MICROPOWER GROUP 2A1A3 Battery Charger 12V 8-30A Li-ion User Manual

: September 19, 2024
: MICROPOWER GROUP

MICROPOWER GROUP 2A1A3 Battery Charger 12V 8-30A Li-ion

Product Information

Specifications

Product Name: CHAMP Battery Charger
Input: 12V
Output: 8-30A
Battery Type: Lithium-ion (Li-ion)
Model Compatibility: 2A1A3, 2A1A5, 2A1A8** Exide 12V/20A LFP and 12/30A LFP

Product Usage Instructions

Safety Precautions
Read and understand the safety precautions outlined in the manual. Always keep the manual nearby for reference. Only qualified personnel should install, use, or service the product. Follow all safety instructions provided.

Intended Use
The battery charger is designed for charging lithium-ion (Li-ion) batteries.

Battery Charger and BMS Adjustment
The charging process should be controlled by an external Battery Management System (BMS) tailored to the battery being charged. The charger does not have an internal integrated BMS system, so an external BMS system must be used. The BMS can communicate with the charger via serial data communication (CAN bus) or analog I/O functions. Ensure the BMS can disconnect the charger and load from the battery in case of emergency. Monitor the charging process and battery status closely.

FAQ

Q: Can children use the battery charger?

A: The appliance can be used by children aged 8 years and above in the European market if supervised. In markets outside Europe, it is not intended for use by persons with reduced capabilities unless supervised.

Q: What should I do before connecting/disconnecting the charger?
A: Always connect the battery cables before connecting the main power. Disconnect mains power before disconnecting battery cables to ensure safety.

Safety

Safety precautions
Read the instructions. The manual contains important safety and operating instructions. Always keep this manual near the product.

Read and understand this instruction, the battery instruction provided by your battery manufacturer, and your employer’s safety practice, before using, installing, or servicing the product.
Only qualified personnel should install, use, or service this product.
Applies to the European market, EN standard: This appliance can be used by children aged 8 years and above and persons with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge if they have been given supervision or instruction concerning the use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be done by children without supervision.
Applies to markets outside Europe, IEC standard: This appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge unless they have been given supervision or instruction concerning the use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance.

****CAUTION

Always connect the battery cables before connecting the mains. Disconnect mains before disconnecting battery cables.
Intended use
The battery charger is intended for charging lithium-ion (Li-ion) batteries.
Battery charger and BMS adjustment
The charging process must be controlled by an external Battery Management System (BMS), connected and adjusted to the battery. The chargers covered in this manual do not have any internal integrated BMS system, which means that an external BMS system must be used. The BMS can communicate with the charger via serial data communication (CAN bus), by analog I/O functions, or both in combination. When the CAN bus is used, the charger and the charging process may be controlled by the BMS system, and the battery charger uses given values from the BMS system to charge the battery. While controlling the charger and charging process via CAN bus, the BMS system must be able to disconnect the charger and load from the battery by external switches in case of emergency. The charger can alternatively charge the battery through a pre-set charging algorithm adjusted to the actual battery. Also in this charging mode, the charging process must be monitored and controlled by an external BMS system. The BMS system must monitor the charging process and the battery status and must stop the charging algorithm generated from the charger if needed. The BMS unit can communicate with the charger via analog I/O functions but must then also be able to disconnect the charger from the battery via external switches in case of emergency.

Before start charging
Proper installation of the battery charger and implementation of necessary safety devices and measures, including their maintenance, is the responsibility of the operating company/customer. As a basic rule, a risk and hazard analysis must be prepared according to local requirements and best practices.

CAUTION
Incorrect settings of the battery charger may damage the battery. Always check the settings before starting charging. Ensure that the battery is equipped with a suitable and adjusted BMS and that the conditions for any of the following two alternative
charging process- es are met.

BMS-controlled charging by use of serial communication and analog control. Ensure that the charger is adjusted for correct:
- Serial data communication
- Analog I/O functions (if used)
Charger algorithm- driven charging, monitored by external BMS.
Ensure that the charger is adapted for the battery type. Check, confirm, and if adjustable, set the following for each battery type before charging:
- Charging curve
- Number of battery modules
- Battery capacity (Ah)
- Analog I/O functions (if used)

WARNING

RISK OF BATTERY DAMAGE! – Read and follow the precautions provided below:
Charging of lithium-ion batteries may only be performed when a battery and battery charger-approved safety system for battery monitoring and module balancing is connected and active. The complete system is further referred to in this manual as a BMS system (Battery Monitoring System). The BMS system must:

Monitor and protect the battery so that no hazardous conditions can occur when charging or using the battery
Monitor and balance each series-connected module in the battery
Disconnect the battery from the battery charger and power load, by applicable national standards, before a hazardous situation may arise.
Ensure that each module is balanced considering voltage and charge level.
Operate automatically without the need for manual monitoring.

