KOP3 Battery Charger
24V / 125A 48V / 62.5A
User's Manual
1.Introduction
KOP3 battery chargers are modern fully automatic devices suitable not only for
charging but also for maintaining and monitoring the batteries. The charger stores data
about charging times and Ah charged. This data may be accessed for further analysis.
The device is protected against reverse polarity and short circuit, has adjustable time
limitations for every charging phase, battery temperature monitoring and compensation
and current reduction at elevated ambient temperatures.
Your battery charger was factory programmed for a specific battery type. Make sure the
charging profile suits your 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 suit
the battery type. Up to five charging phases can be programmed with separate values
for charging voltages, currents, charging times, temperature compensation and other
control functions. Please contact your dealer for further information.
When programming the charging profile always follow the battery manufacturer's
recommendations.
Please read the operating and safety instruction carefully
before using or installing the KOP3 battery charger!
2. Start of the charging process
Establish a safe connection between the battery and the charger first. Then plug the
mains connector. When removing the connection, remove the mains plug 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 measured values 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
temperatures or when exposed to strong sunlight, the charging current is reduced and
the charging time increased accordingly.
The charger can remain connected to the battery permanently. The power consumption
is less than 0.5 mA.
2
The pictures below illustrate the values shown on the charger display.
Main screen
Secondary screen
In the first row the battery voltage and the battery
current are shown. The battery voltage indicates the
voltage at the battery terminals and not the output
voltage of the charger. This value is exact only if the
voltage drop compensation parameter has been set
correctly.
The charging current may be smaller as the charger
nominal value if a lower value has been programmed
or if the charging power or the mains current are at
their limits or if cooling is insufficient and the
overheating protection is active.
The abbreviation SN is for serial number of the
charger. Firmware and Revision show the version
and revision of charger firmware in the left column and
of display firmware in the right column.
Touching of the English or German national flag
switches between the languages for displaying
warnings and error messages.
The current and voltage values depend on battery state of charge, on charger
parameters (up to five charging phases can be set), environment temperature, mains
voltage and battery temperature if temperature compensation has been enabled with
charger parameters. If the charging current is lower than the parameter value for one of
these reasons, then the charging time is increased accordingly.
The symbol after the displayed number shows that the
corresponding value 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 pictures on
the left side).
The bottom row shows the current charging phase on the left
and the total charging time in hours and minutes on the right
Info screen
3
Batt.
temp.
Battery temperature in ºC
This value is displayed only if the temperature sensor is connected. When
the battery temperature monitoring and battery temperature compensation
have been unlocked with the charger parameters, then the measured
value is also checked for validity.
Charg.
temp.
Charger temperature in ºC
Internal temperature of the charger power stage in ºC
Charge
The charged Ah (Ampere-hours)
After the completion of charging the value of the charged Ah is displayed
until 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 request for current
reduction (percentage of nominal current) is shown (“OFF“ means
charging is blocked or no connection to the BMS).
Iac
Line current in A (current from the mains socket)
This current is limited to 14.7 A by charger firmware. It can be higher as
14.7 A during fast load or mains changes only.
Iac Max
Current value of line current limitation when the BMS input is used to
choose/select the maximum line current limit.
Power
Charging power in W = Charging current x Battery voltage
The power output (total power) of the charger is not the same as the
charging power. It also includes losses at the cables, fuses and plugs. The
voltage drops are compensated by the charger. The charger output power
limit includes losses of the various voltage drops. Therefore, the maximum
achievable charging power can be somewhat smaller than 3000 W in
practice since the total charger output is limited to 3000 W and not to the
battery charging power.
A charging power of less than 3000 W can also be caused by a low supply
voltage (limit of the line current).
Ucomp.
Compensation of the charging voltage in V
This value indicates for how much the voltage measured inside of the
charger is higher than the voltage at the battery terminals.
Phase
The current charging phase
After the charging has been completed and the charger has turned off the
text "END" text appears on the display.
If the message "Charging completed" appears, although 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 equalization.
3. Meanings of the values shown on the display
4
4. Mechanical installation
The following things must be considered during the installation:
a. Ensure the distance from the walls or other objects
Ensure the distance from the walls or other objects. Leave enough space (at least 10
cm) between the cooling openings and other objects or walls, so that the air can
circulate well.
b. Avoid the heat build-up
Despite very high efficiency quite a lot of heat arises. Therefore, the charger must
only be installed in places with enough air exchange. Otherwise, the air temperature
rises in the vicinity of the device and the charging current may be reduced or the
device may turn off.
c. Horizontal mounting
Mount the charger on a flat surface (from the top) as
shown on the image. The device can withstand higher
stress due to vibration and shock in the horizontal
position.
d. Vertical mounting
The cables and terminals must be on the lower side so
that the fan moves the hot air up - as shown on the
image.
