Cotek Easy Charger Wizard User manual

1
Easy Charger Wizard Product Guide

2
1. Scope
Easy Charger Wizard is a flexible kit to make your COTEK Power
converters a three -stage battery charger, which can easily fit all
frequently used battery types and different battery voltage (12/24/48).
The package of easy charger wizard is consisted of below items:
1. Charger wizard board
2. Cable 1 (Refer to Section 5 Hardware Specification)
You will need a COTEK AE/AEK series power supply and CT-201
(RS232 communication board) to work with Easy Charger Wizard. For
installation instruction, please refer to Section 4-1.
To change default charger setting, there are 2 ways to do it:
1. RS232 protocol
2. COTEK Charger Wizard GUI interface
For more details, please refer to Section 4-2.

3
Note. Please read carefully the precautions and instructions on the
product package & the product Guide before installation and use. Thank
you.

4
2. Packing Configuration
3. Functions & features
3-1 Charger Wizard
⚫Single model (e.g. 60V) can be used to charge different types of
batteries including Lithium Ion, Gel, AGM, Lead Acid, etc. Suitable
charging voltage from 1V ~ 60V.
(NOTE: Please refer to Cotek AE/AEK Spec. sheet for the max.
charging current. For example, max. charging current of
AE-1500-60 is 25A, but AC input voltage must be 100Vac or
above. For AEK-3000-60, the max. charging current can support
50A, but AC input voltage must be 180Vac or above. Please

5
refer to the de-rating curve spec. of Cotek AE/AEK Series for more
detail info.)
⚫Memorize charging curve setting
⚫Programmable charger solution (higher flexibility for different type
of batteries)
⚫High Voltage / Current charging requirement
⚫LED to show different charging status
⚫The software can automatically detect the model name connected,
and allow user to control the output voltage and current within
supported spec. and select the suitable battery type.
⚫Protection: Overvoltage (This function is to protect the battery)
3-2 COTEK SMPS Features
⚫Universal input (90-264Vac)
⚫Active PFC design with high power density and efficiency (up to
93%)
⚫Remote setting multiple RS232 communication
⚫Operation temperature -20C ~ 70C (de-rating)
⚫Safety Standards: UL, TUV, and CB (Worry-Free design-in)
⚫EMI conduction & Radiation: Certified EN55032
⚫Protection: OVP, OLP, OTP, Fan failure
4. Installation Notice (Warning)
4-1 Hardware Installation

6
⚫Step 1: Set up COTEK AE/AEK power supply with proper wiring.
(Make sure the AC is off during wiring p
⚫Step 1: Make sure to connect Power supply DC wire before
connecting battery
⚫Step 2: Make sure to check battery spec. before setting the
charging voltage / current
⚫Step 3: Add suitable ORingFET in between the output side of
SMPS & battery to avoid battery current damaging power supply.

7
Output voltage
Recommend ORingFET
12V/15V/24V/30V
40V MOSFET
BSC010N04LS or equivalent
36V/48V/60V
80V MOSFET
BSC026N08NS5 or equivalent
⚫Step 4: connect Battery +/- with AE/AEK power supply DC
outputs (be aware of reverse polarity)
⚫Step 5: Install Charger Wizard to Cotek SMPS Front Panel
(Connection diagram as shown below, please be aware of reverse
connection)
AE/AEK Series AE-800
⚫Step 5: connect cable 1 to 4 Pin connector of Charger Wizard.

8
⚫Step 6: connect the white 24 pin connector of cable 1 to Cotek
communication board, CT-201
⚫Step 7: AC Power On
⚫Step 8: Install Charger Wizard GUI to perform charging curve
setting
4-2 Charger Wizard charging curve setting

9
It’s also easy to change default settings of COTEK Charger Wizard, via
below 2 ways:
4-2-1 RS232
⚫Connectivity and necessary equipment (Please refer to section 4-
1)
⚫Install “TR Broard”GUI software to set charging voltage and
current
4-2-2 COTEK Charger Wizard GUI interface
⚫Connectivity and necessary equipment (Please refer to section 4-1
Hardware Installation info.)
⚫Software download: available from Cotek Website, Partner
Section (或是申請 ftp 以利客戶 download)
⚫A brief explanation of GUI section
1. Software GUI Main Page