The battery chargers covered by this manual do not have their own integrated BMS system. All use of battery chargers covered by this manual requires that an external BMS system is connected and active during all charging and use of the battery. The BMS system must be automatic and approved for battery and battery charger. Even if a battery charging curve for lithium-ion batteries is selected and adjusted in the battery charger, an external BMS system must be connected and active during all charging and use of the battery. The BMS system must be automatic and approved for battery and battery charger.

Ensure that the battery’s limitations according to its data sheets are not exceeded during charging or use. Note that the restrictions apply to each module in the battery
Charging lithium-ion batteries must not be performed if the modules have a temperature lower than 0 °C
The lithium-ion modules to be charged should have a uniform temperature
Battery modules must not be hermetically enclosed in external housings without proper ventilation being ensured

GENERAL PROTECTIVE MEASURES

CAUTION

RISK OF MATERIAL DAMAGE! – Read and follow the precautions provided below:
Do not disconnect the battery when the charging process is in progress. Arc flash may occur and damage the connector pins.
Always stop the charging process before the battery is disconnected
Do not keep inflammable material close to the battery charger
Before connection, check the marking on the battery and the battery charger
Do not charge non-rechargeable batteries, damaged batteries, or battery types not intended for the charger

ELECTRIC SHOCK

WARNING: RISK OF ELECTRIC CHOCK! – Read and follow the precautions provided below:
WARNING, risk of electric shock. High voltage inside. The battery charger contains voltage at a level that can cause personal injury.

Disconnect the battery and power supply before maintenance, servicing, or dismantling
Check that the power supply at the site of the installation complies with the rated voltage specified on the battery charger’s data label
the battery charger may only be connected to a power outlet with protective earth
Do not operate the charger if there is any evidence of damage
If the supply cord or plug is damaged
The manufacturer, its service agent, or a similarly qualified person must carry out any replacement of the cord / plug to avoid a hazard.
Appliances with specially prepared cords must be replaced by a special cord or assembly available from the manufacturer or its service agent.
Other appliances that have a supply cord that cannot be replaced, should be scrapped.
If a stationary appliance is not fitted with a supply cord and a plug, or with other means for disconnection from the supply mains, disconnection must be incorporated in the fixed wiring by the national wiring rules.

WARNING
Risk of electric shock. High output voltage. Do not touch uninsulated battery terminals, connectors, or other live electrical parts. When installing or performing work on battery, charger, and battery terminals – do not risk short circuits. A short circuit may cause personal injury and permanently damage the battery. For all work on battery chargers, batteries, and BMS, suitable insulated tools must be used.

Warning information
Hazardous situations and precautions are presented in the text as follows.

WARNING
Indicates a potentially dangerous situation. Death or serious injury may occur if appropriate precautions are not taken.

CAUTION
Indicates a situation where damage or injury could occur. If it is not avoided, minor injury and/or damage to property may result.

NOTE: General information not connected to safety for a person or the product.

Graphical symbols
The following graphical attention symbols may appear on the products and in the documentation. Read the instructions. The manual contains important safety and operating instructions Stop operation. Always stop the charging process by disconnecting the mains before disconnecting the battery.

WARNING, risk of electric shock. High voltage inside. High output voltage. Do not touch uninsulated battery terminals, connectors, or other live electrical parts.

CAUTION, undesirable consequences. The situation needs operator awareness or action.

Introduction

This document contains use and maintenance instructions for the intended battery charger. This document is of relevance for the one who uses the battery charger for its purpose; charge batteries. It includes connecting the charger to the battery, handling the charging process, and managing basic settings. Target groups:

Installers
Operators
Maintenance personnel and technicians

Description

Champ is a compact and waterproof battery charger for charging lithium-ion (Li-ion) and lithium-iron phosphate (LiFePO4) batteries. The battery charger is delivered preprogrammed. The charger can also be delivered with power supply software, giving a steady output of preset voltage level. The built-in microprocessor controls current and voltage during the charging process. The charger’s LEDs indicate the status of the charging process. The charging time and temperature of the charger are monitored throughout the charging process. The charging is limited in the event of defective cells insufficient cooling etc.

