LEAB ABC SCHUTZKLASSE II User manual

www.leab.eu
USER MANUAL
VERSION 6
01/09/2022
CHARGER
ABC SCHUTZKLASSE II
LEAB Automotive GmbH Thorshammer 6 24866 Busdorf

Table of contents
1 About this Manual ................................................................................ 3
2 Safety ................................................................................................... 4
2.1 Intended use...................................................................................... 4
2.2 Foreseeable misuse ........................................................................... 6
3 About this product ................................................................................ 7
4 Package contents .................................................................................. 8
5 Technical specifications......................................................................... 9
6 Charging characteristics ........................................................................ 11
7 Setting charging characteristics ............................................................. 12
8 Assembly .............................................................................................. 13
9 Installation............................................................................................ 13
9.1 Connecting the battery...................................................................... 13
9.2 Connecting the unit to the 230 V mains ............................................ 13
9.3 Connecting the sensor cable ............................................................. 14
9.4 Connecting the CBL control relay ...................................................... 14
9.5 Connecting the remote display.......................................................... 15
10 Operation ............................................................................................. 15
10.1 Switching on the unit......................................................................... 15
10.2 Charging the battery.......................................................................... 15
10.3 LED status display on the charger...................................................... 16
11 Maintenance......................................................................................... 16
12 Disposal ................................................................................................ 17
13 EU Declaration of Conformity................................................................ 17
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.
3LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
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 appear
as follows:
TIP
Tips provides additional, useful information.
Read the tip carefully and follow the instructions where
applicable.
2 Safety
This user manual will help you to handle the unit safely. Use the unit solely in
accordance with its intended use. Observe the safety instructions. Keep this
user manual in an easily accessible place.
Any modifications to the unit or its components are prohibited and do not
conform to its intended use.
2.1 Intended use
The ABC charger has been developed for permanent installation in vehicles for
charging 12 and 24 V lead acid batteries. The unit is designed for a temperat-
ure range of -30°C to +60°C, do not charge the unit outside the this temperat-
ure range. At higher temperatures, the output power of the charger automat-
ically decreases.
Only connect the mains plug of the charger to easily accessible sockets with
230 V mains so that you can intervene quickly in the event of a fault.
4 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
2 Safety LEAB Automotive GmbH

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
Burns from escaping acid
Acid can leak out when handling batteries.
1. Wear acid-proof clothing when handling batteries.
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.
5LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 2 Safety

2.2 Foreseeable misuse
The charger is designed for permanent installation in vehicles; never install
the charger outside the vehicle. Do not expose the unit to strong sunlight for a
long period of time. Only charge Lead-acid batteries (wet, gel, AGM) with this
charger. The charger must not be used as a starting aid.
To avoid damage, do not pinch the leads of the charger. In the event of dam-
age to the charger, unplug the charger immediately and contact your dealer.
Notice
Device defects from incorrect installation
Incorrect installation can result in device defects.
1. Install the device in a dry and cool location.
6 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
2 Safety LEAB Automotive GmbH

3 About this product
The ABC chargers have been developed for permanent installation in vehicles
for charging lead acid batteries. They cover a battery voltage range from 12 V
to 48 V and provide charging currents from 15 A to 100 A. Battery charging is
fully automatic and microprocessor-monitored with a selectable charging
characteristic. This guarantees optimum and gentle charging. Thanks to their
compact design, high performance and excellent radio interference suppres-
sion, LEAB chargers have been used for many years wherever optimum bat-
tery charging is required.
1 2 3
Fig.1: ABC charger front view
1 Potentiometer for setting the
charging characteristic
2 Potentiometer for fine adjust-
ment of the output voltage
3 Status display LED
7LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 3 About this product

1 2 3 4 5
Fig.2: ABC charger connection side
1 AC wire 2 On/off switch
3 DC wire 4 Sensor cable connection (CTS/
TS)
5 Remote display connection
4 Package contents
Package contents No.
Battery charger 1x
Mounting clamp 2x
User manual 1x
8 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
4 Package contents LEAB Automotive GmbH

