LEAB RBC 1280 User manual

www.leab.eu
USER MANUAL
VERSION 3
22/06/2021
CHARGER
RBC IP54
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.................................................................................................. 5
3 About this Product............................................................................................................... 6
4 Technical Specifications.................................................................................................... 8
5 Package Contents................................................................................................................. 12
6 Assembly.................................................................................................................................. 12
7 Setting the Charging Parameters................................................................................... 12
8 Checking the Charging Parameter Settings............................................................... 15
9 Changing charging parameters....................................................................................... 16
10 Installation.............................................................................................................................. 16
11 Operation................................................................................................................................. 19
11.1 Switching On ............................................................................................................... 19
11.2 Switching Off............................................................................................................... 21
12 Maintenance........................................................................................................................... 21
13 Disposal.................................................................................................................................... 21
14 EU Declaration of Conformity.......................................................................................... 21
15 Appendix .................................................................................................................................. 22
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. Any modifications to the device or its com-
ponents are prohibited and do not conform to its intended use. Observe the
safety instructions.
Keep this manual is a place where it can be accessed quickly.
2.1 Intended Use
The charger is a robust charger for permanent installation in vehicles, with 12
and 24 V on-board power supply, for charging lead batteries and LION Brix
lithium batteries.
The device is designed for a temperature range of -35 °C ... 55 °C. Do not
charge batteries with this charger outside the specified temperature range. At
higher temperatures, the output power of the charger automatically de-
creases.
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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.
2.2 Foreseeable Misuse
The charger is designed for Interior use in vehicles. Never assemble the char-
ger outside the vehicle. The charger is designed to charge all types of Lead-
acid batteries (wet, gel, AGM) and lithium batteries. Charge only the specified
battery types with the charger.
To avoid damage, never pinch the leads of the charger. In the event of dam-
age, unplug the charger immediately and contact your dealer or LEAB.
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

3 About this Product
RBC chargers are microprocessor-controlled battery chargers for charging
open and closed lead-acid, lead-gel and AGM batteries.
2
3
4
5
6
7
8
1
Fig.1: RBC charger front view
1 'Data connection’ LED 2 Stop button
3 F1 button 4 F2 button (no function)
5 'Ready for operation’ LED 6 'Charging complete’ LED
7 'Charging’ LED 8 'Error‘ LED
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3 About this Product LEAB Automotive GmbH

1 2 3 4 5
Fig.2: RBC charger connection side
1 Mains connection cable of the
charger 2 Charging cable, red
3 Charging cable, blue 4 Battery data line
5 Mounting bracket
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LEAB Automotive GmbH 3 About this Product

4 Technical Specifications
0101036980 0101036097
Modell RBC 1280 RBC 12105
Battery type Open and closed lead
batteries (wet, gel/AGM) Open and closed lead batteries (wet, gel/AGM)
Charging characteristics 30 selectable charging
parameters 30 selectable charging parameters
Battery capacity 50 Ah ... 800Ah 50 Ah ... 800Ah
Charging current 80 A 105 A
Ripple < 3 % 3 %
Main charging 14.1 V - 14.4 V 14.1 V - 14.4 V
Trickle charging 13.5 V - 13.8 V 13.5 V - 13.8 V
Input values 230 V/50 Hz 230 V/50 Hz
Input voltage 195 V ... 264 V 195 V ... 264 V
Input frequency 47 Hz ... 63 Hz 47 Hz ... 63 Hz
Degree of efficiency, max. > 93% > 93%
International Protection
(IP class) IP54 IP54
Protection class I I
Operating temperature -35 °C ... +55 °C -35 °C ... +55 °C
Cooling Active Active
Dimensions (L x W x H) 410 mm x 230 mm x 78
mm 367 mm x 230 mm x 83 mm
Weight 5.3 kg 6.7 kg
AC cable 1.5 m, two-pin earthed
plug 1.5 m, two-pin earthed plug
DC cable 2 x 2 m, without plug 2 x 2 m, without plug
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4 Technical Specifications LEAB Automotive GmbH

