3,. 75Þ1,. - Piktronik
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1. PIKTRONIK Programmable chargers User Manual 4 ICONS ATE THE SCREEN AND THEIR MEANING Icon Shortcut Description of the command Li lt Ctrl N gt A new parameter file NEW K61 with the default parameter values will be opened pE lt Ctrl O gt Open the parameter file m lt Ctrl S gt Save the modified parameter file or parameters loaded from the charger to disk may be used to save status Ah counters to the file also E lt Ctrl P gt Print the contents of the currently open window Parameters Ah counters or Status n lt Ctrl R gt Read the parameters from the charger This option is available only if the charger is connected to the charger Important The charger always load complete data from the charger parameters and all other information which the charger collect If the file is saved to the disk then all of this parameters are saved Thus the complete information file from the charger can be sent to the supplier for the analysis for example by e mail a lt Ctrl W gt Write parameters to the charger If many chargers have to receive the same parameter file then this can be accomplished quickly by loading the parameter file first and then just pressing the lt Ctrl W gt key combination or clicking on this button after the new charger is connected to the PC interface j fpl Selection of the font type and size This fonts are used in the text windows Ah counter Stat2. charg current This is the maximum output current that the charger can provide This value is reached only when battery voltage is lower than set with the Max charg voltage parameter Time limit h min Max duration of charging time hours minutes This parameter can be used in two different ways If this parameter is not used as time switch for the next charging phase the charger switches off and reports an error Time out If this parameter is set as time switch for the next charging phase on Switch phases at then the charger just switches the phases when this time elapses If the environment temperature is very high or the cooling fan is disabled the charger reduces the current The maximal time duration is then extended accordingly PIKTRONIK Programmable chargers User Manual 9 Switch phases at The following criteria can be selected for the termination of a charging phase The charger switches to the following charging phase or switched off after the last charging phase Ub gt Umax The battery voltage must reach the voltage set by this parameter Ib lt Imin The battery current must be reduced under the minimal min charge current determined by this parameter Time out The determined time duration must pass over by the charging phases where it is necessary No switch No switch of charging phases This parameter is used for trickle maintenance
3. charge T Ub gt Uma It is switched over after the time T or when the battery voltage x reaches the voltage determined by this parameter T Ib lt Imin It is switched over when the time T passes over or when the battery current drops under the minimal value set by this parameter By many chargers two charging phases must be set separately At the beginning the charging with constant current is executed until the certain voltage is reached then this voltage must be kept until the charging current drops to a certain value For the KOP programmable chargers this can be set with a single charging phase With the parameter Max charg current the maximal charge current is set and with the parameter Max charg voltage the charge voltage which must be reached The charging phases for constant current and constant voltages must be set separately only if battery producer defines the max charging duration for each charging phase separately Cond phase exec after In the first charging phase there are no conditional settings It means that the battery is always charged until ca 80 In the following charging phases up to 20 repetitions of the available charging phase can be selected or the next phase can be conditionally executed after a defined number of Ah put into the battery C Off C Ah aaa Ah Phasel x fe z Cancel OK PIKTRONIK Programmable chargers User Manual 10 The f
4. each charging phase Ah counting may be separately enabled for example Ah are not measured for the floating charge phase how many Ah have been put into the battery during the last 32 chargings Ah counters tell you if the battery capacity degrades or if the battery has been properly charged and also how the vehicle has been used measurement of the charging time for the last charging each charging phase separately and for all chargings together This data may be accessed trough the same PC interface as for the charger parameters e High precision Every charger is factory calibrated no additional user calibration is necessary No potentiometers or other movable parts are used therefore no vibration or corrosion problems for chargers built into the vehicles e Temperature compensation The charger adjusts the charging voltage to compensate for the battery temperature providing an accurate charge in any climate A low cost external battery temperature sensor may be used to monitor battery temperature The battery temperature monitoring and voltage compensation can be enabled for each charging phase separately and set separately two different values for the main charging process and for the trickle charge e Battery status LED indicators Three LED s Error Charging and 100 display the executed charging phase completed charging float charge Charging LED is user programmable e Compact size low weight ruggedized construction and mainten