IMPORTANT:
The charger should be mounted vertically in
applications such as electric vehicles, since high
sh o ck an d v ibr a ti o ns ar e c omm o n i n s uch
applications and it can withstand better in such
position.
IMPORTANT: Observe the additional warnings (see the table). Do not make any holes
on the chassis, as components can be damaged.
Mount the charger on a flat surface.
5
5. Connections
CAN/BMS
PTC
RELAY
CAN/BMS
Mini-XLR 5p
PTC
Mini-XLR 3p
RELAY
Phoenix MSTBV
BAT+
BAT
230 V
NO
NCC
1
3
2
5
1
3
2
4
Max. 5 A
Pinout of the PTC connector
1
GND
Connected to the battery minus internally
2
SER-OUT
Serial output (communication with KOP-USB or KOPPROT)
3
PTC
PTC connection for battery temperature measurement
The signals on the PTC connector are not galvanically separated from the battery.
Pinout of the CAN/BMS connector
1
BMS-IN
Cathode of the optocoupler for the BMS PWM input
(anode connected to +12 V through a 1k0 resistor).
Current through the optocoupler diode min. 1 mA
2
+12V
Power supply for the external display (max.100 mA)
3
GND2
Ground connection for the external display
4
CAN-H
Communication with the display or other devices
(no CAN Bus termination resistor in the charger)
5
CAN-L
All signals and the 12 V power supply are galvanically separated from the mains
(230 V) and from the battery.
6
RELAIS connection
NO
Normally open
C
Common
max. 5 A continous/switching current
NC
Normally closed
6. Functions of the charger software (standard version)
a. Mains current limiter
Most sockets are protected between 10 A and 16 A on the mains side. Very few
sockets tolerate a continuous current of more than 15 A. To avoid overheating with
excessive mains current, it is limited to max. 14.7 A (see the description below for
further current limit selection with the BMS input).
Comment:
For 230 V mains voltage and full output power the charger needs approx. 14.2 A from
the socket. At low mains voltage, the mains current would increase at the same
power, but this would be reduced to max. 14.7 A. In the short term, the current can
also be somewhat higher than 14.7 A in the case of very fast mains voltage
fluctuations. 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 interrupted.
b. BMS input
The selection of the mains current limitation is the standard function of this input. If
this input is connected to ground (GND), the mains current is limited to 8.7 A, if not,
then the mains current is limited to 14.7 A. Other values on request. A plug with the
preassembled switch can be ordered as an option.
Special software versions are to be ordered if the BMS input is used for
communication with the battery management system. Contact Piktronik for the
description of the BMS PWM interface.
c. CAN Bus
The standard firmware version supports the external display. For support of special
functions, like E.g. communication with the BMS, please contact Piktronik.
d. Relay output
This is switched on when 230 V is connected. Other software options for relay output
on request.
If other functions are required, the charger software can also be changed later via the
PTC connector with the KOP-USB programming adapter.
7
NOTE: The charger has very low power consumption. Therefore, depending on the
function, the display can remain switched on for more than 20 seconds after the
mains plug has been disconnected.
7. Technical characteristics
Charger type
KOP3-24V
KOP3-48V
Nominal voltage / current
24 V
48 V
Charging current
125 A
62.5 A
Minimal starting voltage
10.5 V
13.0 V
Adjustable charging voltage
range
10.5 V to 33.6 V
24.0 V to 62.0 V
Typ. efficiency
91%
92%
Power factor
> 0.95, typ. 0.99 at full power and 230 V
Mains voltage
180 V - 264 V / 47 - 63 Hz
Mains current
max. 15 A
Standby power consumption
from the battery
< 0.5 mA
Output power
max. 3000 W
Dimensions (L x W x H)
380 x 265 x 95 mm
Weight incl.mains cable
6.3 kg
6.6 kg
Protection grade
IP20 (IP21 with horizontal mounting)
Approvals
EN 55011 Class B, EN 60335-1, EN 60335-2-29
EN 61000-3-2, EN 61000-3-3, EN 61000-4-2,
EN 61000-4-5, EN 61000-4-6, EN 61000-4-11,
EN 61000-6-2, EN 61000-6-3
8. Troubleshooting
Issue
Remedy
Display on the device does
not turn 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 minimum
value at which the charger is allowed to start.
8
The battery voltage at the start of the charge must be higher than half of the "Max.
Voltage" parameter in the first charge phase and higher than the "Minimum start
voltage" parameter.
