Piktronik KOP3 Battery Charger User Manual

KOP3 Battery Charger
User’s Manual

10/2021

Introduction

KOP3 battery chargers are modern fully automatic devices, suitable not only for charging but also for maintaining and monitoring of the batteries. The charger stores data about charging times and Ah charged. This data can 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 programmed for a specific battery type by your dealer. 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!

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 before disconnecting the battery.
When the charger gets connected to the mains, the first value to appear is the charger type, followed by measured values such as battery voltage – see the following page.
The charging time depends on battery size and the state of charging. If the battery was only slightly loaded, 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 increases accordingly.
The charger can permanently remain connected to the battery. The current consumption of the battery is less than 0.5 mA.
Pictures below illustrate the values shown on the charger display.

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 is at its limits or if cooling is insufficient and the overheating protection is active. The symbol after the displayed number indicates that the corresponding value has reached the limit.
At the bottom line is the info icon [ ]. By ckicking it, you can switch among the three screens (see pictures on the left).
The bottom row shows the current charging phase on the left and the total charging time in hours and minutes on the right side. The abbreviation SN represents the 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.

 Meanings of the Values Shown on the Display

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.| Charger temperature in ºC
temp.| Internal temperature of the charger power stage in ºC
Charge| When charging is completed, the value of the charged Ah is displayed until a new battery is connected or charging is restarted for the same battery. The charged Ah (Ampere-hours)
BMS| BMS limit in %
If a battery management system is connected, its request for current reduction (percentage of nominal current) is shown (“OFF“ means
charging is blocked or there is no connection to the BMS).
Iac| 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.
Line current in A (current from the mains socket)
Iac Max| Current value of line current limitation when the BMS input is used to choose/select the maximum line current limit.
Power| 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 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).
Charging power in W = charging current x battery voltage
Ucomp.| This value indicates how much the voltage measured inside of the charger is higher than the voltage at the battery terminals.
Compensation of the charging voltage in V
Phase| The current charging phase
After the charging has been completed and the charger has turned off the text “END” appears on the display.
If the message “Charging completed” appears even though charging is still taking place and the charging phase is displayed, the trickle charging phase has been started. Trickle charging is necessary for battery charge maintenance and for cell equalization of some battery types.

Mechanical Installation

Following things must be considered during the installation:
a. Ensure distance from walls or other objects
Ensure distance from walls or other objects. Leave enough space (at least 10 cm) between cooling openings and other objects or walls to ensure good air circulation.
b. Avoid heat build-up
A lot of heat is generated even though efficiency is very high. 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. In horizontal position, the device can withstand higher stress due to vibration and shock.
d. Vertical mounting

The cables and terminals must be on the lower side so the fan can move the hot air upwards – as shown in the image.
IMPORTANT: The charger should not be mounted vertically in applications such as electric vehicles, since high shock and vibrations are common in such applications.
IMPORTANT: Observe additional warnings (see the table). Do not make any holes on the chassis as components can get damaged.
Mount the charger on a flat surface.

Connections

Pinout of the PTC connector

The signals on the PTC connector are not galvanically separated from the battery.
Pinout of the CAN/BMS connector

1| Shield|
---|---|---
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
5| CAN-L| (no CAN bus termination resistor in the charger)

All signals and the 12 V power supply are galvanically separated from the mains (230 V) and from the battery.
RELAIS connection

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 V AC, the KOP3 charger is switched off. When the mains voltage rises again, the charging is restarted where it  was interrupted.
b. 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.
c. Relay output
The relay output is switched on when 230 V is connected. Other software options for relay output are available 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.
NOTE: The charger has a 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.

Technical Characteristics

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

Troubleshooting

Check the mains connection.
Check if the mains voltage is present.
Charging does not start| Check the warning or error message shown on the display. The list of possible errors is presented on the following page.
Battery voltage is too low| Battery voltage is lower than the minimum value at which the charger is allowed to start.

Battery voltage at the start of charging must be higher than half of the “Max. Voltage” parameter in the first charging phase and higher than the “Minimum start voltage” parameter.

Error List

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. Internal charger temperature too high
5. Battery voltage too low during charging
6. Battery temperature too low during charging
7. Battery temperature too high during charging
8. Charger disconnected from the battery during charging
9. LASH error
10. System error

If an error appears on the display (on a red background), the error information is displayed with a number and text description – e.g. “12.2 …”.
Please provide that error number when you contact the supplier or manufacturer.

Accessories for KOP3 Chargers

shows the same information as the built-in display.
CKOP-T3,6| Other lengths and versions on request.
Battery temperature sensor with Mini-XLR plug (3.6 m long)
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.

General Information

• Read the manual thoroughly.
• The charger must be used with the original cables only. Do not change, shorten, extend or short circuit the cables.
• Remove the mains plug from the mains socket before breaking the battery connection.
• Only rechargeable batteries can be used. Do not connect any non-rechargeable batteries (like dry-cell batteries) to the charger.
• The charger must be used for the correct battery type only.
• Do not install the charger inside motorhomes, campers or caravans.
• Check the charger for cable, housing and connector damages before use. Do not operate the charger when damaged.
• There are no user serviceable parts inside. Refer servicing to qualified service personnel.
• Do not expose the charger to rain, moisture, direct sunlight or dust.
• 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.
• Observe the warnings on the last page of this manual.

 Warnings

COOLING| Do not cover the charger housing and protect it from direct sunlight or other heat sources. Charging current is reduced at elevated ambient temperatures and 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.
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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 mains fuse meet this current.
BATTERY TYPE AND SIZE| Use this charger for the preset battery type and size only, otherwise the battery may not get fully charged or it can get damaged or its life can get 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 in accordance with the Battery Disposal Regulations.

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

http://www.piktronik.com
www.piktronik.com

References

• Piktronik - Piktronik

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