5. feature for safe battery connection e time out programmable separately for each of the charging phases e battery temperature monitoring with optional temperature sensor for battery protection and charging voltage compensation e self check functions at start and during operation Piktronik d o o Cesta k Tamu 17 SI 2000 Maribor Slovenia Phone 386 2 4602 250 Fax 386 2 4602 255 Web Site http www pikronik com Information info piktronik com Support support piktronik com PIKTRONIK Programmable chargers User Manual 17
6. have larger values then the battery has been not treated properly by the user deeply discharged too often It is well known that the battery voltage quickly within seconds recovers to a normal value gt 12V for lead acid battery with 12V nominal voltage after the load is switched off if the battery has not been deeply discharged Deeply discharged already damaged or too old batteries may never reach normal value after the load is switched off PIKTRONIK Programmable chargers User Manual 8 The following parameters must be set for each charging phase separately Max charg voltage The maximal output voltage of the charger When the battery voltage reaches this value the charging current is reduced as far as necessary If the temperature compensation is active the charging voltage is equal to the value of this parameter only at 25 C If the battery temperature is higher than 25 C the charging voltage is consequently lower and increased if the temperature is lower Min charg current This parameter is used only if the charging phase should be terminated when Ib lt Imin see the description bellow Otherwise the parameter has no meaning In the so called trickle charging phase Switch phases at No switch this parameter represents the value of temperature compensation for this charging phase For all other charging phases the main parameter for the temperature compensation is active Max
7. the parameters from the charger or use the appropriate button or from a file File gt Open Meaning of the parameters Name Description Charging phases Number of charging phases 1 5 Aut restart charging __ days or Ub lt __ If charger is permanently connected to the battery and supplying mains this parameter defines when the charging is automatically restarted The following paramete rs are valid for all charging phases Min start volt If the voltage in the beginning of charging process is lower than this value the charger does not start This function prevents that a charger could not overcharge a battery with a lower nominal voltage for example 36V charger connected to the 24V battery Voltage drop comp With this parameter the voltage drops between the charger output and battery terminals are compensated If the parameter value is equal to zero the charger voltage is not increased to compensate the voltage drops If it has a specific value PIKTRONIK Programmable chargers User Manual 6 the charging voltage will be increased for this specific value at charger not at battery if the charge current has nominal value If the charge current is lower the charge voltage will be increased lower To set this parameter correctly the maximal possible charge current must be set and up to the battery voltage at which battery are measured to the point of end charge volta
8. PICTRAMIK Propulsion and charging devices for battery powered systems Programmable Battery Chargers USER MANUAL For chargers with firmware versions from 2 00 to 2 04 and Windows software tools Piktronik d o o Ver 10 2007 KOP302 KOP602 and KOP1001 Battery Charger Families Microprocessor controlled continuous duty fully programmable multi stage battery charger and battery monitor Batteries have to be properly charged to achieve long term reliability The KOP302 602 and 1001 charger families are fully programmable accordingly to the battery manufacturer charging specifications The parameters may be set in the factory or in the field through a unique PC interface over the charger battery output leads Through the same interface not only the charging parameters but also a lot of other information is accessible like charged amp hours for the last 32 chargings charging times error information voltages at which charging has been started etc PRODUCT FEATURES e Fully automatic operation Charger may be left permanently attached to the batteries It takes care about battery charging and also monitors the charging process e Completely programmable Nickel zinc or lead acid flooded sealed and traction batteries may be charged accordingly to battery manufacturer specifications Up to five charging phases may be enabled to charge the battery with constant current constant voltage or floating charge For each of the c
