LZ design FES KOP2300 User manual
FES KOP2300 High Power Charger, v1.0 August 2019
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Table of content
1. Important notices..................................................................................................... 3
1.1 Limited Warranty ................................................................................................. 3
1.2 Invalid Warranty.................................................................................................. 3
2. Introduction ............................................................................................................. 4
3. Technical characteristics ........................................................................................... 4
3.1 Mains current limiter ............................................................................................ 5
4. Mechanical installation .............................................................................................. 5
5. Connections ............................................................................................................. 6
5. LED Functions .......................................................................................................... 7
6. Charger to FES Battery pack connection and charging.............................................. 8
7. Error codes ............................................................................................................ 10
8. Troubleshooting ..................................................................................................... 10
9. Revision history...................................................................................................... 11
FES KOP2300 High Power Charger, v1.0 August 2019
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1. Important notices
This user manual contains important information about proper and safe usage of
FES KOP2300 charger. If you need more information, please contact LZ design company.
Information in this document are subject to change without notice. LZ design
reserves the right to change or improve this product and to make changes in the content
of this material without obligation to notify any person or organization of such changes or
improvements.
Caution: A Yellow triangle is shown for parts of the manual which should be
read carefully and are important.
Warning: Notes with a red triangle describe procedures that are critical an
may result in reduced safety or may lead to critical situation.
Note: A bulb icon is shown when a useful hint is provided to the reader.
1.1 Limited Warranty
This product is warranted to be free from defects in materials or workmanship for
two years from the date of purchase. Within this period, LZ design will, at its sole option,
repair or replace any components that fail in normal use. Such repair or replacement will
be made at no charge to the customer for parts and labour, however the customer shall
be responsible for any transportation cost.
Usage of device is at user’s own risk. LZ design will not under any circumstances
accept any responsibility or will be liable for possible damage on people, animals or things,
which might directly or indirectly happen from using the charger.
To obtain warranty service, please contact LZ design directly.
1.2 Invalid Warranty
The warranty does not cover failures due to abuse, misuse, accident, or unauthorised
alterations or repairs.
The warranty becomes invalid in the case of connecting and charging any other
unauthorized batteries.
The device is not waterproof in anyway.
© LZ design. All rights reserved.
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2. Introduction
FES KOP2300 battery charger is modern fully automatic device 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 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.
Required input voltage is 110 V or 230 V~ 50/60 Hz, so it is suitable for EU and
also US owners of FES battery packs without usage of voltage converter.
FES KOP2300 High Power Charger is programmed with suitable settings and
equipped with suitable connectors for charging FES 14S battery packs.
3. Technical characteristics
FES KOP2300
Nominal charging voltage
48 V
Max charging current
45 A (currently reduced to 30 A for FES application)
Min. starting voltage set to
40 V
Max charging voltage set to
59,5 V
Typical efficiency at 230 V
96 %
Charger power supply voltage range
90 V - 264 V / 47 - 63 Hz
Output power
max 2300 W (currently reduced to 2000 W for FES
application)
Dimensions (L x W x H)
407 x 159 x 140 mm
Weight
5,6 kg
Environmental protection grade
IP65
Approvals
EN55022 Class B; EN 60905 Class; EN61000-3-2;
EN61000-3-3; EN61000-4-2; EN61000-4-5;
EN61000- 4-6; EN61000-4-11; EN61000-6-2;
EN61000-6-3
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3.1 Mains current limiter
The mains current is limited to max. 13 A for 230 V systems and to max. 16 A for 120 V
systems. FES KOP2300 automatically detects the mains voltage.
Comment:
For 230 V mains voltage and full output power the charger needs approx. 10.5
A from the socket. At low mains voltage, the mains current would increase at the same
power, but this would be reduced to max. 13 A. In the short term, the current can also be
somewhat higher than 13 A in the case of very fast mains voltage fluctuations.
If the mains voltage drops below approx. 90 VAC, the KOP2300 charger is switched off.
After the mains voltage rises again, the charging is restarted where it was interrupted.
Note:
Before using the charger, check that the fuse on the grid is suitable.
For 2300 W charger it should be minimum 16 A fuse (for 230 V grid) or
minimum 20 A (for 110 V grid). Always try to connect charger directly to
inlet, without extension cables and splitters.
Warning:
If you have another pair of Battery pack, make sure that you do
not mix packs between the two sets. The same two packs of one set (first
marked as A, second marked as B) must be always used in pair!
4. Mechanical installation
Before the installation, please consider the following:
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.
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.
The device can withstand higher stress
due to vibration and shock in the horizontal position.
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d) Vertical mounting
The cables and terminals must be on the
lower side as shown on the image.
Caution:
Do not make any holes on the chassis, as components can be
damaged.
5. Connections
All contact arrangements shown from the mating side.
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5. LED Functions
Power
100 %
Charging
Error
Function
Flashing
OFF
OFF
OFF
No firmware loaded or bad firmware
version (bootloader is active).
ON
OFF
OFF
OFF
No battery connected or battery
completely empty.
ON
OFF
Flashing
Flashing
Battery voltage under the minimal
parameter value. The Charging and Error
LED's are flashing intermittently.
ON
ON
OFF
OFF
Charger waits for the programmed
automatic restart or battery voltage under
the minimal parameter value.
