Lea CHAMP PRO 12 V User manual

www.leab.eu
USER MANUAL
VERSION 8
19/08/2021
CHARGER
CHAMP PRO 12 V
LEAB Automotive GmbH Thorshammer 6 24866 Busdorf

Table of Contents
1 About this Manual................................................................................................................ 3
2 Safety......................................................................................................................................... 4
2.1 Intended Use............................................................................................................... 5
2.2 Foreseeable Misuse.................................................................................................. 6
3 About this Product............................................................................................................... 7
4 Technical specifications..................................................................................................... 8
5 Package Contents................................................................................................................. 11
6 Charging Characteristics.................................................................................................... 12
7 Assembly.................................................................................................................................. 14
8 Installation.............................................................................................................................. 15
9 Operation................................................................................................................................. 16
9.1 Charging the battery................................................................................................ 16
9.2 Charging the battery................................................................................................ 16
9.3 Change charging characteristic........................................................................... 17
9.4 Temperature Sensor................................................................................................ 17
10 Maintenance........................................................................................................................... 18
11 Disposal.................................................................................................................................... 18
12 EU Declaration of Conformity.......................................................................................... 18
13 Appendix .................................................................................................................................. 19
13.1 Information on outdoor use of the PowerSystem 12/24 V...................... 19
13.2 MagCodePowerPort installation instructions................................................ 20
13.3 MagCodePowerClip assembly instructions..................................................... 20
Table of Contents LEAB Automotive GmbH

1 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 ac-
cessories.
Throughout the manual, you will be alerted to warnings and safety notices
about potential hazards associated with handling the device. The colours 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
Danger that can lead to minor injuries
Safety instructions with the signal word CAUTION indicate a
hazard which, 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 which, if not avoided, can result in death or severe injury.
Read the safety instructions carefully and follow them to avoid
the hazard.
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LEAB Automotive GmbH 1 About this Manual

DANGER
Danger that will lead to severe injury or death
Safety instructions with the signal word Danger indicate a hazard
which, 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 ap-
pear as follows:
TIP
Tips provides additional, useful information.
Read the tip carefully and follow the instructions where
applicable.
2 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 ofLead-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 is a place where it can be ac-
cessed quickly.
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2 Safety LEAB Automotive GmbH

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 de-
signed 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 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 un-
damaged 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.
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LEAB Automotive GmbH 2 Safety

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.
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2 Safety LEAB Automotive GmbH

3 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 ad-
justed to ensure optimum charging of the battery.
1
2
3
Fig.1: Champ Pro charger
1 Display 2 AC cable
3 DC cable
4 5 6 7
Fig.2: Champ Pro charger display
4 Charging characteristic indicator 5 Mode button
6 Charge status indicator 7 Error indicator
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LEAB Automotive GmbH 3 About this Product

4 Technical specifications
Part no. 0101043880 Part no. 0101056008
Modell Champ Pro 1217 Champ Pro 1217
Battery type Lead acid (wet, gel/AGM)/
traction Lead acid (wet, gel/AGM)/ traction
Charging characteristics Choice of 4charging char-
acteristics Choice of 4charging char- acteristics
Battery capacity 55 Ah ... 170Ah 55 Ah ... 170Ah
Temperature sensor Yes Yes
AC cable 2.0 m, two-pin earthed
plug 0.2 m; DEFA
DC cable 1,5 m, ring terminal, M8 1,5 m, ring terminal, M8
Charging current 17 A 17 A
Ripple < 3 % < 3 %
Main charging 14.2 V/14.4 V 14.2 V/14.4 V
Equalisation charging 16.0 V 16.0 V
Trickle charging 13.6 V/13.8 V 13.6 V/13.8 V
Mains part function 13.7 V 13.7 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
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4 Technical specifications LEAB Automotive GmbH

Part no. 0101043890 Part no. 0101043915
Modell Champ Pro 1230 Champ Pro 1230
Battery type Lead acid (wet, gel/AGM)/
traction Lead acid (wet, gel/AGM)/ traction
Charging characteristics Choice of 4charging char-
acteristics Choice of 4charging char- acteristics
Battery capacity 90 Ah ... 300Ah 90 Ah ... 300Ah
Temperature sensor Yes No
AC cable 2.0 m, two-pin earthed
plug 2.0 m, two-pin earthed plug
DC cable 1,5 m, ring terminal, M8 5 m, ring terminal, M8
Charging current 30 A 30 A
Ripple < 3 % < 3 %
Main charging 14.2 V/14.4 V 14.2 V/14.4 V
Equalisation charging 16.0 V 16.0 V
Trickle charging 13.6 V/13.8 V 13.6 V/13.8 V
Mains part function 13.7 V 13.7 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
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LEAB Automotive GmbH 4 Technical specifications

Part no. 0101056012
Modell Champ Pro 1230
Battery type Lead acid (wet, gel/AGM)/traction
Charging characteristics Choice of 4charging characteristics
Battery capacity 90 Ah ... 300Ah
Temperature sensor Yes
AC cable 2.0 m, Neutrik
DC cable 5 m, ring terminal, M8
Charging current 30 A
Ripple < 3 %
Main charging 14.2 V/14.4 V
Equalisation charging 16.0 V
Trickle charging 13.6 V/13.8 V
Mains part function 13.7 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
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4 Technical specifications LEAB Automotive GmbH

