LEAB 0101043890 Champ Pro Charger User Manual

CHARGER
CHAMP PRO 24 V
User Manual

LEAB Automotive GmbH

 About this Manual

Read this manual carefully and keep it in a safe place. This manual is aimed at Skilled workers in the field of automotive electrics.
Any modifications to the product or its components are prohibited and do not conform to its intended use. Only use original LEAB or LEAB-approved accessories.
Throughout the manual, you will be alerted to warnings and safety notices about potential hazards associated with handling the device. The colors and signal words indicate the severity of the hazard:

Notice
Possibility of material damage
The signal word Attention indicates that there is a possibility of material damage. To avoid material damage, follow the instruction.

CAUTION
The danger that can lead to minor injuries
Safety instructions with the signal word CAUTION indicate a hazard that, if not avoided, can result in minor or moderate injury. Read the safety instructions carefully and follow them to avoid the hazard.

WARNING
Hazards that can lead to severe injuries or death
Safety instructions with the signal word WARNING indicate a hazard that, if not avoided, can result in death or severe injury. Read the safety instructions carefully and follow them to avoid the hazard.

DANGER
The danger that will lead to severe injury or death
Safety instructions with the signal word Danger indicate a hazard that, if not avoided, will result in death or severe injury. Read the safety instructions carefully and follow them to avoid the hazard.
You will find useful tips and tricks in certain parts of the manual. These appear as follows:

TIP
Tips provide additional, useful information.
Read the tip carefully and follow the instructions where applicable.

Safety

This manual will help you to handle the device safely. Use the device solely in accordance with its intended use. Observe the safety instructions.
The charger is a trickle and battery charger for permanent installation in vehicles. This charger can be used to charge all types of lead-acid batteries (wet, gel, AGM).
Any modifications to the device or its components are prohibited and do not conform to its intended use. Keep this manual in a place where it can be accessed quickly.

2.1 Intended Use
The charger is designed for permanent installation in vehicles with 12 or 24 V on-board power systems for charging Lead-acid batteries (wet, gel, AGM). It is suitable for charging and trickle charging auxiliary batteries. The device is designed for a temperature range of -30 °C … 60 °C. Do not charge batteries with this charger outside the specified temperature range. At higher temperatures, the output power of the charger automatically decreases.

WARNING
Risk of fire from an overheated battery
Flammable gases can escape if the battery overheats.

1. Always charge batteries in well-ventilated rooms and away from ignition sources.

WARNING
Risk of injury from damaged, frozen or deformed batteries
Damaged, frozen or deformed batteries can cause injuries.

1. Before using the battery, make sure that the battery is undamaged and the electrolyte is not frozen.

WARNING
Burns from escaping acid
Acid can leak out when handling batteries.

1. Wear acid-proof clothing when handling batteries.

Notice
Device defects from incorrect installation
Incorrect installation can result in device defects.

1. Install the device in a dry and cool location.

2.2 Foreseeable Misuse
The charger is designed for permanent installation in vehicles. Do not mount the device outside the vehicle. Only charge lead-acid batteries (wet, gel/AGM) and traction batteries with this charger.
The negative lead of the charger may contain a temperature sensor, do not shorten or lengthen the lead under any circumstances.
Never pinch the leads of the charger to avoid damage. In the event of damage, unplug the charger immediately and contact your dealer or LEAB.

About this Product

The Champ charger is a trickle and battery charger for permanent installation in vehicles. This charger can be used to charge all types of Lead-acid batteries (wet, gel, AGM). With the Champ charger, the charging characteristic can be adjusted to ensure optimum charging of the battery. Fig. 1: Champ Pro charger

