Piktronik KOP3-24V User manual

KOP3 Battery Charger
24V / 125A 48V / 62.5A
User's Manual

1.Introduction
KOP3 battery chargers are modern fully automatic devices 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 may 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 factory programmed for a specific battery type. 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!
2. 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 first, before disconnecting the battery.
The charger type is shown first after the charger has been connected to the mains and
then the measured values as the battery voltage – see the following page.
The charging time depends on battery size and state of charge. If the battery was only
slightly loaded, then 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 increased accordingly.
The charger can remain connected to the battery permanently. The power consumption
is less than 0.5 mA.
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The pictures below illustrate the values shown on the charger display.
Main screen
Secondary screen
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 are at
their limits or if cooling is insufficient and the
overheating protection is active.
The abbreviation SN is for 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.
The symbol after the displayed number shows that the
corresponding value has reached the limit.
In the bottom line is the info icon [ ]. By pressing on the info it
can be switched between the three screens (see the pictures on
the left side).
The bottom row shows the current charging phase on the left
and the total charging time in hours and minutes on the right
Info screen
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Batt.
temp.
Battery temperature in ºC
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.
temp.
Charger temperature in ºC
Internal temperature of the charger power stage in ºC
Charge
The charged Ah (Ampere-hours)
After the completion of charging the value of the charged Ah is displayed
until a new battery is connected or charging is restarted for the same
battery.
BMS
BMS limit in %
If a battery management system is connected then it's request for current
reduction (percentage of nominal current) is shown (“OFF“ means
charging is blocked or no connection to the BMS).
Iac
Line current in A (current from the mains socket)
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.
Iac Max
Current value of line current limitation when the BMS input is used to
choose/select the maximum line current limit.
Power
Charging power in W = Charging current x Battery voltage
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 the 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).
Ucomp.
Compensation of the charging voltage in V
This value indicates for how much the voltage measured inside of the
charger is higher than the voltage at the battery terminals.
Phase
The current charging phase
After the charging has been completed and the charger has turned off the
text "END" text appears on the display.
If the message "Charging completed" appears, although still charging and
the charging phase is displayed, then the trickle charging phase has been
started. The trickle charging is for battery charge maintenance and for
some battery types for cell equalization.
3. Meanings of the values shown on the display
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4. Mechanical installation
The following things must be considered during the installation:
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, so that the air can
circulate well.
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 (from the top) as
shown on the image. The device can withstand higher
stress due to vibration and shock in the horizontal
position.
d. Vertical mounting
The cables and terminals must be on the lower side so
that the fan moves the hot air up - as shown on the
image.
IMPORTANT:
The charger should be mounted vertically in
applications such as electric vehicles, since high
shock and vibrations are common in such
applications and it can withstand better in such
position.
IMPORTANT: Observe the additional warnings (see the table). Do not make any holes
on the chassis, as components can be damaged.
Mount the charger on a flat surface.
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