BEIYANG ELECTRIC APPARATUS KCG3 User manual

KCG3 SMART BATTERY CHARGER
USER MANUAL
BEIYANG ELECTRIC APPARATUS FACTORY
TEL: [phone] FAX: [phone]
ADDR: 66 JIANGXI ROAD, QINGDAO 266071, P. R. CHINA
WEB: www.byauto.com.cn Email: [email protected]
Version: 1.30.0004

1. Introduction
KCG3 smart battery charger is the
upgrade of our KCG2 automatic battery
charger. The inside micro-controller,
PIC18F of Microchip Corp., controls the
whole charge procedure. Friendly user
interface, LCD display and key input, makes it easy
to use. KCG3 supports different charge curves,
makes a complete charge and long battery life and
has all-around protections.
KCG3 is high frequency switching mode
charger. IGBT/MOSFET and PWM controller are
the main components. For single-phase input,
Active power factor correction circuit makes a high
power factor. And Soft switching technology
(resonant zero voltage switching and zero
current switching) increases the efficiency
and reduces electromagnetic interference.
INPUT EMI
filter
Rectifier &
filter
A、V、Status
LCD display
Isolation & driver
PWM IC Control
Soft
start Constant
Voltage
Constant
Current
Reset
Battery
Indicator
light Relay/Beeper
CPU
Fan cooling
Key input
Temperature
sensor
Temperature
Switch
ON/OFF
Power for
Control
Rectifier PFC PFC
Snubber
Isolated Inverter
Diagram 1. Block diagram of KCG3
KCG3 charger can be widely used in Marine, e-forklift, railway vehicle,
and many other places for all kinds of storage batteries. It also can be
used as a DC power supply. . 1 .
KCG3-200A/E80V-3G
KCG3-120A/24V-3G

2. Technique Specifications
(1) Power supply:
1 or 3 phase, 220VAC, 380VAC, 440VAC, etc. –10%~+10%, 50/60Hz
(2) Outputs:
Rated output power = Equalize constant voltage (E. CV) * constant current (CC);
Different battery requires different E. CV, Floating CV (F. CV) and CC values;
e.g. 24V battery:
LA battery, we set 28.2V as E. CV and 26.7V as F. CV;
Alkaline battery, we set 31-36V as E. CV and 27.2V as F. CV;
Maximum output power: 20KW. See Appendix 1, 2. Support LA, GEL. See Appendix 3.
(3) Set charging parameter precision:
voltage: 0.1V; current: 1A
(4) Charge curve (programmable for any charge curve.):
(4-1) 3-stage charge
A: limited current / Boost, B: Constant Voltage, C: floating
Diagram 2. 3-stage recharge voltage/current curve.
(4-2) Other curves as customer’s requirement. E.g., 4-stage charge
A: Constant current 1, B: Constant Voltage 1, C: C.C. 2, D: C. V. 2
Diagram 3. 4-stage recharge voltage/current curve.
. 2 .

(5) Protection and Alarm:
Over voltage protection, Over load protection,
Input voltage low protection,
Input fuse protection.
Battery reverse connection protection with output fuse; for larger than 3KW,
DC contact (optional) can protect and eliminate battery connecting spark.
Output power limitation,
Temperature control fan cooling (about 45℃)
Reduce output power (about 75°C -78°C), resume (about 65°C)
Over temperature protection (about 80°C -85°C) (stop and auto restart).
(6) Low ripple, 0.3% of the charge voltage
voltage display precision: 0.1V; amps display precision: 1A
(7) Password for parameter setting (optional).
(8) PFC (optional). APFC for single phase input, cosΦ=0.99; Passive
PFC for 3-phase input, cosΦ>0.93.
(9) Parallel running, droop characteristic, load share deviation 5%
(optional)
(10) Battery temperature compensation (optional)
(11) PC remote control with RS-232, RS-485 or CAN bus (optional)
(12) Charge efficiency: Higher than 85%
(13) Operating temperature range: 0~50°C (32~122°F)
(14) Design for marine.
(15) Safety class: IP20, IP44.
3. Naming
. 3 .
KCG3- (E)xxx V-A/
INPUT
Blank: 220VAC
G: 380VAC
G1: 440VAC
G2: 110VAC
G3: 480VAC
G4: 600VAC
P1:110V, PFC
P2:220V, PFC
INPUT
Blank: 1 phase
3: 3 phase
Blank: Bench mount
W: Wall mount
Maximun output-current
xxxV: Nominal battery
voltage
Start with letter "E",
xxxV is the maximum
output voltage