5 Package Contents
Name No.
Battery charger 1x
User manual 1x
Accessories
Name Part number
Connection cable and sensor (3m) 1019003005
Connection cable and sensor (4.7m) 1019003004
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LEAB Automotive GmbH 5 Package Contents

6 Charging Characteristics
Battery charging is fully automatic and micro-processor controlled with a 3-
stage IU1U2 characteristic curve for gentle and optimum charging of the batter-
ies. 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 traction battery
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6 Charging Characteristics LEAB Automotive GmbH

I phase: Charging with constant current
Depending on the battery charge state, the battery is charged with 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 char-
ging 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 bat-
tery increasingly charges, the current decreases continuously and approaches
a lower limit.
Battery Type Main charge voltage
Gel/AGM battery 12 V 14.4 V
Wet cell battery (stand-
ard) 12 V 14.2 V
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 load-
ing the battery.
Battery Type Charge voltage
Gel/AGM batterie 12 V 13.8 V
Wet cell batterie (stand-
ard) 12 V 13.6 V
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 on board com-
puter and radio data loss due to the loss of power and having to be repro-
grammed.
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LEAB Automotive GmbH 6 Charging Characteristics

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 char-
ging characteristic.
7 Assembly
To assemble the device, perform the following steps:
üChoose a cool, dry and well-ventilated assembly site.
üDo not mount the device directly next to or above batteries.
üOptimum cooling is achieved by mounting the unit vertically on a flat sur-
face.
1. Fasten the device to the 4 holes on the side (Ø 5 mm)
ðThe 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.
ðThe charging characteristic is set.
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7 Assembly LEAB Automotive GmbH

8 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 temperat-
ure 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 con-
nection.
ðThe 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.
ðOne of the 4 charging LED flashes orange while the device is connecting
to the battery. There is no voltage output at this stage.
ðAfter 2 seconds, the LEDs of the charge status indicator flash, the char-
ging process starts.
ðThe charging progress is indicated in the charge status indicator via the
illuminated LEDs.
ðIf the green LED on the charge status indicator is lit, the charge is com-
plete and the battery can be disconnected from charger.
ðThe charger is connected to the 230-V mains supply.
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LEAB Automotive GmbH 8 Installation

9 Operation
9.1 Charging the battery
To start the charging operation, proceed as follows:
üThe device is installed.
üThe battery is connected.
1. Connect the mains plug to a 230 V mains supply.
ðCharging starts automatically, the yellow LED of the charge status indic-
ator lights up.
ðIf the charging current is 15% below the maximum value, the yellow and
green LEDs of the charging status indicator light up.
ðWhen the battery is fully charged, the green LED on the charging status
indicator lights up and indicates the trickle charge
ðThe battery is charged.
9.2 Charging the battery
To start the charging operation, proceed as follows:
üThe device is installed.
üThe battery is connected.
1. Connect the mains plug to a 115 V mains supply.
ðCharging starts automatically, the yellow LED of the charge status indic-
ator lights up.
ðIf the charging current is 15% below the maximum value, the yellow and
green LEDs of the charging status indicator light up.
ðWhen the battery is fully charged, the green LED on the charging status
indicator lights up and indicates the trickle charge.
ðThe battery is charged.
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9 Operation LEAB Automotive GmbH

9.3 Change charging characteristic
To change the charging characteristic, proceed as follows:
üThe device is installed.
üThe battery is connected.
1. Connect the mains plug to a 230 V/115 V mains supply.
ðOne 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.
ðAfter 2 seconds, the LEDs of the charging status display flashes and the
charging process starts.
ðThe charging progress is indicated in the charging status display by illu-
minated LEDs.
ðIf the green LED of the charging status indicator lights up, charging is
complete and the battery can be disconnected from the charger.
ðThe 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 loc-
ated in the negative lead. The temperature sensor corrects the charging
voltage as a function of the temperature in order to provide an optimal, ef-
fective and gentle battery charge.
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LEAB Automotive GmbH 9 Operation

10 Maintenance
Check the device as follows before using it each time:
– Check the mains cable and mains plug for damage.
– Check charging cables and connections for damage.
– Check the charger for external damage.
– Ensure that the wiring between the charging cable and the charger is se-
cure.
TIP
Battery maintenance
For battery maintenance, refer to the battery manufacturer's
instructions.
11 Disposal
Dispose of the device in accordance with the Waste Elec-
trical 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.
12 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
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12 EU Declaration of Conformity LEAB Automotive GmbH

13 Appendix
13.1 Information on outdoor use of the PowerSystem 12/24 V
MagCode PowerSystems were originally developed for vehicle interiors. How-
ever, 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 mainten-
ance 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 con-
tact 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.
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LEAB Automotive GmbH 13 Appendix

13.2 MagCodePowerPort installation instructions
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 MagCode PowerPort in place of an existing
car socket, proceed as follows:
DANGER!Short circuit hazard - Remove the fuse be-
fore 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).
ðThe installation opening is prepared.
4. Slide the MagCode PowerPort , with or without spacer
ring, into the installation opening.
5. Screw the MagCode PowerPort on the back with a nut
(M28).
6. Connect the cables with each other by soldering,
crimping or with connection terminals.
7. Put the fuse back in place.
ðThe MagCode PowerPort 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 MagCode PowerClip .
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.
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13 Appendix LEAB Automotive GmbH