0101036990 0101036992
Modell RBC 2440 RBC 2440
Battery type Open and closed lead
batteries (wet, gel/AGM) Open and closed lead batteries (wet, gel/AGM)
Charging characteristics 30 selectable charging
parameters 30 selectable charging parameters
Battery capacity 50 Ah ... 800Ah 50 Ah ... 800Ah
Charging current 40 A 40 A
Ripple 3 % 3 %
Main charging 28.2 V - 28.8 V 28.2 V - 28.8 V
Trickle charging 27.0 V - 27.6 V 27.0 V - 27.6 V
Input values 230 V/50 Hz 230 V/50 Hz
Input voltage 195 V ... 264 V 195 V ... 264 V
Input frequency 47 Hz ... 63 Hz 47 Hz ... 63 Hz
Degree of efficiency, max. > 93% > 93%
International Protection
(IP class) IP54 IP54
Protection class I I
Operating temperature -35 °C ... +55 °C -35 °C ... +55 °C
Cooling Active Passive
Dimensions (L x W x H) 320 mm x 235 mm x 110
mm 410 mm x 230 mm x 78 mm
Weight 5.5 kg 5.6 kg
AC cable 1.5 m, two-pin earthed
plug 1.5 m, two-pin earthed plug
DC cable 2 x 2 m, without plug 2 x 2 m, without plug
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LEAB Automotive GmbH 4 Technical Specifications

0101036081 0101036096
Modell RBC 2480 RBC 24105
Battery type Open and closed lead
batteries (wet, gel/AGM) Open and closed lead batteries (wet, gel/AGM)
Charging characteristics 30 selectable charging
parameters 30 selectable charging parameters
Battery capacity 50 Ah ... 800Ah 50 Ah ... 800Ah
Charging current 80 A 105 A
Ripple 3 % < 3 %
Main charging 28.2 V - 28.8 V 28.2 V - 28.8 V
Trickle charging 27.0 V - 27.6 V 27.0 V - 27.6 V
Input values 230 V/50 Hz 230 V/50 Hz
Input voltage 195 V ... 264 V 195 V ... 264 V
Input frequency 47 Hz ... 63 Hz 47 Hz ... 63 Hz
Degree of efficiency, max. > 93% > 93%
International Protection
(IP class) IP54 IP54
Protection class I I
Operating temperature -35 °C ... +55 °C -35 °C ... +55 °C
Cooling Active Active
Dimensions (L x W x H) 410 mm x 240 mm x 78
mm 367 mm x 230 mm x 83 mm
Weight 5.2 kg 6.7 kg
AC cable 1.5 m, two-pin earthed
plug 1.5 m, two-pin earthed plug
DC cable 2 x 2 m, without plug 2 x 2 m, without plug
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4 Technical Specifications LEAB Automotive GmbH

0101078560 0101036095
Modell RBC 4860 RBC 24105
Battery type Open and closed lead
batteries (wet, gel/ AGM) Open and closed lead batteries (wet, gel/AGM)
Charging characteristics 30 selectable charging
parameters 30 selectable charging parameters
Battery capacity 50 Ah ... 800Ah 50 Ah ... 800Ah
Charging current 60 A 105 A
Ripple < 3 % < 3 %
Main charging 56.4 V - 57.6 V 28.2 V - 28.8 V
Trickle charging 54.0 V - 55.2 V 27.0 V - 27.6 V
Input values 230 V/50 Hz 230 V/50 Hz
Input voltage 195 V ... 264 V 195 V ... 264 V
Input frequency 47 Hz ... 63 Hz 47 Hz ... 63 Hz
Degree of efficiency, max. > 93% > 93%
International Protection
(IP class) IP54 IP54
Protection class I I
Operating temperature -35 °C ... +55 °C -35 °C ... +55 °C
Cooling Active Active
Dimensions (L x W x H) 367 mm x 230 mm x 83
mm 367 mm x 230 mm x 83 mm
Weight 6.9 kg 6.7 kg
AC cable 1.5 m, two-pin earthed
plug 1.5 m, two-pin earthed plug
DC cable 2 x 2 m, without plug 2 x 2 m, without plug
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LEAB Automotive GmbH 4 Technical Specifications