5 Technical specifications
Part no. 0101236020 Part no. 0101236030
Model ABC 2420 ABC 2430
Battery type Lead acid (wet, gel/AGM) Lead acid (wet, gel/AGM)
Battery capacity 60 Ah ... 200 Ah 90 Ah ... 300 Ah
Charging characteristics 15 optional characterist-
ics (see characteristics
sheet)
15 optional characterist-
ics (see characteristics
sheet)
Charging current 20A 30A
Ripple < 3% < 3%
Main charging 28.2 V/28.8 V 28.4 V/28.8 V
Trickle charging 27.0 V/27.6 V 27.2 V/27.6 V
Input voltage (rated val-
ues)
230 V/50 Hz/4 A 230 V/50 Hz/4 A
Input voltage 230 V 230 V
Input values 90 V … 270 V (< 200 V re-
duced charging current)
90 V … 270 V (< 200 V re-
duced charging current)
Input frequency 47 Hz ... 400Hz 47 Hz ... 400Hz
Switching frequency 100kHz 100kHz
Mains fuse B16A or C16A B16A or C16A
Degree of efficiency,
max.
> 88% > 88%
Protection class II II
Operating temperature -30°C ... +60°C -30°C ... +60°C
IP rating IP21 IP21
Dimensions (LxWxH) 240 mm x 135 mm x 85
mm
240 mm x 135 mm x 85
mm
Weight 2.0kg 2.0kg
AC wire 2m, 0.75mm² 1.5m, 1mm²
DC wire 2m, 2 x 6mm² 2x2m, 6mm²
CBL connection No No
9LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 5 Technical specifications

Part no. 0101236020 Part no. 0101236030
CTS/TS connection Yes Yes
Remote display connec-
tion
Yes Yes
On/off switch Yes Yes
Part no. 0101236120 Part no. 0101236130
Model ABC 1220 ABC 1230
Battery type Lead acid (wet, gel/AGM) Lead acid (wet, gel/AGM)
Battery capacity 60 Ah ... 200 Ah 90 Ah ... 300 Ah
Charging characteristics 15 optional characterist-
ics (see characteristics
sheet)
15 optional characterist-
ics (see characteristics
sheet)
Charging current 20A 30A
Ripple < 3% < 3%
Main charging 14.2 V/14.4 V 14.2 V/14.4 V
Trickle charging 13.6 V/13.8 V 13.6 V/13.8 V
Input voltage (rated val-
ues)
230 V/50 Hz/4 A 230 V/50 Hz/4 A
Input voltage 230 V 230 V
Input values 90 V … 270 V (< 200 V re-
duced charging current)
90 V … 270 V (< 200 V re-
duced charging current)
Input frequency 47 Hz ... 400Hz 47 Hz ... 400Hz
Switching frequency 100kHz 100kHz
Mains fuse B16A or C16A B16A or C16A
Degree of efficiency,
max.
> 88% > 88%
Protection class II II
Operating temperature -30°C ... +60°C -30°C ... +60°C
IP rating IP21 IP21
Dimensions (LxWxH) 240 mm x 135 mm x 85
mm
240 mm x 135 mm x 85
mm
10 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
5 Technical specifications LEAB Automotive GmbH

Part no. 0101236120 Part no. 0101236130
Weight 2.0kg 2.0kg
AC wire 2m, 1mm² 1.5m, 1mm²
DC wire 2x2m, 6mm² 2x2m, 6mm²
CBL connection No No
CTS/TS connection Yes Yes
Remote display connec-
tion
Yes Yes
On/off switch Yes Yes
6 Charging characteristics
The ABC charger contains 15 different charging characteristics which you can
select before connecting to the battery. Battery charging is fully automatic
and micro-processor controlled with a 3-stage IU1U2 characteristic curve for
gentle and optimum charging of the batteries.
The available charging characteristics can be taken from the .
11LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 6 Charging characteristics

7 Setting charging characteristics
Notice
Battery defect due to incorrect charging
To protect the battery from damage due to incorrect charging, set
a suitable charging characteristic before installation. Follow the
battery manufacturer's instructions.
To set a charging characteristic, proceed as follows:
1. Turn the potentiometer to the desired position (see characteristics sheet in
Appendix).
NOTE!The arrow in the middle of the potentiometer indicates the selected
characteristic.
2. To prevent accidental adjustment of the charging characteristic, stick the
supplied sticker on the potentiometer. NOTE!Ensure that the notch in the
sticker is above the LED.
ðThe charging characteristic is set.
Adjusting the output voltage
You can adjust the output voltage with the potentiometer (±0.75 V).
Notice
Battery defect due to incorrect charge voltage
If you use the fine adjustment, check the charge voltage regularly.
To change the output voltage, proceed as follows:
1. Turn the potentiometer for fine adjustment until the desired charge voltage
is reached.
ðThe output voltage is adjusted.
12 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
7 Setting charging characteristics LEAB Automotive GmbH