10
A. Model Name
B. Power Supply Rated Output Voltage and Rated Output Current
C. Rated Battery Voltage
2. Parameter Setting Description
A
B
C
A
B
C
D
E
F
G
H
I
J
L
K
M
N
O
P
Q
R
S

11
A: Read Charger Wizard Setting
B: Save the Easy Charger Wizard setting to EEPROM
C: Transfer the setting values of the software on the PC to the Charger
Wizard
D: Set the communication interface, battery type, reset, archive, archive
before loading and other function settings
E~S: The charging current and charging voltage parameters can be
entered manually or drag the parameter. The maximum setting will
depend on the rated voltage and current of SMPS (Cotek AE/AEK). It
will also reference to the rated battery voltage selected by the operator.
Parameters as follow:
E~I: BULK(C.C) Parameter:
⚫Fixed charging current is 'G' in BULK mode
⚫Conditions to enter the ABSORPTION mode (either one):
1. Start timing 'H' when the battery voltage reaches the 'E'
voltage
2. When the battery voltage reaches the 'F' voltage and the time
is maintained 'I'
⚫J~M: ABSORPTION (C.V) Parameter
⚫Fixed charging voltage is 'J' in ABSORPTION mode
⚫Conditions to enter the FLOAT Mode (either one):
1. When the time in this mode exceeds 'L'.
2. When the charging current is less than 'K', and the time is
maintained above 'M'.
⚫ N、O、Q、R. FLOAT Parameter:
⚫Repeat steps 1 and 2 after entering FLOAT mode

12
Step 1: Change the charging voltage to N, when the time reaches
'Q'
Step 2: Generate a charging pulse (charge voltage is 'O', time
remain at 'R')
⚫P、S Parameter:
Under ABSORPTION or FLOAT, when the battery voltage is lower
than 'P' and the hold time will change to BULK mode if it exceeds
'S'
3. Function setting page
A. Communication Port setting
B. Battery Voltage setting
A
B
C
D
E

13
C. Reset
D. Load the previously stored settings parameter file
E. Save parameters to the file
NOTE:
- Max. charging voltage: 15.6V (For 12V battery), 31.2V (For
24V battery) and 60V (for 48V battery)
- Max. charging current: same as the rated output current of the
power supply installed
⚫Three step Plus charge system
The first step of the three step Plus charge system is the BULK
phase, in which the output current of the charger is 100%, and the
greater part of the capacity of the battery is rapidly charged. The
current charges the batteries and gradually the voltage rises to the
absorption voltage of 14.4V (12V models) or 28.8V (24V models).
The duration of this phase depends on the ration of battery to
charger capacity, and naturally also on the degree to which the
batteries were discharged to begin with.
The bulk phase is followed by the absorption phase. Absorption
charging starts when the voltage on the batteries has reached
14.4V (12V models) / 28.8V (24V models) , and ends when the
battery is completely full. Battery voltage remains constant at
14.25V (12V models) / 28.5V (24V models) @ 25°C / 77°F
throughout this stage, and the charge current depends on the

14
degree to which the battery was initially discharged, the battery
type. Once the battery is 100% full, the charger automatically
switches over to the float phase.
During the float phase the unit switches to 13.5V (12V models) or
27 (24V models). Once consumption decreases, the charger goes
back to normal operation of the three-step charge system.
⚫User can store the charging curve set in the Charger Wizard
⚫User can use Charger Wizard tool to adjust the charging curve
settings at any time.
Warning
Warning 1. User must check the wiring length and gauge to avoid
data loss
1. AC input interface:
AE800 Series
SMPS AC Terminal
Wire color
Wire length/gauge
AC
Terminal
L
Black
Within 6 feet
/AWG#16
N
White
FG
(Earth Ground)
Green/
Yellow
26~32 feet/
AWG#16
AE1500 Series