5 Package Contents
Item No.
Battery charger 1x
User manual 1x
6 Assembly
To assemble the device, proceed as follows:
üChoose a cool, dry and well-ventilated assembly site.
üDo not mount the device directly next to or above batteries.
üGuarantee adequate cooling for an unimpeded supply of cooling air.
1. Fasten the device to the side holes (5 mmØ) on a flat surface.
ðThe device is assembled.
7 Setting the Charging Parameters
The RBC charger contains 30 different charging parameters (charging charac-
teristic, battery capacity and charging mode) which you can select before con-
necting to the battery. A graphical illustration of the charging characteristics
can be found in Appendix [ } 22] .
To set the charging parameters, proceed as follows:
üBefore setting, select the desired settings using the table below.
üThe charger is disconnected from the 230 V mains.
üThe charger is not connected to the battery.
1. Connect the mains plug to a 230 V mains supply.
2. As soon as the 'Ready for operation' LED lights up blue (after approx. 5 s),
press the STOP button for 10 s until all LEDs are flashing briefly.
ðYou are in configuration mode.
NOTE!When first used, charging parameters 1 (charging characteristic
LK10-06) and 9 (battery capacity 50 Ah) are preset by default.
3. To select a parameter from the list, keep pressing the STOP button until you
reach the desired position.
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Fig.3: F1 and F2
buttons
4. Select or deselect a setting by pressing the F1 button.
5. Remove the device from the 230 V mains.
ðThe charging parameters are set and saved.
Set the following parameters for the different 'Power
Supply’ charging modes:
NOTE!Depending on the charger, a voltage of 12 V or 24
V is permanently output as standard in the 'Power Sup-
ply' charging modes. If you require a higher voltage,
please contact LEAB directly.
Charging mode Settings
Charging mode (default) 25, Charging mode: OFF
27, CAN mode: OFF
30: Charging mode: OFF
PDO Power Supply 25, Charging mode: OFF
27, CAN mode: ON
30: Charging mode: OFF
SDO Power Supply 25, Charging mode: ON
27, CAN mode: ON
30: Charging mode: OFF
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LEAB Automotive GmbH 7 Setting the Charging Parameters

Fig.4: Charging parameter settings
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7 Setting the Charging Parameters LEAB Automotive GmbH

8 Checking the Charging Parameter Settings
To check the charging parameter settings, it is necessary to switch back to
configuration mode.
Check the Charging Characteristic Setting
To check the charging characteristic setting, proceed as follows:
üThe desired charging parameters are set and saved.
üThe charger is disconnected from the 230 V mains.
1. Connect the mains plug to a 230 V mains supply.
2. As soon as the 'Ready for operation' LED lights up blue (after approx. 5 s),
press the Stop button for 10 s until all LEDs are flashing.
ðThe device is in configuration mode.
3. Press the Stop button until you are in the desired setting for the charging
characteristic.
ðThe LED next to the F1 button lights up orange. The charging characteristic is
set and saved.
Check the battery capacity setting
To check the battery capacity settings, proceed as follows:
4. Keeping pressing the Stop button until you are in the desired battery capa-
city setting.
ðThe LED next to the F1 button lights up orange. The battery capacity is set
and saved.
Check the charging mode setting
The charging mode setting can be checked using the following features:
– If one of the charging modes 'Charging mode (25), External input On (26),
CAN mode Master (27), ON:Parallel operation activated (28) or Charging
mode (30)' is set, the LED next to the F1 button is not lit.
– If one of the charging modes 'Power Supply (25), External Input Off (26) or
CAN mode Master ext. (27)' is set, the LED next to the F1 button lights up or-
ange.
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LEAB Automotive GmbH 8 Checking the Charging Parameter Settings

9 Changing charging parameters
The settings of the charging parameters can be changed at any time. To do
this, proceed as follows:
üThe device is disconnected from the 230 V mains supply.
üThe device is not connected to a battery.
1. Connect the mains plug to a 230 V mains supply.
2. As soon as the 'Ready for operation' LED lights up blue (after approx. 5 s),
press the Stop button for 10 s until all LEDs are flashing.
ðThe device is in configuration mode.
3. Set the desired charging parameters as described in Setting the Charging
Parameters [ } 12] .
ðThe charging parameters are changed.
10 Installation
Battery Connection
To install the device in the vehicle, proceed as follows:
1. Disconnect the battery from the on-board power supply.
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 device to the positive terminal of the bat-
tery.
4. Connect the negative cable of the device to the negative terminal of the
battery.
5. Connect the vehicle battery to the on-board power supply.
ðThe device is installed.
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10 Installation LEAB Automotive GmbH