4. Operating panel
KCG3 Indicator
Light
Reset
OFF
ON
Battery Charger
Back/
Cancel
▲
▲
Menu/
set
o-
5. Installation and Operations:
(1) Ensure a clearance of at least 10 cm around the battery charger to
ensure adequate ventilation. The battery charger must not be
installed in the vicinity of heat sources or exposed to water.
Ventilation slots must not be obstructed.
(2) The storage batteries should be connected correctly. Be
careful and don’t reverse the poles “+” and “-”.
(3) The input wires and the GND should be
connected correctly. Then connect the AC power.
The LCD will show voltage, current and status.
(4) Set the charge parameters.
There are 5 buttons on the front panel. Press
“Back/Cancel”, when the LCD display abnormal.
If not work, press “Reset”.
(4.1) Press “Menu/Set” to enter the menu. Then
Press tochooseitem;or
Press “Back/Cancel”, quit the menu.
(4.2) Choose an item, press “Menu/Set”, the value
will flash. Then
Press to increase or decrease the
value. Then
Press “Menu/Set”, save the new value; or
Press “Back/Cancel” back to menu without save.
(4.3) If “Password” function is enable, password is
required before enter the menu. If password is
accepted, user can modify the values; if password is
denied, user can view the values only. The default
password is “000”
. 4 .
OUTPUT
+ -
Reset
Back/
Cancel
▲
▲
Menu/
set
▲
▲
▲
▲
024.0V 000A
Stop Charge
024.0V 000A
Stop Charge
1. Floating Volt
26.7V
2. Constant Curr
040A
Diagram 4.
User control interface.
Enter Password
***
Password invalid
Password OK.

(4.4) 3-stage charge parameter set. (KCG3-40A/24V for example)
Set floating voltage.
Set the constant current.
Automatic change according to the Equalize voltage.
Set the constant/equalize voltage.
Set the current value to floating charge.
Set the floating charge time.
0,1, 2, 3 hours or NO STOP.
If set “NO STOP”, floating charge until equalize day (See 7.).
Set the over voltage protection value
Set the cycle of equalize charge.
Set the Delay time “NO STOP” to enable.
Set voltage values for LAor GEL or AGM battery.
See appendix 2.
Set all to default values (LA battery, 3-stage curve).
See appendix 2.
Optional functions:
Choose charging curve 3-stage or 4-stage
Set password, digit 0-9.
Choose nominal voltage for different voltage
battery. The charge voltage values
(Equalize/Floating/Protect voltage) will change automatically.
Enable / Disable the temperature compensation
function. Range: 0.01V-0.20V/℃
For example: set at 0.02V/C. If the temperture is 10℃, the floating
voltage will rise (25℃-10℃)*0.02V/℃, that is 0.3V.
Set parameters when the charger is in the status: Stop Charge.
. 5 .
6. Over Volt.
31.2V
2. Constant Curr
040A
4. Curr to Float
008A
5. Delay time
01 Hours
7. Equalize day
20 Days
8. Set Battery
LA / GEL
1. Floating Volt
26.7V
3. Equalize Volt
28.2V
10. Charge Curve
3-stage curve
11. Set Password
***
12. Nominal Volt
24.0V
13. T. Compenst.
DISABLE
9. Set default
YES