15
SMPS AC Terminal
Wire color
Wire length/gauge
AC
Terminal
L
Black
Within 6 feet
/AWG#14
N
White
FG
(Earth Ground)
Green/
Yellow
26~32 feet/
AWG#14
AE-3000 / AEK-3000 Series
SMPS AC Terminal
Wire color
Wire length/gauge
AC
Terminal
L
Black
Within 6 feet
/AWG#8
N
White
FG
(Earth Ground)
Green/
Yellow
26~32 feet/
AWG#10 ~8
2. DC output interface:
2.1 Before installation:
The DC cables should be as short as possible (less than 6 feet / 1.8
meters ideally)
The size of the cable should be thick enough to limit the voltage drop
to less than 2% when carrying the maximum output current.
The following sizes of cables are recommended distance (<6 ft.)
between the batteries and the power supply.
Wire AWG
SMPS output current (MAX.)
#0
≧200A~250A
#1
≧150A~200A

16
#4
≧100A~150A
#6
≧50A~100A
#8
≧0A~50A
Warning 2. User must check charging voltage / current setting and
suitable charging voltage / current according to battery type and spec to
avoid damage to the battery.
Warning 3. When using the Easy Charger Wizard, if the Charger
Wizard is pulled out by external force, the COTEK AE/AEK series will
restore the original power supply status (Please make sure to power off
the power supply before installing or removing the Easy Charger
Wizard)
Warning 4. Please make sure the Easy Charger Wizard is installed in
the correct direction before power on to avoid possible damage.
Warning 5. Suitable SMPS for Charger Wizard：
⚫AE-800/1500/3000- LV Series (12V~60VDC)
⚫AEK3000-LV Series (12V~60VDC)
Warning 6. Please make sure to add suitable ORingFET in between
the output side of SMPS & battery to avoid battery current damaging
power supply.
Output voltage
Recommend ORingFET

17
Warning 7. The following precautions should be taken when working
on the Inverter Charger:
⚫Remove watches, rings, or other metal objects.
⚫Use tools with insulated handles.
⚫Wear rubber gloves and boots.
5. LED Indicator
5-1 Failure Indicator:
Failure Description
LED Status
EEPROM checksum fail
Solid Red
EEPROM Null
Red Slow
every 3 secs
Over current or Over voltage
Red light twice
flash every 3 secs.
Charging Voltage or current setting over
power supply’s rated voltage or current
Red light flash
three times every
3 secs
12V/15V/24V/30V
40V MOSFET
BSC010N04LS or equivalent
36V/48V/60V
80V MOSFET
BSC026N08NS5 or equivalent

18
Battery voltage detected is not within the
set range
Single battery: 8.5v~16.75v
2 batteries: 16.75v~33.5v
4 batteries: 33.5v~67v
Red light flash
four times every 3
secs
power supply communication or status
error
Red light flash five
times every 3 secs
5-2 Charging Status LED Indicator
Charging status
LED Status
Bulk-1
Orange fast
Bulk-2
Orange slow
Absorption-1
Orange solid
Absorption-2
Green solid
Float
Green flash
6. Hardware specifications
Dimensions: 34.5 x 29 x 10 mm

19
Cable 1 :
P1
P2
Pin. No
Function
Pin. No
Function
Description
1~20
N.C
X
X
X
21
AUX
4
AUX
+5V / 0.5A or +9V / 0.3A
Auxiliary power
22
GND
3
GND
Ground
23
RX
2
RX
For RS232 Receiver
function

20
24
TX
1
TX
For RS232 Transmission
function
7. Warranty
We guarantee this product against defects in materials and
workmanship for a period of 24 months from production month/yr
(refer to product serial number). Please contact with your local
COTEK authorized distributor for RMA (Return material
Authorization) service. Please note that COTEK will ensure our
products are operational before delivery and the warranty service is
offered to the unit which has defect caused under normal use, in the
judgment of COTEK’s technician. The warranty is null and void
under the following circumstances：
(a) If the unit has been damaged through abuse, misuse,
negligence (such as bumping, wetting), fault voltage supply,
air/water pollution accidents and natural calamities.
(b) If the serial number has been altered, effaced or removed.