1. Display
2. AC cable
3. DC cable

Fig. 2: Champ Pro charger display

4 Charging characteristic indicator
5 Mode button| 6 Charge status indicator
7 Error indicator
---|---

Technical specifications

| Part no. 0101043982| Part no. 0101043881
---|---|---
Modell| Champ Pro 2412| Champ Pro 2412
Battery type| Lead-acid (wet, gel/ AGM)/traction| Lead-acid (wet, gel/AGM)
Charging characteristics| Choice of 4 charging characteristics| Choice of 4 charging characteristics
Battery capacity| 40 Ah … 120 Ah| 65 Ah … 200 Ah
Temperature sensor| No| Yes
AC cable| 2.0 m, two-pin earthed plug| 2.0 m, two-pin earthed plug
DC cable| 1,5 m, ring terminal, M8| 1,5 m, ring terminal, M8
Charging current| 12 A| 12 A
Ripple| < 3 %| < 3 %
Main charging| 28.4 V/28.8 V| 28.4 V/28.8 V
Equalization charging| 32.0 V| 32.0 V
Trickle charging| 27.0 V/27.6 V| 27.0 V/27.6 V
Mains part function| 27.4 V| 27.4 V
Input voltage| 230 V| 230 V
Input values| 195 V … 250 V| 195 V … 250 V
Input frequency| 40 Hz … 60 Hz| 40 Hz … 60 Hz
Quiescent current (from the battery)| < 1 mA| < 1 mA
Mains fuse| B16 A or C16 A| B16 A or C16 A
Degree of efficiency, max.| > 88 %| > 88 %
International Protection (IP class)| IP67| IP67
Protection class| I| I
Operating temperature| -30 °C … +60 °C| -30 °C … +60 °C
Dimensions (L x W x H)| 195 mm x 98 mm x 47 mm| 195 mm x 98 mm x 47 mm
Weight| 1.5 kg| 1.5 kg
| Part no. 0101043891| Part no. 0101043999
---|---|---
Modell| Champ Pro 2420| Champ Pro 2420
Battery type| Lead-acid (wet, gel/ AGM)/traction| Lead-acid (wet, gel/ AGM)/traction
Charging characteristics| Choice of 4 charging characteristics| Choice of 4 charging characteristics
Battery capacity| 65 Ah … 200 Ah| 65 Ah … 200 Ah
Temperature sensor| Yes| Yes
AC cable| 2.0 m, two-pin earthed plug| 1.5 m, two-pin earthed plug
DC cable| 1.5 m ring terminal, M8| 3 m, ring terminal, M8
Charging current| 20 A| 20 A
Ripple| < 3 %| < 3 %
Main charging| 28.4 V/28.8 V| 28.4 V/28.8 V
Equalization charging| 32.0 V| 32.0 V
Trickle charging| 27.0 V/27.6 V| 27.0 V/27.6 V
Mains part function| 27.4 V| 27.4 V
Input voltage| 230 V| 230 V
Input values| 195 V … 250 V| 195 V … 250 V
Input frequency| 40 Hz … 60 Hz| 40 Hz … 60 Hz
Quiescent current (from the battery)| < 1 mA| < 1 mA
Mains fuse| B16 A or C16 A| B16 A or C16 A
Degree of efficiency, max.| > 88 %| > 88 %
International Protection (IP class)| IP67| IP67
Protection class| I| I
Operating temperature| -30 °C … +60 °C| -30 °C … +60 °C
Dimensions (L x W x H)| 195 mm x 98 mm x 47 mm| 195 mm x 98 mm x 47 mm
Weight| 1.5 kg| 1.5 kg
| Part no. 0101056901| Part no. 0101056005
---|---|---
Modell| Champ Pro 2420| Champ Pro 2420
Battery type| Lead-acid (wet, gel/ AGM)/traction| Lead-acid (wet, gel/AGM)
Charging characteristics| Choice of 4 charging characteristics| Choice of 4 charging characteristics
Battery capacity| 65 Ah … 200 Ah| 65 Ah … 200 Ah
Temperature sensor| Yes| No
AC cable| 1.5 m, two-pin earthed plug| 1.5 m, Neutrik
DC cable| 0.5 m, MTA connector, 3 pin| 5.0 m, without plug
Charging current| 20 A| 20 A
Ripple| < 3 %| < 3 %
Main charging| 28.4 V/28.8 V| 28.4 V/28.8 V
Equalization charging| 32.0 V| 32.0 V
Trickle charging| 27.0 V/27.6 V| 27.0 V/27.6 V
Mains part function| 27.4 V| 27.4 V
Input voltage| 230 V| 230 V
Input values| 195 V … 250 V| 195 V … 250 V
Input frequency| 40 Hz … 60 Hz| 40 Hz … 60 Hz
Quiescent current (from the battery)| < 1 mA| < 1 mA
Mains fuse| B16 A or C16 A| B16 A or C16 A
Degree of efficiency, max.| > 88 %| > 88 %
International Protection (IP class)| IP67| IP67
Protection class| I| I
Operating temperature| -30 °C … +60 °C| -30 °C … +60 °C
Dimensions (L x W x H)| 195 mm x 98 mm x 47 mm| 195 mm x 98 mm x 47 mm
Weight| 1.5 kg| 1.5 kg
| Part no. 0101043981
---|---
Modell| Champ Pro 2420
Battery type| Lead-acid (wet, gel/AGM)
Charging characteristics| Choice of 4 charging characteristics
Battery capacity| 65 Ah … 200 Ah
Temperature sensor| No
AC cable| 2.0 m, two-pin earthed plug
DC cable| 3,0 m, ring terminal, M8
Charging current| 20 A
Ripple| < 3 %
Main charging| 28.4 V/28.8 V
Equalization charging| 32.0 V
Trickle charging| 27.0 V/27.6 V
Mains part function| 27.4 V
Input voltage| 230 V
Input values| 195 V … 250 V
Input frequency| 40 Hz … 60 Hz
Quiescent current (from the battery)| < 1 mA
Mains fuse| B16 A or C16 A
Degree of efficiency, max.| > 88 %
International Protection (IP class)| IP67
Protection class| I
Operating temperature| -30 °C … +60 °C
Dimensions (L x W x H)| 195 mm x 98 mm x 47 mm
Weight| 1.5 kg