Receiving

NOTE: Installation may only be performed by a qualified service partner.

MECHANICAL INSTALLATION The battery charger:

is intended for installation in vehicles and other applications
is suitable for indoor and outdoor use
is required to be mounted against a solid surface
should, when fitted on a wall or in a vehicle, be vertically mounted for optimal cooling

CAUTION

Avoid high ambient temperature, i.e. not near turbochargers, exhaust manifolds, etc.
The battery charger may become warm during use. Ensure ventilation around the charger.
The battery charger should always be securely fastened. Use screws and lock washers when attaching the charger (the installation must withstand shocks and vibrations in e.g. a vehicle)

Electrical installation

WARNING
High voltage! Incorrect connection of battery cables can cause personal injuries and damage to the battery, battery charger, and cables. Make sure the connections are correct.

WARNING
High voltage! Risk of live chassis. Always connect the charger to a power outlet with protective earth.

The battery charger is produced for different mains voltages. Check that the power supply at the site of the installation complies with the rated voltage specified on the battery charger- er’s data label. The label is located on the side of the charger. The charger is normally equipped with a fixed mains cable with a connector
Check the polarity of the battery connector and cable before connecting the battery. The charger is normally delivered with a battery cable with the following polarity:
- Positive (+) = Red
- Negative (−) = Blue or Black
Connect the battery cables to the battery

Operation

Overview
See Fig. 2 Components and dimensions

Mains cable
Battery cables
LED

NOTE: Cable lengths and connections may vary depending on the variant of the charger.

CHARGING

WARNING
High voltage! If there is evidence of damage to the battery charger, cables, or connectors, switch off the main power. Do not touch damaged parts. Do not touch uninsulated battery terminals, connectors, or other live electrical parts. Contact service personnel.

Connect and start charging.

Check the cables and connectors for visible damages
Connect the battery charger to the battery
Connect the mains cable

The battery charger starts charging. The time it takes before a battery charger starts charging depends on the:

connected battery type
battery voltage
capacity

The LED lights up or flashes in different patterns to indicate the condition and state of charge (SOC), see section LED indication. For more information about the different battery types and their charging curves, see Fig. 1 Charging curves. NOTE: The green LED will not light immediately if a fully charged battery is connected. This time can vary depending on the battery capacity and the software in the charger.

STOP CHARGING AND DISCONNECT

CAUTION
RISK OF MATERIAL DAMAGE! Do not disconnect the battery when the charging process is in progress. Arc flash may occur and damage the connector pins. Always stop the charging process before the battery is disconnected.

Turn off the charger by disconnecting the mains cable
Disconnect the battery

LED indication

Battery charger (w/o power supply software

*LED indication*	On *Off Flashing*

Left

| ****

Middle

| ****

Right

| ****

Information YL: Yellow – GN: Green – RD: Red

YL

| | | • The charging process starts with max power – I Phase

• The current drops as the battery is recharged

• The charging time is determined by the battery capacity and the degree of discharge

| ****

YL

| ****

| • When the threshold value (IBR) is reached, the internal timer starts the U phase of the charging process

• The U2 phase keeps the charger in the higher charging voltage. For how long depends on the software in the charger. Ensures recharge and equalizes the charge in all battery

cells

| ****

GN

| • Maintenance charge to set voltage

• The battery is kept fully charged and the charger can in this phase be left on, over time

• Possible parallel load or consumption is supplied from the charger and the battery is kept fully charged

• The battery charger can provide full power

| | ****

GN

| ****

Low battery voltage or no battery connected

| | ****

RD

| ****

Battery polarity error

YL

| |

RD

| ****

Time error (timeout), the battery is probably too big for the charger.

Battery charger with power supply software: PSU version 1

*LED indication*	On *Off Flashing*

Left

| ****

Middle

| ****

Right

| ****

Information YL: Yellow – GN: Green – RD: Red

|

YL

| ****

GN

| • The charging process starts with max power – PSU Phase

• The current drops as the battery is recharged

• The charging time is determined by the battery capacity and the degree of discharge

| ****

GN

| ****

The threshold value (IBR) is reached.

| ****

GN

| ****

• Possible parallel load or consumption is supplied from the charger and the battery is kept fully charged

• The battery charger can provide full power

YL

| ****

YL

| ****

RD ****

| ****

High current, the battery charger has reached the maximum output current.

