KCG-2 SWITCH MODE BATTERY CHARGER USER MANUAL
Contents
1. Over load LILI LIL LILI LILI 4 QOQON COCOON Sis Floating _ Equalizer Diagram 3 Front panel outline Bench mounted The ON OFF switch is on the right hand in the wall mounted charger 4 General Information Naming KCG2 AN V xx Nominal battery voltage Exx Max output voltage INPUT T 440VAC Blank 1 phase G2 110VAC 3 3 phase G3 480VAC G4 600VAC Diagram 4 Naming regulation PE Dimensions L x W x H Weight Kg KCG2 100A 80V 3G Bench mounted 550 x 430 x 160 mm 25 28 KCG2 50A 192V 3G KCG2 100A 60V 3G Bench mounted 520 x 380 x 150 mm 20 22 KCG2 100A 48V 3G KCG2 120A 24V 3G KCG2 100A 24V 3G Bench mounted 460 x 350 x 128 mm 11 14 KCG2 80A 24V 3G Bench mounted 370 x 310 x 113 mm og KCG2 60A 24V 3G Wall mounted 350 x 140 x 500 mm KCG2 40A 24V Bench mounted 350 x 243 x 113 mm 6 KCG2 40A 12V Wall mounted 300x140x400 8 fe iTA J dl B a a 96 i I s ays Diagram 6 Installation Figure Diagram 7 Installation Figure Bench mounted Top view Wall mounted TYPE Bench mounted A mm B mm C mm D mm E mm F mm KCG2 100A 80V 3G 550 438 100 230 108 8 KCG2 100A 48V 3G 520 388 80 220 88 8 KCG2 120A 24V 3G 460 358 70 210 78 7 5 KCG2 60A 24V 370 318 50 210 58 7 5 KCG2 40A 24V 350 243 50 135 58 7 5 TYPE Wall mounted A mm B mm C mm D mm KCG2 60A 24V W 350 500 152. Switch index gt 5 4 6 3 7 2 8 1 ON Floating 7 days OFF OFF pada OFF Floating 10 days OFF ON Floating 15 days ON OFF Floating 25 days ON ON Eun Ah Are OEE Default setup ualizing 4 hours f A 3 8 hour equalize charge and Equalizing 6 hours OFF ON ia gt ON OEF 10 day floating charge Eau 8 hours 5 4 OFF 6 3 ON Equalizing 10 hourd ON ON 7 2 ON 8 1 OFF Then the battery will work as follows See diagram 3 Constant current stage the charge current will be kept at the limitation of the maximum charge current While charging the voltage will go up step by step Constant voltage stage as soon as it reaches the equalizing voltage the current will go down step by step with the constant of the voltage 8 hours later including the constant current stage the constant voltage changes to floating voltage Floating charge stage this stage lasts 10 days Note Change charging mode manually will clear the charge stage timer 6 Other setup switches 1 8 2 7 3 6 4 5 ON Reserved Temperature Timer Test Enable disable the auto OFF protection Work charge mode control Turn switch 2 7 to OFF position the 2 level temperature protection function see technique specification 9 will be OPEN Turn it to ON position the function will be closed Turn switch 3
3. 6 to ON position the charge mode time will decrease to 1 60 For example if set 8 hours and 10 days timer and set switch 3 to ON the timer will be 8 minutes and 4 hours This will test the timer in a short time Turn switch 4 5 to ON position the auto charge mode control is enabled when connect AC power the charge mode will be at Equalizing Turn it to OFF the charge mode can only be changed by turning the charge mode switch manually when connect AC power the charge mode will be same as the position of the charge mode switch 7 When protect over voltage over temperature or over load the alarm lamp lights on the charger stops and the relay picks up Normally open red and green Normally close red and black Relay capacity 0 3A Press the reset button to acknowledge the over volt and over load protection and restart the charger The charger will auto restart when it is cool if it over temperature protects 8 Adjust the constant charge voltage by the voltage adjuster on the front panel Turn it clockwise to increase the voltage counter clockwise to decrease it Warning the adjustment must be adjusted accurately Incorrect charge voltage makes the battery uncompleted charge and short life 9 When connect battery to charger make sure that turn off the charge switch to stop charge 10 When connect battery to the output cable spark will happen Before connect the battery turn