Package Contents

Charging Characteristics

Battery charging is fully automatic and microprocessor controlled with a 3stage IU1U2 characteristic curve for gentle and optimum charging of the batteries. The charging phase of the charger is indicated by the LEDs on the display of the unit (About this Product [ 7], Fig. 2, no.7). Fig. 3: Charging characteristic of lead-acid battery (wet, gel/AGM) Fig. 4: Charging characteristic of the traction battery

I phase: Charging with constant current
Depending on the battery charge state, the battery is charged with the maximum charging current to store as much energy as possible in the battery. After reaching the set main charging voltage, the charger switches to the next charging phase (U1). If the set main voltage is not reached within max. 10 h, the device enters the U2 phase and reports an
error.
NOTE! Deep discharged batteries with a voltage below 6 V are not charged for safety reasons.
U1 phase: Main charging with constant voltage
In the main charging phase, the voltage is kept at a constant value. As the battery increasingly charges, the current decreases continuously and approaches a lower limit.

U2 phase: Trickle charge with reduced voltage
In this phase, the charging voltage is reduced in order to maintain the battery charge for an unlimited period and counteract self-discharge. Additionally, connected consumers are supplied via the charger in this phase without loading the battery.

Charging characteristic: POWER SUPPLY
Champ Pro chargers In the “Power Supply” setting can also be used without the battery connected to supply DC consumers. This setting can be used, for example, when replacing the battery in the vehicle to avoid onboard computer and radio data loss due to the loss of power and having to be reprogrammed.
Note that the power required must be no higher than the output power of the charger. In the “Power Supply” setting, the charger gives off a constant voltage of 13.7 V or 27.4 V. The green LED of the charge status indicator is continuously lit. The “Power Supply” setting also allows deeply discharged batteries to be reactivated so that they be identified and recharged by one of the automatic loaders. After reaching the minimum voltage, switch to the appropriate charging characteristic.