(5) Turn on the control switch. The charger is going to work.
LCD shows output voltage, current in the first
line and the status of charger in the second
line. The charge stage and charging time
depend on the battery.
Status Display Indicator
Constant current Equalize charge Yellow flash
Constant voltage Constant voltage Yellow light
Floating charge Floating charge Green flash
3-stage
Charge complete. COMPLETED Green flash
Over volt protection OVER VOLTAGE Manually restart
Over Load protection OVER HEAT
Over temperature
protection (80°C -85°C)
OVER LOAD
AC input voltage low
protection
INPUT ABNORMAL
Red flash
Auto restart
(If restart 3 times in
1 minute, manually
restart.)
Stop charge STOP CHARGE Green light
Table 1. Charger status list
(6) Press key to see the time of charge. The
time will be clean when turn off the “ON/OFF” switch.
(7) Stop and alarm
• When over voltage and over load protection occurs, the charger
will stop and alarm. The indicator is red and flash.
• When over temperature or AC input voltage low protection
occurs, the charger will stop and alarm. The indicator is red and flash.
When resume, it will restart automatically.
• When over load or AC input voltage low protection acts, the
charger will try to restart 3 times. If it still protects, it will not restart
and try to auto restart once every hour. Press “Menu/Set” key to
acknowledge the alarm and press “Back/Cancel” key to restart
manually.
• When charge is completed, it will stop and alarm. The indicator is
green and flash.
. 6 .
▲
▲026.7V 008A
00D 06H 15M
024.0V 000A
Stop Charge

• Alarm relay output (3 wires. Red black green). Normally open: red and
green. Normally close: red and black. Relay capacity: 0.3A, 110VDC/125VAC.
Note: Specifications is subject to change without notice.
Appendix 1. Standard types and dimensions.
12V 24V 36V 48V 60V 72V 80V 96V 108V 192V 216V 324V
3A
5A BB
10A A A A A A B B C C
15A A B B B C C D
20A A A B B C C C D D D
25A A C C C D D E
30A A B C C C C D E E E
40A A A B C C C D D D E E F
50A A B C C C D D D E F F G
60A A B C C D D D E E F F G
70A B C C D D D D E E F G
80A B C C D D D E E F G G
90A B C D D D E E F G
100A B C D D E E E F F
120A C C D D E E F F F
130A C D D E F F F F G
150A C D D E F F G G G
180A C E E F F G G G
200A C E E F G G G
. 7 .
V.
C.

Dimensions (mm) Weight (KG) POWER(KW)
A Bench mounted, 350×243×113 mm 6-7 ≤1.2
Wall mounted, 350×140×500 mm 10
B Bench mounted, 370×310×113 mm 8-9 ≤1.8
Wall mounted, 350×140×500 mm 12
C Bench mounted, 460×350×128 mm 12-14 ≤3.6
D Bench mounted, 520×380×150 mm 20-22 ≤6.5
E Bench mounted, 550×430×160 mm 25-28 ≤10
F Cabinet, 540×260×1000 mm 50-60 ≤15
G Cabinet, 600×320×1000 mm 65-75 ≤20
Appendix 2. Choose charge voltage and current
Voltage: charging voltage per cell ×number of cells;
For example, 9 pcs of 12V LAbattery in series
Equalize constant voltage, 14.1V ×9 = 119.7V,
Floating constant voltage, 13.4V ×9 = 126.9V
Current: Battery capacity ×charging factor.
If choose 0.1 as the factor, it will take no more than 16 hours to charge the
completed discharged battery. If choose 0.2, it will take less than 8 hours to
charge the completed discharged battery.
For example, 48V 630Ah battery, Constant current,
0.1 ×630 = 63A. So choose 60A or larger charger;
0.2 ×630 = 126A. Choose 120Aor larger charger.
Appendix 3. Default voltage, for 3-stage charging curve.
Battery Nominal Voltage 12V 24V 48V 60V 72V 80V 216V
Floating 13.4V 26.7V 53.4V 66.5V 80.0V 89.3V 241VLA/VRLA/AGM Equalize 14.1V 28.2V 56.4V 70.5V 84.6V 94.0V 254V
Floating 13.5V 27.0V 54.0V 67.5V 81.0V 90.0V 243VGEL Equalize 14.3V 28.6V 57.2V 71.5V 85.8V 95.3V 257V
AGM: Absorbed Glass Matt
Note: If the temperature compensation function is enabled, the charging
voltages set in the menu are voltages when the environment temperature is at
25℃. The real output voltage changes according to the temperature.
. 8 .