Connection to the 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.
ðThe charger is connected to the 230 V mains supply.
Connecting the Sensor Cable
The sensor cable measures the battery temperature (sensor cable TS) or the
battery temperature and voltage (sensor cable CTS) in order to charge the bat-
tery optimally.
To connect the sensor cable, proceed as follows:
NOTE!When connecting, pay attention to the instructions and notes in the
sensor cable installation instructions.
1. Connect the sensor cable to the charger.
ðThe sensor cable is connected.
Connecting the D-Sub Connector
The integrated D-Sub connector allows you to control various signals.
Pin Description
1 CAN Bus high*
2 Voltage sensor (+)
3 Temperature sensor (+)
4 LED green (+)
5 LEB yellow (+)
7 Insulated ground*
8 Pilot Brix
9 CBL relay contact, normally closed
10 CAN bus low*
11 Remote input (-)*
12 Temperature sensor (-)
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LEAB Automotive GmbH 10 Installation

Pin Description
14 LED red (-)
18 CBL relay contact, normally open
19 Remote input (+)*
20 Voltage sensor (-)
22 LED (-)
25 Insulated 5 V (50 mA) output (+)*
26 CBL input
*The CAN bus signals, CBL, the remote input and the insulated 5 V output are
galvanically isolated from the DC output.
NOTE!Pins that are not listed are not assigned.
External LED Connection
The LED shows the charge status of the battery.
To connect the external LEDs, proceed as follows:
1. Connect the wire ends of the external LEDs to pin 4, pin 5, pin 14 and pin 22.
ðThe external LEDs are connected.
EBrix Connection (24 V)
You can connect the RBC 24 V charger to the eBrix system using a suitable ad-
apter.
NOTE!Note that the RBC 24105 with part number 101036095 cannot be con-
nected to an eBrix.
CBL Control Relay Connection
A potential-free changeover contact is integrated in the RBC chargers, which
switches during charging operation. This option can be used, for example, to
implement an electrical start interlock with 230 V connection or charge monit-
oring.
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10 Installation LEAB Automotive GmbH

Switching Function of the Changeover Contact
Fig.5: Switching
Function of the
Changeover Contact
– When the charger is switched off, pin 9 and pin 26 are
connected.
– When the charger is switched on, pin 26 and pin 18 are
connected.
Technical Data (insulation) Capacity (max.values)
Output to hous-
ing: 500V Max. 60 V (DC): 0.25A
Output to ground 120V
To install the CBL control relay, proceed as follows:
1. Solder the end of the cable to the D-sub connector.
2. Connect the wire ends to pin 26, pin 9 and pin 18.
3. Plug the D-sub connector into the connector for the
CBL control relay on the device.
ðThe CBL control relay is installed.
11 Operation
11.1 Switching On
To switch on the device, proceed as follows:
1. Connect the mains plug to a 230 V mains supply.
ðThe device is switched on.
NOTE!After connection to the mains, the LED flashes red for 2 seconds
(device test).
NOTE!When the battery is charging, the 'Charging' LED is lit orange.
NOTE!When the battery is fully charged, the 'Charging complete' LED is lit
green.
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LEAB Automotive GmbH 11 Operation

Operating status
Description
Battery not connected/No CAN signal
Charging is interrupted
Charger in first charging phase
Charger in second charging phase
Charger in third charging phase
Battery fully charged
Charger waiting for remote
Tab.1: Display of the operating status LEDs
Charging the Battery
The charger begins to charge the battery as soon as the charger is connected
to the 230 V mains.
Interrupting the Charging Process
To interrupt the charging process, proceed as follows:
1. To interrupt charging, press the Stop button.
ð‘Charging complete' LED flashes green.
2. To continue charging, press the Stop button again.
ðThe charging process is now interrupted
NOTE!If the Stop button is not pressed again, charging remains interrupted.
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11 Operation LEAB Automotive GmbH