Assembly

To assemble the device, perform the following steps:
√ Choose a cool, dry, and well-ventilated assembly site.
√ Do not mount the device directly next to or above batteries.
√ Optimum cooling is achieved by mounting the unit vertically on a flat surface.

1. Fasten the device to the 4 holes on the side (Ø 5 mm)
   ⇒ The device is assembled.

Setting the charging characteristic for the first time
To select a charging characteristic, perform the following steps:

1. Connect the mains plug to a 230 V mains supply.
2. Within 3 to 6 seconds, press the Mode button repeatedly until the LED next to the desired charging characteristic is lit on the display (4).
3. Disconnect the charger from the 230 V mains.
   ⇒ The charging characteristic is set.

Installation

The charger is designed for permanent installation in vehicles. When installing the charger, note the following:

Notice
Incorrect installation can damage the device
The negative lead of the unit may contain a temperature sensor.

1. Never shorten or extend the negative cable with a temperature sensor.

To install the charger in the vehicle, proceed as follows:

1. Disconnect the battery from the vehicle power circuit.
   WARNING! Disconnect the negative cable first.

2. Connect the plug of the DC cable to the connection cable that is connected to the battery. NOTE!  Use the appropriate connection cable for the connection.
   ⇒ The device is installed.

Connection to 230 V mains
To install the device to the 230 V mains, proceed as follows:
NOTE! The charger is only suitable for connection to fused, earthed 230 V mains supplies.

1. Connect the mains plug to a 230 V mains supply.
   ⇒One of the 4 charging LED flashes orange while the device is connecting to the battery. There is no voltage output at this stage.
   ⇒After 2 seconds, the LEDs of the charge status indicator flash, and the charging process starts.
   ⇒The charging progress is indicated in the charge status indicator via the illuminated LEDs.
   ⇒ If the green LED on the charge status indicator is lit, the charge is complete and the battery can be disconnected from the charger.
   ⇒The charger is connected to the 230-V mains supply.

Operation

9.1 Charging the battery
To start the charging operation, proceed as follows:

√ The device is installed.
√ The battery is connected.

1.  Connect the mains plug to a 230 V mains supply.
   ⇒Charging starts automatically, and the yellow LED of the charge status indicator lights up.
   ⇒If the charging current is 15% below the maximum value, the yellow and green LEDs of the charging status indicator light up.
   ⇒When the battery is fully charged, the green LED on the charging status indicator lights up and indicates the trickle charge
   ⇒The battery is charged.

9.2 Charging the battery
To start the charging operation, proceed as follows:

√ The device is installed.
√ The battery is connected.

1. Connect the mains plug to a 115 V mains supply.
   ⇒Charging starts automatically, and the yellow LED of the charge status indicator lights up.
   ⇒If the charging current is 15% below the maximum value, the yellow and green LEDs of the charging status indicator light up.
   ⇒When the battery is fully charged, the green LED on the charging status indicator lights up and indicates the trickle charge.
   ⇒The battery is charged.

9.3 Change charging characteristic
To change the charging characteristic, proceed as follows:

√ The device is installed.
√ The battery is connected.

1. Connect the mains plug to a 230 V/115 V mains supply.
   ⇒One of the 4 charging characteristic LEDs lights up orange while the unit is establishing a connection to the battery. There is no voltage output yet.

2. Press the Mode button repeatedly until the LED next to the desired charging characteristic lights up.
   ⇒After 2 seconds, the LEDs of the charging status display flash, and the charging process starts.
   ⇒The charging progress is indicated in the charging status display by illuminated LEDs.
   ⇒ If the green LED of the charging status indicator lights up, charging is complete and the battery can be disconnected from the charger.
   ⇒The charging characteristic has been changed and the battery is being charged.

9.4 Temperature Sensor
Depending on the model, the Champ charger has a temperature sensor located in the negative lead. The temperature sensor corrects the charging voltage as a function of the temperature in order to provide an optimal, effective and gentle battery charge.