YL

| |

RD ****

| • Overcurrent, the battery charger exceeds its capacity

• The charger delivers full (nominal) current, but the voltage drops

| | ****

RD

| ****

Battery polarity error

PSU version 2

*LED indication*	On *Off Flashing*

Left

| ****

Middle

| ****

Right

| ****

Information YL: Yellow – GN: Green – RD: Red

| | ****

GN

| • The charging process starts with max power – PSU Phase

• The current drops as the battery is recharged

• The charging time is determined by the battery capacity and the degree of discharge

| ****

GN

| ****

• Possible parallel load or consumption is supplied from the charger

• The battery charger can provide full power

| ****

RD

| ****

Battery polarity error

Maintenance and troubleshooting

The checks below are recommended to be carried out during troubleshooting and maintenance.
WARNING
High voltage! Only qualified personnel should install, use, maintain, and service this product. Disconnect the battery and power supply before maintenance, servicing, or dismantling. Safety shut-off Charging is terminated if:

Voltage and current exceed the maximum set value
The battery is disconnected without the battery charger being turned off\

NOTE: The PSU versions continue to provide power even when the battery is disconnected. Only when the mains cable is disconnected is the power supply terminated. Charging power is temporarily reduced if:

The internal charger temperature is too high
The current is too high

Checking error messages

If the battery charger’s built-in self-testing function detects a fault, this is indicated via the status LEDs on the front panel, see section LED indication. Please make a note of any faults and send them to authorized service personnel. Checks

Check the cables and connectors for damages.
Check that the battery is free from defects, in good condition, and is the correct type for the battery charger.
Check that the battery is properly connected and that the battery fuse, if any, is not broken.
Check that the mains voltage is right and that there are no blown fuses

Technical data

WARNING
High voltage!
If there is evidence of damage to the battery charger, cables, or connectors, switch off the main power. Do not touch damaged parts. Do not touch uninsulated battery terminals, connectors, or other live electrical parts. Contact service personnel.

Operational ambient temperature: −25 to 50 °C (−13 to 122 °F) (1)
Storage temperature: −40 to 85 °C (−40 to 185 °F)
Mains voltage: See data label (2)
Battery types: Li-ion and LiFePO4
Efficiency: > 90 % at full load Ingress protection: IP67
Approvals: CE and/or UL. See data label (2)
- 30 to 50 °C (86 to 122 °F) with derated charging power
- Located on the battery charger

Recycling

The battery charger is recycled as metal and electronics scrap. Local regulations apply and must be followed

Contact information

Micropower Sweden AB Idavägen 1, SE-352 46 Växjö, Svezia
Telefono: +46 (0)470-727400
e-mail: support@micropower.se
www.micropower-group.com

Figures

Approvals

Declaration of Conformity

Product: CHAMP Battery charger 100 – 450 W & Pro
Models: 2A1A101, 2A1A102, 2A1A301, 2A1A302, 2A1A401, 2A1A402, 2A1A501, 2A1A502, 2A1A801,
2A1A802, 2A1A901, 2A1A902, 2A1AA01, 2A1AA02.
Ratings: 100-450 W; 12 V e 24 V; 0-30 A

We, Micropower Sweden AB, Idavägen 1, SE-35246 Växjö, Svezia, declare under our sole responsibility that the named products are by the following European Directives and manufactured complying with the following harmonized standards:

Directive| Standards|
---|---|---

2014/35/EU Low Voltage Directive

| EN 60335-1:2012+A11+A13+A1+A14+A2
EN 60335-2-29:2004+A2+A11
| ****

EN 61000-6-2:2005

2014/30/UE EMC Directive| EN 61000-6-3:2007+A1:2011 EN 61000-3-2:2014
| EN 61000-3-3:2013

2011/65/EU RoHS Directive

| ****

Restriction of the use of hazardous materials

This declaration certifies the conformity with the named regulations. It does not mean any assurance of features. Place and data: Product owner: Micropower Sweden AB Växjö, Svezia, 01-01-2022 Attila Nagy Idavägen 1, SE-352 46 Växjö, Svezia
T: +46 (0)470-727400
sales@ micropower.se
www.micropower.se