9. ance free operation PIKTRONIK Programmable chargers User Manual 2 1 PC Software Package KOPTERM 1 1 System requirements The software tool runs on the standard PC or notebook under operating systems from Windows 95 to Windows XP It allows the modification of battery charger parameters and the insight into all the information that the charger saves during operation The software is always delivered together with the PC interface module This is an adapter that is put between the battery and the charger and is connected to the PC serial port COM1 COM4 The same PC interface can be used for all versions of the programmable chargers The software is delivered on a CD or by e mail Updates are distributed by e mail The files are delivered as a self extracting ZIP file See the installation instructions below In the DATA folder are always some sample parameter files files with the extension K61 When the software is started the first time the File Open function will always start inside of this folder For many battery types Piktronik or charger distributors already have parameter files made according to the producer s references Please contact your supplier or support piktronik com 1 2 Installation instructions See the INSTALL PDF file which is distributed together with the software on the CD or inside of a ZIP file sent by e mail 1 3 First start The following screen appears after the charger is connected
10. d from battery during charging O x 9 Bad parameter checksum O x 10 Bad current measurement offset value O x 11 Bad parameter or working variable value O x 12 Current does not start to flow O x 13 Charging current too high current limiting problem O x 14 Charging current too high current control problem For each charging phase it is counted how often the phase was completed So it can be found out how the battery is charged by a customer The charger saves information about the errors which have occurred during charging Each time the error occurs the corresponding error counter is incremented by one up to max 255 The charger tries to restart charging after a while and if the same error occurs again during restart the error counter is not incremented once again PIKTRONIK Programmable chargers User Manual 15 Appendix 3 Error messages No LED lights or blinks after The following things have to be checked first connection to the battery and mains 1 Battery connections and cables Mains 230V connections and cable 2 3 Is 230V present in the socket 4 Battery voltage it s value must be higher than the value of nn parameter otherwise the charger is not allowed not start Error LED is blinking N Number of consecutive LED flashes shows the error number 2 seconds pause N x flashes See the following table for the explanation of errors ERROR MESSAGES Light signal
11. e the max duration time for the next phase is 2 hours In this way the different charging phases can be fit together or be together limited in their duration R1 the time limit is set separately for this phase F cooling fan speed control F0 cooling fan operates at full speed or it is switched off by low ambient temperatures or low charge current F1 The speed of the cooling fan is regulated regarding the charging current and ambient temperature so the noise can be reduced PIKTRONIK Programmable chargers User Manual 11 SIR O0 98 For using all of the functions a pin code is necessary Without the correct pin code some functions like changing parameters deletion of data stored by the charger are disabled A user without pin code can only inspect the parameters data but not change them About Charger Tools Version I User number Piktronik d o o Tel 386 2 460 22 50 Fax 386 2 460 22 55 www piktronik com support piktronik com Please open the Help gt About and then enter the pin code in the bottom field PIKTRONIK Programmable chargers User Manual 12 Please consider the following issues when parameters setting parameters 1 The max output power of the charger is limited The output power current x voltage can not go beyond the defined max power value of the charger The software informs via error message if the false parameter are saved o