8 Assembly
To assemble the unit, proceed as follows:
üChoose a cool, dry and well-ventilated assembly site.
üDo not mount the unit directly next to or above batteries.
üGuarantee adequate cooling for an unimpeded supply of cooling air.
1. Fasten the assembly bracket to the unit using the 4 lateral holes (5mmØ).
ðThe unit is assembled.
9 Installation
9.1 Connecting the battery
To connect the battery, proceed as follows:
1. Disconnect the battery from the vehicle power circuit.
WARNING!Disconnect the negative cable first.
2. Secure the positive cable of the device as close as possible to the vehicle
battery with a suitable fuse.
3. Connect the positive cable of the unit to the positive terminal of the bat-
tery.
4. Connect the negative cable of the unit to the negative terminal of the bat-
tery.
5. Connect the vehicle battery to the vehicle power circuit again.
ðThe battery is connected.
9.2 Connecting the unit to the 230 V mains
To connect the unit to the 230V mains, proceed as follows:
1. Connect the mains plug to a 230 V mains.
ðThe charger is connected to the 230 V mains.
13LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 9 Installation

9.3 Connecting the sensor cable
The TS sensor cable measures the ambient temperature to optimally charge
the battery. The CTS sensor cable measures the battery temperature and
voltage to optimally charge the battery.
NOTE!When connecting, pay attention to the instructions and notes in the
sensor cable installation instructions.
9.4 Connecting the CBL control relay
A potential-free changeover contact is integrated in the
ABC chargers, which switches during charging. This op-
tion can be used, for example, to implement an electrical
start interlock with 230 V connection or charge monitor-
ing.
Switching function of the changeover contact
– Pin 1 and pin 3 are connected when the charger is
switched off.
– Pin 1 and pin 2 are connected when the charger is
switched on.
Technical Data (insula-
tion)
Capacity (max.values)
Output to housing 500 V 24 V(DC): 0.5A
Output to ground 120 V 120 V(AC): 0.5A
To connect the CBL control relay, proceed as follows:
1. Plug the RJ plug connector into the connector for the
CBL relay.
ðThe CBL control relay is connected.
14 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
9 Installation LEAB Automotive GmbH

9.5 Connecting the remote display
The remote display shows the charge status of the battery via an LED.
To connect the remote display, proceed as follows:
1. Plug the connecting cable for the remote display into the connector for the
remote display of the charger.
ðThe remote display is connected.
10 Operation
10.1 Switching on the unit
To switch on the unit, proceed as follows:
1. Connect the mains plug to a 230 V mains.
2. If your unit is equipped with an on/off switch, set the switch to position I.
ðCharging starts automatically.
ðThe unit is switched on.
10.2 Charging the battery
The ABC charger begins to charge the battery as soon as it is switched on.
15LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 10 Operation

10.3 LED status display on the charger
Status Description Action
Steady light, or-
ange
Battery is charging.
The charger is in the main char-
ging phase.
Steady light,
green
Battery is fully charged, charger
is in trickle charge phase.
Charger can be switched off
and the battery can be used.
Steady light,
red
Error, overheating – Check battery connection
– Measure battery voltage
– Disconnect the unit from
the battery and allow it
to cool down.
Flashing, red Timeout in the main charge
phase, charging interrupted.
– Check battery
– Select larger charger
– Consumer too large:
Switch off consumer dur-
ing charging.
11 Maintenance
Check the charger as follows every time before you use it:
– 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.
NOTE!For battery maintenance, refer to the battery manufacturer’s instruc-
tions.
16 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
11 Maintenance LEAB Automotive GmbH

12 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.
13 EU Declaration of Conformity
The ABC charger complies with the requirements of the
following directives:
– 2014/30/EU: EMV
– 2014/35/EU: NRL
– 2011/65/EU: RoHS
17LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 13 EU Declaration of Conformity

18 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
13 EU Declaration of Conformity LEAB Automotive GmbH

19LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 13 EU Declaration of Conformity

LEAB Automotive GmbH
Thorshammer 6
24866 Busdorf
Tel: [phone]
Fax: [phone]
[email protected]
We make energy
mobile.
It is prohibited to copy, duplicate, translate or otherwise pass on the
content of this document to third parties without the express written
permission of LEAB.