4. on the charger without load and then turn it off This will eliminate the spark 11 Please see your battery document to get more information about how to charge it properly Optional functions Note Specifications is subject to change without notice Appendix 1 Choose charge voltage and current Voltage charging voltage per cell X number of cells For example 9 pcs of 12V LA battery in series Equalize constant voltage 14 1V Xx 9 119 7V Floating constant voltage 13 4V X 9 126 9V Current Battery capacity X 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 X 630 63A So choose 60A or larger charger 0 2 X 630 126A Choose 120A or larger charger 7
5. 00A Depends on battery capacity Maximum output power 10KW See Appendix 1 on how to choose voltage and current Charge control 3 stage charge automatic charge mode control A Constant current B Constant Voltage C floating V A 30 100 28 90 26 80 24 70 22 60 20 50 40 30 20 10 0 A B C charge voltage V lt 100 100 vol charge current A 0 5 10 15 20 25 charging period Diagram 2 Recharge voltage current regulation Manual Automatic Charge mode control Automatic charge mode control function is optional 5 3 level temperature protection 1 Temperature control fan cooling about 45 C 2 Reduce charge voltage about 75 C 78 C resume about 65 C optional 3 Over temperature protection about 80 C 85 C 6 Protection over load manually reset over voltage manually reset over temperature auto reset and output short circuit 7 Accuracy voltage 0 5 current 1 8 Low ripple 0 5 of the charge voltage 9 LED digital display voltage meter display precision 0 1V amps meter display precision 0 1A 0 Efficiency higher than 80 1 Operating temperature range 0 50 C 32 122 F 2 High quality and design for marine 3 Safety class IP20 or 1P44 PPP PH 3 Operating panel KcG2 vOv O Over volt Voltage Battery Charger Voltage Current Over temp
6. 15 KCG2 40A 24V W 300 400 15 15 KCG2 20A 24V W 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 batteries should be connected correctly Be careful and DON T CONNECT REVERSLY 3 The input wires and the GND should be connected correctly Then input the AC power The LED digital indicators will light on and show the battery voltage 4 Turn on the charge switch The charger is going to work a LED shows charge voltage and current You can manually choose floating charge or equalizing charge by setting the charge mode switch on the front panel Two lights indicate the active charge mode Note If the switch position is different from the light user should turn the switch to the other side wait 2 3 seconds and then turn it back to change the charge mode Set the charge stage timer The charger auto changes the charge mode from floating to equalize and then to floating periodically Please open the setup window on the back for bench mounted and turn the jumper switches on or off to set the stage time For wall mounted charger open the door the switches are on a little PCB Note The switch index is bench mounted The index in parenthesis is wall mounted
7. Ver 1 50 0003 KCG 2 SWITCH MODE BATTERY CHARGER USER MANUAL BEI YANG ELECTRIC APPARATUS FACTORY TEL 86 532 85849015 FAX 86 532 85814619 ADDR 66 JIANGXI ROAD QINGDAO 266071 P R CHINA WEB www byauto com cn Email info byauto com cn 1 Introduction IGBT Power CMOSFET and PWM IC controller have been contained in the KCG2 battery chargers They are automatic high frequency switch mode 4 LZ baz oo gt e battery chargers Please see Diagram 1 block diagram of KCG2 Switch mode technology makes oe them light compacted quiet and have an accurate charge characteristic 3 stage charging system constant current constant voltage and floating see diagram 2 makes a complete charge and long battery life Isolated Inverter Amp Volt LED HEHE Battery Limited Current Protection Over Voltage Over Heating Temperature Switch Charge parameters Diagram 1 Block diagram of KCG2 2 Technique Specifications 1 Power supply 110VAC 220VAC 3 380VAC 3 440VAC etc 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 Charge voltage e g for 24V battery 3 4 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 CC 20A 2
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