12. ge This point is reached when charge current starts to decline For this parameter set the value of the voltage drop between the charger output and battery terminals This function is very useful when charge cable is longer When charge cable changes length or diameter or connector change properly this parameter Many customers use Piktronik intelligent chargers in similar conditions for electric vehicles for example Optimization of parameters is recommended to get the best performance This optimization procedure is to made only once and store in the parameter file This file can be loaded into other chargers working in similar conditions using PC and PC interface Warning Use only calibrated instruments especially for the battery voltage measurement Consider that most battery types are very sensitive to overcharging Battery type After the charger has been connected to the battery the red LED flashes as often as this parameter has been set Many customers use more than one battery type To make a clear distinction which charger has been set for which battery type this parameter can be set differently for different battery types Temp compensation The value of this parameter indicates how much the charging voltage will be increased or decreased if the battery temperature changes for 1 C Please consider that battery manufacturers specify the value for one cell only and that for example a 12V battery has 6 ce
13. harging phases a lot of parameters may be set as max current and voltage max charging time for that phase etc see example Each charging phase except the first one may be conditionally executed after a defined number of Ah put into the battery or after a defined number of completed 1 charging phases The fully automatic equalization charging phase is achievable with standard parameter set up and may be executed after every completed charging or after pre defined number of chargings or charged Ah s Programmable automatic top up cycle prevents self discharge during non operational periods charger starts charging after a pre defined number of days or when the battery voltage is lower than the parameter value The charger is fully re programmable without opening the box The software for the PC and a KOP IF adapter is all what you need e Battery monitor and Ah counter This charger is also a battery monitor at no additional cost It collects data about how the battery has been charged total number of charging starts and total number of connections to the battery at what battery voltage the charging has been started frequent deep discharges can be monitored 16 voltage windows between 18 and 24V 24V charger or between 36 and 48 48V charger total Ah charged has the battery pack been used a lot or not for each charging phase Ah counting may be separately enabled for example Ah are not measured for the floating charge for
14. lication Some chargers use four wires to compensate for the voltage drops on the cables We have selected the software compensation since it is simpler cheaper for the end customer less wires simpler connectors and also more reliable PIKTRONIK Programmable chargers User Manual 13 Appendix 1 Ah display The charger saves also information about the number of Ah put into the battery for the last 32 chargings separately and total counter for all chargings If the customer has problems with the battery then it is possible to find out how the battery has functioned during the last month if for example the battery has been charged once each day With additional information how the battery has been charged information if the single charging phases were completed or how the battery was discharged perhaps discharged to much The following screen will be displayed after the IQQ tntees option is selected in the menu KOP Charger data loj x File Edit Tools Options Help olela S Z 42030 Nominal battery capacity fi 0 Ah Ah Counters in the Charger Charger serial number 1486 Charger type 2 KOP601 24V 17A Total Ah 0 00 Ah counters for the last 32 chargings 0 Ah 0 0 Ah 0 Ah 0 Ah 0 Ah 0 Ah Ah Ah Ah Ah Ah Ah ooococMW oO CCC Cc fo ooo0oc0cc 97 C0 C0 00 amp qQooqooqoqoqaooqoo0oqo a eo oc ec eo eo a a ec eo COM1 Connected KOP Charger PIKTRONIK Prog
15. lls Here the total value for all cells together must be entered If this parameter is equal to zero the temperature compensation is switched off In this case the temperature sensor does not need to be connected The value for trickle maintenance charging phase is set separately and this value also has to be zero if the temp sensor will not be connected Max voltage This parameter is used only during the active temperature compensation It defines to which voltage the charger can increase the voltage due to temperature compensation Batt temperature from The battery temperature at which the charger is allowed to operate If the measured C to aC battery temperature is not within this range the charger stops charging and increases the error counter After some time elapses the charger checks if the temperature is within this range and restarts operation if temperature is within PIKTRONIK Programmable chargers User Manual 7 range Discharg table from The charger stores information about the value of battery voltage when the charging is started The chargers have 16 counters for 16 voltage windows See the Appendix 2 second example Number of charging starts accordingly to the state of battery voltage If the value of the battery voltage is within one of this windows at start of the charging then the belonging counter is incremented by one If many counters at lower voltages
