MICRO-POWER CHAMP Pro User manual

CHAMP PRO
USER MANUAL 'ONLINE VERSION'
Battery charger 12/24V 12-30A (Lead-acid)
Valid for Champ Pro with Model Code:
2A1A9**, 2A1AA**

Safety.......................................................................................................................................................................... 3
Safety precautions....................................................................................................................................................... 3
Warning information..................................................................................................................................................... 4
Graphical symbols........................................................................................................................................................5
Introduction................................................................................................................................................................ 5
Description................................................................................................................................................................. 6
Receiving.................................................................................................................................................................... 6
Installation.................................................................................................................................................................. 6
Mechanical installation.................................................................................................................................................6
Electrical installation.....................................................................................................................................................7
Operation.................................................................................................................................................................... 7
Overview...................................................................................................................................................................... 7
Charging.......................................................................................................................................................................7
LED indication..............................................................................................................................................................9
Maintenance and troubleshooting............................................................................................................................9
Built-in temperature sensor..........................................................................................................................................9
Safety shut-off............................................................................................................................................................10
Checking error messages.......................................................................................................................................... 10
Checks....................................................................................................................................................................... 10
Technical data.......................................................................................................................................................... 10
Recycling.................................................................................................................................................................. 10
Contact information................................................................................................................................................. 11
Figures...................................................................................................................................................................... 12
Fig. 1 Charging curves...............................................................................................................................................12
Fig. 2 Components and dimensions...........................................................................................................................14
Fig. 3 Temperature compensation..............................................................................................................................15
Approvals..................................................................................................................................................................16
Declaration of Conformity...........................................................................................................................................16
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Safety
Safety precautions
Read the instructions. The manual contains important safety and operating instructions. Always keep
this manual nearby 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 from 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 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 made 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 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 mains. Disconnect mains before disconnecting battery
cables.
Intended use
The battery charger is intended for charging lead-acid batteries.
Battery charger adjustment
The charger must be adjusted to each type of battery to be charged (Freely Ventilated FVLA or Valve regulated
VRLA). Each charger can be ordered as pre-adjusted with charging curve and parameters optimized for a specified
battery.
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 in accordance with local requirements and best practice.
Ensure that the charger is adjusted for the battery type. Before connection, check the marking on the battery and
the battery charger.
EXPLOSIVE GASES
WARNING
RISK OF EXPLOSION! - Read and follow the precautions provided below:
WARNING, explosive gases. Lead-acid batteries generate explosive gases during charging.
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•Incorrect settings of the battery charger may damage the battery and generate explosive gases from the battery
during charging. Always check settings before start charging.
•Do not charge non-rechargeable batteries, damaged batteries or battery types not intended for the charger.
•Do not disconnect the battery when the charging process is in progress. Sparks may occur and cause hydrogen
explosion when charging lead-acid batteries. Arc flash may occur and damage the connector pins. Always stop
the charging process before the battery is disconnected.
No open flame. Fire, open ignition source and smoking are prohibited near battery.
•Explosive gases. Prevent flames and sparks. Provide proper ventilation during charging.
•Do not smoke, cause sparking or use open flames near battery.
•Do not keep inflammable material close to battery charger.
Well-ventilated. Always provide proper ventilation during charging.
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 similarly qualified persons must carry out any replacement of the
cord / plug in order 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 in accordance with the national wiring
rules.
WARNING, risk of electric shock. High output voltage. Do not touch uninsulated battery terminals, con-
nectors 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.
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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 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.
CAUTION, undesirable consequences. The situation needs operator awareness or action.
Well-ventilated. Always provide proper ventilation during charging.
WARNING, explosive gases. Lead-acid batteries generate explosive gases during charging.
No open flame. Fire, open ignition source and smoking are prohibited near battery.
Wear protective gloves. The battery cables / battery connectors may become hot during charging.
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.
Target groups:
•Installers
•Operators
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•Maintenance personnel and technicians
Description
Champ Pro is a compact and waterproof battery charger for charging the following lead-acid batteries:
•Standard (STD)/flooded batteries: sealed batteries with a liquid electrolyte (recognisable by the vent plugs) and
low maintenance/maintenance-free flooded batteries.
•Absorbent Glass Mat (AGM) batteries: sealed batteries (VRLA) with immobilized electrolyte (Glass mat).
•GEL batteries: sealed batteries (VRLA) with immobilized electrolyte (gel).
•Traction batteries: vented, closed Pb-flooded batteries with liquid electrolyte. The most common are PzS and
GiS.
The battery types' different charging curves are selectable via the buttons on the charger's front. The charger also
has a power supply mode, 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 defect cells or insufficient cooling etc.