ON
OFF
ON*
OFF
*Charging with full current.
ON
OFF
Flashing*
OFF
*Charging with reduced current –the
battery is almost completely charged.
ON
OFF
OFF
Flashing
Error –see the table in Chapter 8. Number
of consecutive LED flashes defines the
error number.
*This LED functions depend on the settings of charger parameters
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6. Charger to FES Battery pack connection and charging
Caution:
Place charger on a safe, secure position. Keep away from dust,
direct sunlight, fire, smoke, children and any unattended person!
Warning:
Before charging, physical condition inspection of the battery
packs should be done. Any sign of mechanical damage, such as a puncture,
dents, scratches, must be evaluated and reported to manufacturer before
charging.
Battery to charger connection procedure:
1. Connect RED + and BLUE - cables from charger to first battery pack.
2. Connect the charger and the battery pack with FES KOP2300 BMS-Charger-PC
cable.
FES KOP2300 BMS-Charger-PC cable
3. Plug in the charger to the outlet (220 V AC, 50-60 hz).
4. Turn on the BMS switch on top of the battery pack cover.
Immediately after BMS is switched ON, the BMS starts a test procedure - a check of
all 14 cells, one by one. Red »Error LED« turns ON during system's test procedure
and turns OFF again when the test is completed without error.
After the test procedure, several LEDs turn ON for about 1 second. The number of
the LEDs that light up, represent a state of charge (SOC) of the battery pack. Each
LED represents around 7% SOC, for example:
- 2 LEDs are lit: SOC is approximately 14 %;
- 7 LEDs are lit: SOC is approximately 50 %;
- 14 LEDs are lit: SOC is approximately 100 %.
5. When the test procedure is completed the green »Power LED« starts blinking
indicating that the BMS is working in the normal mode. At this time, BMS sends a
signal to the charger to start charging. Orange LED on front panel of the charger
lights up, which indicates charging. It is also possible to hear the contactor "click"
inside of the charger. Charging current increases slowly to the maximum value of
30 A and charger cooling fans turn on after a while.
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6. In normal mode, the green »BMS Power« LED is flashing. This means that the BMS
is turned ON, but not necessary balancing. Balancing starts when one cell reaches a
pre-set balancing voltage value, usually 4.1 (this can be changed using BMS Control
Software). If any of 14 green LED cell balancing indicators is ON, this means that
the corresponding cell has a slightly higher voltage compared to the cell with the
lowest voltage.
−If one or more cells have higher voltage than the others, they will be
discharged and the BMS temperature rise will be minimal.
−In case that one cell has lower voltage than the others, all cells with higher
voltage will need to be discharged to reach a balanced stat. This leads to
higher BMS temperature rise, even if the voltage difference is only 0.010 V
(10 mV).
The cooling fans turn on when the BMS cooling plate reaches 50°C.
Caution: Cooling fans may not be able to cool down the BMS sufficiently in
hot conditions and the temperature of the BMS cooling plate can continue
rising. In this case, charging is interrupted automatically when the BMS
cooling plate reaches 55°C, until it drops to 45°C and charging resumes.
7. The red »Error LED« is ON only during the initial test procedure. After the test is
finished it turns OFF. If a system error is detected the LED blinks a certain number
of times followed by a pause. Number of blinks identifies the error.
8. When the first cell reaches 4.160 V, charging current is reduced. If there is a big
difference between the cells (more than 50 mV), it can take long for all of them to
reach 4,16 V, as charging current is reduced to 1 A.
9. When all cells reach 4.160 V (+/- 2mV), BMS sends a signal to the charger to
stop charging.
The Green “Power LED” stops flashing and starts glowing Green.
This indicates that the charging cycle was completed properly.
10. Switch OFF BMS on top of the Battery pack. Unplug charger from the outlet. Unplug
charging cables and signal cable from the battery pack.
11. Charge second FES GEN2 battery pack!
Warning:
Both battery packs must have approximately the same cell
voltage levels (close to 4.16 V per cell), before usage. Using two packs
with too much difference in voltage is not allowed!
Maximum 1V difference between total voltages of both packs is
acceptable.
For instance, Pack 1: 58,1V (average 4.150 per cell), Pack 2: 57,1V
(4,080V per cell), this is just acceptable! Bigger voltage difference is
not acceptable!
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Caution:
If there is a risk of a lightning strike by an approaching
thunderstorm, stop charging immediately and disconnect the charger
from the outlet.
7. Error codes
List of red error codes:
Number of red blinks
Error 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 to high.
5
Battery voltage too high at the start of the charging.
6
Battery temperature too low during charging < -1°C.
7
Battery temperature too high during charging.
8
Charger disconnected from the battery during charging.
9
Incorrect parameter checksum.
10
Bad value from the power module.
11
Incorrect parameter values.
12
Internal problem with the power module.
13
The charging current measurement is outside of the tolerances.
14
Internal problem with measurement or voltage regulation.
8. Troubleshooting
Issue
Remedy
LED’s on the charger do 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 battery connection, battery voltage,
fuses and connection to the BMS.
Battery voltage is very low.
The battery voltage is lower than the minimum
set voltage level at which the charger is allowed
to start. Contact local dealer of LZ design
directly.
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9. Revision history
August 2019
Initial release, user manual v1.0
Table of contents