16. n the hard disk or transferred into the charger 2 Please consider the battery manufacturer charging recommendations The life of batteries can be shorted if the parameters are not set correctly If batteries are used in a very wide temperature range the temperature compensation for the most batteries is recommended or even prescribed by the battery manufacturers 3 The battery temperature sensor should be preferably be mounted to one of the battery terminals Attachment to the battery housing or even just measurement of ambient temperature does not give very accurate results 4 The charging voltage is measured at the charger output Because of the voltage drops on the cables connectors and battery terminals the battery voltage is always a little bit lower than it has been set Particularly at long battery cables and large charging currents the voltage difference should not be neglected We do not recommend to increase the charging voltages accordingly to the voltage drops since the battery could be overcharged at the end of the charging phase when the charging current is smaller and the voltage drop also The better choice is the correct setting of Voltage drop parameter With this parameter the total voltage drop at maximal charger current is set for example at 17A for 24V 17A charger version For a specific application this has to be done only once and then the parameters have only to be transferred to other chargers used in the same app
17. ollowing functions can be switched on or off for every single charging phase LED Charging Measure Ah gt Temperature compensation Load time limit gt Fan control C Off C No C No C No C No C On o Blink slow Yes Yes Yes Yes Blink fast mg S Cancel OK L LED L1 LED is switched ON LO LED is switched OFF L X LED flashes slowly LX LED flashes fast this function is not available for charger software versions 2 02 or older Usually the LED is set as in the following example e it is ON in the first or first two charging phases s when the most of energy is charged into the battery e flashes slowly in the charging phase where the battery is quite full e flashes fast for the equalizing charge and e is OFF for the trickle maintenance charge A Ah measurement It can be switched on or off for every charging phase A1 Ah measurement switched on AO Ah measurement switched off T temperature Compensation of battery voltage accordingly to battery temperature can be switched on or off for every charging phase T1 temperature compensation switched on TO temperature compensation switched off R reload time limit counter RO The charging time out counter is not reloaded with the new value the remaining time from the previous phase is used For example in the second phase a duration period of 5 hours was programmed and only 3 hours charged In that cas
18. rammable chargers User Manual 14 Appendix 2 Error and time display The following data will be displayed in the Seis window after this option will be selected in the menu CHARGER TIME AND ERROR COUNTERS Charger serial number 1486 Charger type 2 KOP601 2 24V 17A Software version 2 03 Parameters modified by 255 Total number of charging starts 0 Phase Completed chargings Total time hours Last charging hours 1 0 0 00 0 00 2 0 0 00 0 00 3 0 0 00 0 00 4 0 0 00 0 00 5 0 0 00 0 00 Number of charging starts accordingly to the state of battery voltage Ub lt 17 50 0 17 50 lt Ub lt 18 05 0 18 05 lt Ub lt 18 60 0 18 60 lt Ub lt 19 15 0 19 15 lt Ub lt 19 70 0 19 70 lt Ub lt 20 25 0 20 25 lt Ub lt 20 80 0 20 80 lt Ub lt 21 34 0 21 34 lt Ub lt 21 89 0 21 89 lt Ub lt 22 44 0 22 44 lt Ub lt 22 99 0 22 99 lt Ub lt 23 54 0 23 54 lt Ub lt 24 09 0 24 09 lt Ub lt 24 64 0 24 64 lt Ub lt 25 19 0 Ub gt 25 19 0 CHARGER ERROR COUNTERS O x 1 Charger temperature sensor failure O x 2 Charging time out O x 3 Battery temperature sensor failure O x 4 Charger heat sink temperature too high O x 5 Battery voltage too high at start O x 6 Battery temperature too low during charging O x 7 Battery temperature too high during charging O x 8 Charger disconnecte
