Piktronik KOP3 Battery Charger User Manual
- June 13, 2024
- Piktronik
Table of Contents
- Introduction
- Start of the Charging Process
- Meanings of the Values Shown on the Display
- Mechanical Installation
- Connections
- Functions of the Charger Software (Standard Version)
- Technical Characteristics
- Troubleshooting
- Error List
- Accessories for KOP3 Chargers
- General Information
- Warnings
- References
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
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
Batt. | Battery temperature in ºC |
---|---|
temp. | 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.| 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
1 | +12V | 12 V power supply (max. 150 mA) |
---|---|---|
2 | NC | Not connected |
3 | GND-D | Ground connection for +12V and BMS |
4 | HALBE | Charging at half power |
5 | NC | Not connected |
6 | PTC | Battery temperature sensor |
7 | GND-PTC | Ground connection for the PTC |
8 | +12V | 12 V power supply |
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
NO | Normally open |
---|---|
C | Common |
NC | Normally closed |
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
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 | 12 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 | 180-264 V/47-63 Hz | |
Mains current | Max. 15 A | |
Standby current from the battery | < 0.2 mA | |
Output power | Max. 3000 W | |
Dimensions (L x W x H) | 380 x 265 x 95 mm | |
Weight incl.mains cable | 6.9 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
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 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
- Charger temperature sensor or cooling fan failed
- Charging time limit has been exceeded
- Battery temperature sensor failed or not connected or shorted
- Internal charger temperature too high
- Battery voltage too low during charging
- Battery temperature too low during charging
- Battery temperature too high during charging
- Charger disconnected from the battery during charging
- LASH error
- 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
Order code | Description |
---|---|
CKOP3-16-2 | Cable 16 mm Radox 2 m long – for KOP3-48V 2 |
CKOP3-25-2 | Cable 25 mm Radox 2 m long – for KOP3-24V and KOP3-48V 2 |
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| 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.
---|---
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
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>