Maintenance

Check the device as follows before using it each time:

• Check the mains cable and mains plug for damage.
• Check to charge cables and connections for damage.
• Check the charger for external damage.
• Ensure that the wiring between the charging cable and the charger is secure.

TIP
Battery maintenance
For battery maintenance, refer to the battery manufacturer’s instructions.

Disposal

Dispose of the device in accordance with the Waste Electrical and Electronic Equipment Regulations (WEEE).
The system must not be disposed of with household waste. Take it to a recycling point or return it to your point of sale.

EU Declaration of Conformity

The Champ Pro charger complies with the requirements of the following directives:

• 2014/30/EU: EMV
• 2014/35/EU: NRL
• 2011/65/EU: RoHS

Appendix

13.1 Information on outdoor use of the power system 12/24 V
MagCode PowerSystems were originally developed for vehicle interiors. However, in Germany, the BGS, DRK, fire brigade, police, and THW now use these systems in addition to the DIN plug as an outdoor socket for charge maintenance on their emergency vehicles.
With regard to outdoor use, please note:

Port (socket)
When installed with a sealing ring on the front (contacting side to the clip), the port is tight in accordance with IP5K9K. If the rear of the port comes into contact with water, it must be sealed.
Clip (pick-up/connector)
The clip (IP40) is not waterproof. Keep the clip protected from water.
Clip to port connection
This connection is also not waterproof. At best, it is protected against dripping water (IP42).
To prolong the life of the product, the following measures should also be taken:

• After outdoor use, clean the port briefly with a cloth.
• Remove possible deposits of metal chips on the contact side of the port and clip with an adhesive strip from time to time.
• Spray contact spray on port and clip contacts every 1 to 2 months.

TIP
Device defect due to faulty release under load
The MagCode PowerSystemPro 12/24 V has a mechanical bayonet lock. It can be disconnected under load without unlocking, which can damage the system or cause the system to fail completely.

1. Always unlock the system manually.

13.2 MagCodePowerPort installation instruction

Fig. 5: MagCode PowerSystems clip and port

NOTE! An existing car socket can easily be replaced by a MagCode PowerPort, as both have the same diameter. If installing elsewhere, we recommend visiting a specialist workshop.
To install the MagCodePowerPort in place of an existing car socket, proceed as follows:
DANGER! Short circuit hazard – Remove the fuse before starting work.

1. Pull out the existing car socket.
   NOTE!  Note the polarity of the wires.

2. Cut the cable.
   OR…

3. Drill a new installation opening (Ø 28 mm).
   ⇒The installation opening is prepared.

4. Slide the MagCodePowerPort, with or without a spacer ring, into the installation opening.

5. Screw the MagCodePowerPort on the back with a nut (M28).

6. Connect the cables with each other by soldering, crimping, or connecting terminals.

7. Put the fuse back in place.
   ⇒The MagCodePowerPort is installed.

13.3 MagCodePowerClip assembly instructions
To install the device, proceed as follows:

1. Cut off the old connector.
   NOTE!  Note the polarity of the wires.

2. Screw on the MagCodePowerClip.

3. Select the appropriate strain relief for the cable thickness.

4. If necessary, shorten the cable grommet by passing the cables through the grommet and the strain relief and attaching the wire end ferrules.

5. Screw the cables into the terminals.
   NOTE!  Note the polarity of the wires.

6. Screw the housing together.
   ⇒The device is assembled.

We make energy mobile.

LEAB Automotive GmbH
Thorshammer 6
DE-24866 Busdorf
Tel: +49 (0) 4621 9 78 60-0
Fax: +49 (0) 4621 9 78 60-260
info@leab.eu
It is prohibited to copy, duplicate, translate or otherwise pass on the content of this guide to third parties without the express written permission of LEAB.

References

• Spezialist für mobile Stromversorgung // LEAB // mobile energy

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