19. rger the charger manufacturer has to be contacted send the parameter file downloaded from the charger 12 Current does not start to flow Internal error 13 Charging current too high current limiting problem Internal error 14 Charging current too high current control problem Internal error PIKTRONIK Programmable chargers User Manual 16 TECHNICAL SPECIFICATIONS Charger type KOP602 KOP1001 Nominal battery voltage 24V 36V 48V 24V 36V 48V Programmable output voltage 20 33V 30 49 5V 40 66V 20 33V 30 49 5V 40 66V Programmable output current 0 3 17A 0 2 12A 0 15 9A 0 60 34A 0 40 24A 0 30 18A Input voltage 230V 10 50 60Hz 230V 10 50 60Hz Input power 600W 1200W Ambient temperature range 25 to 35 C gradual power reduction at higher ambient temperatures Operating humidity 15 to 95 RH non condensing Weight including 2 m cable 2 0 kg 3 6 kg Dimensions 1 x w x h in mm 240 x 108 x 82 240 x 215 x 82 Env protection and approvals IP21 EN60 335 1 EN60 335 2 29 Options e drive controller disable during charging relay with 10A contact rating for application in electrical vehicles and e serial link to electrical vehicle display Protection features e overload and short circuit protection e reverse polarity protection e gradual power reduction at elevated ambient temperatures e non sparking
20. s Description 1 Charger temperature sensor failure Internal error 2 Charging time out Battery charging has not been completed in the with the parameter defined time This happens for example in case of shorted cell or due to battery aging 3 Battery temperature sensor failure Battery temp sensor not connected broken wire to the sensor problem with the connector 4 Charger heat sink temperature too high Fan openings covered ambient temperature very high charger exposed to direct sunlight 5 Battery voltage too high at start Charger has been connected to wrong battery For example 24V charger to 36V or 48V battery Please consider that connection of a charger to a battery with over 50 higher voltage may damage the charger 6 Battery temperature too low during charging See below 7 Battery temperature too high during charging The battery temperature was not inside the with parameters defined window After the battery cools down or heats up to normal temperature charging continues 8 Charger disconnected from battery during charging Always the mains 230V plug should be pulled out before the charger output plug 9 Bad parameter checksum The parameters should be transferred once again to the charger 10 Current measurement offset too high low Internal error 11 Bad parameter or working variable value If this error does not disappear after the parameters are transferred to the cha
21. to the PC interface and the PC interface is connected either to the battery or power supply The energy for the PC interface and for the charger comes 2 KOP Untitled loj x File Edit Tools Options Help elslm S Z Fel 43558 COM1 Connected KOP Charger 7 PIKTRONIK Programmable chargers User Manual 3 from the battery or power supply The charger should not be connected to the 230V voltage while it is connected to the PC interface If the communication with the charger has failed the following things must be verified 1 Is the PC interface properly connected to the battery is the polarity OK 2 Is the charger properly connected to the PC interface look at the label on the box 3 For chargers with software versions lower than 2 02 the PC software has to been started first and then the PC interface connected to the charger For chargers with software versions 2 02 and newer there are no restrictions to the sequence of software start and connections of the PC interface to the charger and battery The software can also be used without being connected to the PC interface and the charger to modify or edit the parameter file for example The software should not be started from a write protected medium like CD ROM or write protected Flash disk If this will be done then the charger parameters may be transferred and inspected However other data read from the charger Ah Status are not displayed correctly
22. us At the moment the proportional fonts are not fully supported We recommend the use of non proportional fonts like Courier New PIKTRONIK Programmable chargers User Manual Description of parameters Piktronik chargers are fully programmable All the parameters can be set either by the producer or by authorized personal An example of a charger parameters is shown bellow i KOP C Demo K61 lo x File Edit Tools Options Help Battery Charger Parameters Charging Phases f Aut restart charging 30 days or Ub lt 24 30 V Min start volt V 17 00 Voltage drop comp V 0 00 Battery type 1 Temp compensation 58 5 mV C 0 OFF Max voltage 31 00 Vv Batt temperature from 10 C to 50 C Discharg table from 16 90 V Charger type J2 KOP601 24V 17A Parameter Phase Phase _ Max charg voltage V 28 00 Min charg current A d Max charg current A Switch phases at 28 40 0 30 0 80 1 00 30 00 2 00 16 00 27 00 42 0 mv C 10 50 0 01 Ub gt Umax 6x Phase Lx A1 T1 R1F1 time out Time or Ub gt Umaxno switch 300 Ah LO AO TO R1 FO Cond phase exec after L LED A Ah meass L1 A1 T1 RO FO Lx AO TO R1 FO F Z This example was chosen to show the most important parameter options These are not actual parameters for a specific type of battery The parameters may be loaded from the charger start this command with Tools gt Read
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