Receiving
On receipt, visually inspect the product for any physical damage. If necessary, contact the transport company.
Check the delivered parts against the delivery note. Contact your supplier if something is missing, see Contact
information.
Installation
NOTE
Installation may only be performed by 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).
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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.
1. 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’s data label. The label is located on
the side of the charger. The charger is normally equipped with fixed mains cable with connector.
2. 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
3. Connect the battery cables to the battery.
Operation
Overview
See Fig. 2 Components and dimensions
1. Mains cable
2. Battery cables
3. LED
4. MODE button
Charging
WARNING
High voltage!
Do not use the battery charger if it is damaged. Disconnect the mains immediately.
Do not touch damaged parts, uninsulated battery terminals, connectors, or other live electrical parts.
Contact service personnel.
Connect and start charging
1. Check the cables and connectors for visible damage.
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2. Connect the battery charger to the battery.
3. Connect the mains cable.
4. Choose battery type or the power supply mode by pressing the MODE button.
(The power supply mode gives a steady output of preset voltage level).
The battery charger starts charging. The time it takes before a battery charger starts charging depends on the:
a. connected battery type
b. battery voltage (> 1.4 V/c)
For more information about the different battery types and their charging curves, see Fig. 1 Charging curves.
Yellow LED:
•The first charging state is initiated.
•Kept lit until the battery is fully charged.
Green LED:
•Indicates that the battery is fully charged.
•The charger now switches to maintenance charging.
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.
For a detailed description, see the section LED indication.
Stop charging and disconnect
WARNING
Risk of explosion!
Do not disconnect the battery when the charging process is in progress. Sparks may occur and cause hydrogen
explosion when charging lead-acid batteries. Arc flash may occur and damage the connector pins. Always stop the
charging process before the battery is disconnected.
1. Turn off the charger by disconnecting the mains cable.
2. Disconnect the battery.
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LED indication
The LEDs lights up or flashes in different patterns to indicate the condition and state of charge (SOC). For more
information about the different battery types and their charging curves, see Fig. 1 Charging curves.
LED indication Off On Flashing
Bottom Middle Top Error
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 and
prevents sulfating of the battery.
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.
RD
Battery temperature > 50 °C (122 °F).
YL
RD
Time error (timeout), the battery is probably too big for the charger.
Maintenance and troubleshooting
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.
WARNING
High voltage!
Do not use the battery charger if it is damaged. Disconnect the mains immediately.
Do not touch damaged parts, uninsulated battery terminals, connectors, or other live electrical parts.
Contact service personnel.
Built-in temperature sensor
A sensor for temperature measurement is built-in in the charger.
•Controls the charging voltage according to the ambient temperature.
•The temperature compensation is for standard batteries 0.2–0.3 V per 10 °C (50 °F) and default is 25 °C
(77 °F), see Fig. 3 Temperature compensation.
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Safety shut-off
Charging is terminated if:
•The ambient temperature, monitored by a temperature sensor, reaches above 50 °C (122 °F).
•The battery is disconnected without the battery charger being turned off.
Charging power is temporarily reduced if:
•The internal charger temperature 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 LED’s on the front
panel, see section LED indication.
Please make a note of any faults and send for authorised service personnel.
Checks
The following are recommended to be done regularly:
1. Check the cables and connectors for damages.
2. Check that the battery is free from defects, in good condition and is the correct type for the battery charger.
3. Check that the battery is properly connected and that the battery fuse, if any, is not broken.
4. Check that the mains voltage is correct and that there are no blown fuses.
Technical data
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: FVLA, VRLA
Output voltage: See data label(2)
Recommended battery capacity:
- Champ 12V/17A: 50–220 Ah
- Champ 12V/30A: 100–400 Ah
- Champ 24V/12A: 40–200 Ah
- Champ 24V/20A: 80–300 Ah
Efficiency: > 90 % at full load
Ingress protection: IP67
Approval: CE and/or UL. See data label(2)
1) 30 to 50 °C (86 to 122 °F) with derated charging power.
2) Located on the battery charger.
Recycling
The battery charger is recycled as metal and electronics scrap. Local regulations apply and must be followed.
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Contact information
Micropower Group AB
Idavägen 1, SE-352 46 Växjö, Sweden
Phone: [phone]
e-mail: [e-mail]
www.micropower-group.com
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Figures
Fig. 1 Charging curves
LED indication
Yellow bottom Yellow middle Green top
Standard (STD) batteries
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GEL/AGM batteries
Traction batteries
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Fig. 2 Components and dimensions
See Overview
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Fig. 3 Temperature compensation
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Approvals
Declaration of Conformity
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