Error number and description
1
Charger temperature sensor or cooling fan failed
2
Charging time limit has been exceeded
3
Battery temperature sensor failed or not connected or shorted
4
Charger temperature during the charging process too high
5
Battery voltage too high at the start of the charging
6
Battery temperature too low during charging
7
Battery temperature too high during charging
8
Charger disconnected from the battery during charging
9
Incorrect parameter checksum
10
Problems with the current measurement
11
Incorrect parameter values
12
Internal problem with the power measurement or no release signal from the
power stage
13
The charging current measurement is outside of the tolerances or the output
is overloaded at very low output voltage
14
Problem with the current control
9
Order code
Description
CKOP3-16-2
2
Cable 16 mm Radox 2 m long – for KOP3-48V
CKOP3-25-2
2
Cable 25 mm Radox 2 m long – for KOP3-24V and KOP3-48V
KOP-DIS1-6,0
External display with 6 m cable and 5p Mini-XLR plug
The display shows the same information as the built-in display.
CKOP-T3,6
Battery temperature sensor with Mini-XLR plug (3.6 m long)
Other lengths and versions on request.
G00500003
Mini XLR plug - 3 pin version
G00500004
Mini XLR plug - 5 pin version
G00500059
Mating connector to the relay socket
CK3-CURR-SW
Cable with 5p Mini-XLR plug and switch for the selection of
mains current limitation
Other mains/battery plugs, cable lengths and cable versions on request.
10. Accessories for KOP3 Chargers
9.Error list
If an error appears on the display (on a red background), the error information is
displayed with a number with text description - e.g. "12.2 ...".
Please provide that error number when the supplier or manufacturer is contacted.
11. General information
u Read the manual thoroughly.
u The charger must be used with the original cables only. Do not change, shorten,
extend or short circuit the cables.
u Remove the mains plug from the mains first before breaking the battery connection.
u Only rechargeable batteries can be used. Do not connect any non- rechargeable
batteries (like dry-cell batteries) to the charger.
u The charger must be used for the correct battery type only.
u Do not install the charger inside motor-homes, campers or caravans.
u Check the charger for cable, housing and connector damages before use. Do not
operate the charger when damaged.
u There are no user serviceable parts inside. Refer servicing to qualified service
personnel.
u Do not expose the charger to rain, moisture, direct sunlight or dust.
u Always disconnect the mains after charging and generally when the device is not in
use. During the trickle charge the charger remains attached to the mains.
u Observe the warnings on the last page of this manual.
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12. Warnings
COOLING
Do not cover the charger housing and protect it from direct sunlight or
other heat sources. The charging current is reduced at elevated
ambient temperatures and the charging time increases accordingly.
The built-in fan must be able to cool the electronics well. The fan
speed depends on ambient temperature and charging current.
CONNECTION
Output currents are very high. Select the correct wire/cable size, use
ferrules for wire ends, keep contact points clean and properly
connect the output terminals.
FUSES
The fuse in the charger is not a sufficient protection for the battery
cable from the battery to the charger. A corresponding fuse must be
located in the immediate vicinity of the battery terminal.
MAINS
CONNECTION
The line current is limited to 14.7 A by the charger firmware. Please
check if the wall socket and the mains fuse meet this current.
BATTERY
TYPE / SIZE
Use this charger for the pre-set battery type and size only, otherwise
the battery may not be fully charged or the battery can be damaged
or it's life can be reduced.
LITHIUM
BATTERIES
Lithium batteries are very sensitive to overcharging and overheating.
The charger can regulate only the total voltage, but can not
recognize states of individual cells. Therefore, the charger should
only be used together with a battery management system.
LEAD-ACID
BATTERY
GASSES
Lead-acid batteries produce hydrogen-oxygen gases, which can be
explosive, and sulfuric acid that can cause severe burns. Make sure
the working area is well-ventilated. Cigarettes or any open fires or
sparks may cause an explosion. Keep all ignition sources away from
the battery.
ACIDS
Battery acid can damage your eyes and skin. In the event of an
accident, flush with water and seek medical help immediately. Use
proper personal protective devices when handling a damaged or
leaking battery. Treat the material used to clean up the battery acid
spill as hazardous waste.
TOXIC
SUBSTANCES
Batteries contain hazardous materials. Among others, lead and
antimony are toxic substances. Waste lead-acid and many other
battery types are hazardous waste and must be treated according to
the Battery Disposal Regulations.
11
www.piktronik.com
Advanced solutions for battery powered vehicles and boats
Address:
Piktronik d.o.o.
Cesta k Tamu 17
SI-2000 Maribor
Slowenien
Tel:
+386-2-460-2250
Fax:
+386-2-460-2255
Internet:
www.piktronik.com
E-mail:
info@piktronik.com
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