vehicles and boats Address: Piktronik d.o.o. Cesta k Tam 17 SI-2000 Maribor Slowenien Tel: Fax: Internet: info@piktronik.com 04/17