LEAB ABC 1.6 KW Battery Charger User Manual
Brand: LEAB
Manufacturer: LEAB Automotive GmbH
Version: 6
Date: 01/09/2022
Website: www.leab.eu
1 About this Manual
This manual provides essential information for the safe and effective use of the LEAB ABC charger. It is recommended to read this manual carefully and keep it in a safe place. Any modifications to the product or its components are prohibited and do not conform to its intended use. Only original LEAB or LEAB-approved accessories should be used.
The manual uses signal words and colors to indicate the severity of potential hazards:
- Notice (Blue): Indicates a possibility of material damage. Follow the instruction to avoid damage.
- CAUTION (Yellow Triangle): Indicates a hazard that can lead to minor injuries. Safety instructions with this signal word, if not avoided, can result in minor or moderate injury.
- WARNING (Yellow Triangle): Indicates a hazard that can lead to severe injuries or death. Safety instructions with this signal word, if not avoided, can result in death or severe injury.
- DANGER (Red Triangle): Indicates a hazard that will lead to severe injury or death. Safety instructions with this signal word, if not avoided, will result in death or severe injury.
- TIP (Information Icon): Provides additional, useful information.
2 Safety
This user manual is designed to help you handle the unit safely. Use the unit solely in accordance with its intended use and observe all safety instructions. Keep this manual in an easily accessible place.
2.1 Intended Use
The ABC charger is developed for permanent installation in vehicles for charging lead-acid batteries. It is designed for a temperature range of -30°C to +60°C. Charging outside this range is not recommended, as higher temperatures will automatically decrease the charger's output power.
Connect the mains plug to easily accessible 230 V sockets to allow for quick intervention in case of a fault.
Warnings:
- WARNING: Risk of fire from overheated battery. Flammable gases can escape if the battery overheats. Always charge batteries in well-ventilated rooms and away from ignition sources.
- WARNING: Burns from escaping acid. Acid can leak out when handling batteries. 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. Before using the battery, ensure it is undamaged and the electrolyte is not frozen.
2.2 Foreseeable Misuse
The charger is designed for permanent installation in vehicles and should never be installed outside the vehicle. Do not expose the unit to strong sunlight for extended periods. This charger is intended only for charging batteries and must not be used as a starting aid.
To avoid damage, do not pinch the charger leads. If the charger is damaged, unplug it immediately and contact your dealer.
Notice: Device defects from incorrect installation. Incorrect installation can result in device defects. Install the device in a dry and cool location.
3 About this Product
The LEAB ABC charger is designed for permanent installation in vehicles for charging lead-acid batteries. Its compact design, high performance, and excellent radio interference suppression have made LEAB chargers a trusted choice for many years where optimum battery charging is required.
Front View Description (Fig. 1):
- 1: Potentiometer for setting the charging characteristic.
- 2: Potentiometer for fine adjustment of the output voltage.
- 3: Status display LED.
Connection Side Description (Fig. 2 & 3):
- 1: AC wire connection.
- 2: Sensor cable connection (CTS/TS).
- 3: CBL connection.
- 4: DC wire connection.
- 4 (Fig. 3): Remote display connection.
4 Package Contents
| Package Contents | No. |
|---|---|
| Battery charger | 1x |
| Mounting clamp | 2x |
| User manual | 1x |
5 Technical Specifications
The following table details the technical specifications for various LEAB ABC charger models:
| Model | Part no. 0101036178 | Part no. 0101036431 | Part no. 0101036040 | Part no. 0101036050 | Part no. 0101036437 | Part no. 0101036430 | Part no. 0101036060 | Part no. 0101036074 | Part no. 0101036179 | Part no. 0101036170 |
|---|---|---|---|---|---|---|---|---|---|---|
| Battery type | Lead acid (wet, gel/AGM) | Lead acid (wet, gel/AGM) | Lead acid (wet, gel, AGM) | Lead acid (wet, gel, AGM) | Lead acid (wet, gel/AGM) | Lead acid (wet, gel/AGM) | Lead acid (wet, gel, AGM) | Lead acid (wet, gel, AGM) | Lead acid (wet, gel/AGM) | Lead acid (wet, gel/AGM) |
| Battery capacity | 200 Ah ... 1,000 Ah | 90 Ah ... 300 Ah | 120 Ah ... 400 Ah | 140 Ah ... 500 Ah | 90 Ah ... 300 Ah | 90 Ah ... 300 Ah | 150 Ah ... 600 Ah | 150 Ah ... 600 Ah | 200 Ah ... 1,000 Ah | 150 Ah ... 600 Ah |
| Charging characteristics | 15 optional characteristics (see characteristics sheet) | 15 optional characteristics (see characteristics sheet) | 15 optional characteristics (see characteristics sheet) | 15 optional characteristics (see characteristics sheet) | 15 optional characteristics (see characteristics sheet) | 15 optional characteristics (see characteristics sheet) | 15 optional characteristics (see characteristics sheet) | 15 optional characteristics (see characteristics sheet) | 15 optional characteristics (see characteristics sheet) | 15 optional characteristics (see characteristics sheet) |
| Charging current | 100 A | 30 A | 40 A | 50 A | 30 A | 30 A | 60 A | 60 A | 100 A | 60 A |
| Ripple | < 3% | < 3% | < 3% | < 3% | < 3% | < 3% | < 3% | < 3% | < 3% | < 3% |
| Main charging | 14.2 V/14.4 V | 54.0 V/57.6 V | 28.4 V/28.8 V | 28.4 V/28.8 V | 54.0 V/57.6 V | 54.0 V/57.6 V | 28.4 V/28.8 V | 28.4 V/28.8 V | 14.2 V/14.4 V | 14.2 V/14.4 V |
| Trickle charging | 13.6 V/13.8 V | 40.5 V | 27.2 V/27.6 V | 27.2 V/27.6 V | 40.5 V | 40.5 V | 27.2 V/27.6 V | 27.2 V/27.6 V | 13.6 V/13.8 V | 13.6 V/13.8 V |
| Input voltage (rated values) | 230 V/ 50 Hz/4 A | 230 V/50 Hz/4 A | 230 V/50 Hz/4 A | 230 V/50 Hz/4 A | 230 V/50 Hz/4 A | 230 V/50 Hz/4 A | 230 V/50 Hz/4 A | 230 V/50 Hz/4 A | 230 V/ 50 Hz/4 A | 230 V/ 50 Hz/4 A |
| Input voltage | 230 V | 230 V | 230 V | 230 V | 230 V | 230 V | 230 V | 230 V | 230 V | 230 V |
| Input values | 90 V ... 270 V (< 200 V reduced charging current) | 90 V ... 270 V (< 200 V reduced charging current) | 90 V ... 270 V (< 200 V reduced charging current) | 90 V ... 270 V (< 200 V reduced charging current) | 90 V ... 270 V (< 200 V reduced charging current) | 90 V ... 270 V (< 200 V reduced charging current) | 90 V ... 270 V (< 200 V reduced charging current) | 90 V ... 270 V (< 200 V reduced charging current) | 90 V ... 270 V (< 200 V reduced charging current) | 90 V ... 270 V (< 200 V reduced charging current) |
| Input frequency | 47 Hz ... 400 Hz | 47 Hz ... 400 Hz | 47 Hz ... 400 Hz | 47 Hz ... 400 Hz | 47 Hz ... 400 Hz | 47 Hz ... 400 Hz | 47 Hz ... 400 Hz | 47 Hz ... 400 Hz | 47 Hz ... 400 Hz | 47 Hz ... 400 Hz |
| Switching frequency | 100 kHz | 100 kHz | 100 kHz | 100 kHz | 100 kHz | 100 kHz | 100 kHz | 100 kHz | 100 kHz | 100 kHz |
| Mains fuse | B16 A or C16 A | B16 A or C16 A | B16 A or C16 A | B16 A or C16 A | B16 A or C16 A | B16 A or C16 A | B16 A or C16 A | B16 A or C16 A | B16 A or C16 A | B16 A or C16 A |
| Degree of efficiency, max. | > 88% | > 88% | > 88% | > 88% | > 88% | > 88% | > 88% | > 88% | > 88% | > 88% |
| Protection class | I | I | I | I | I | I | I | I | I | I |
| Operating temperature | -30°C ... +60°C | -30°C ... +60°C | -30°C ... +60°C | -30°C ... +60°C | -30°C ... +60°C | -30°C ... +60°C | -30°C ... +60°C | -30°C ... +60°C | -30°C ... +60°C | -30°C ... +60°C |
| IP rating | IP21 | IP21 | IP21 | IP21 | IP21 | IP21 | IP21 | IP21 | IP21 | IP21 |
| Dimensions (L x W x H) | 265 mm x 135 mm x 85 mm | 265 mm x 135 mm x 85 mm | 265 mm x 135 mm x 85 mm | 265 mm x 135 mm x 85 mm | 265 mm x 135 mm x 85 mm | 265 mm x 135 mm x 85 mm | 265 mm x 135 mm x 85 mm | 265 mm x 135 mm x 85 mm | 265 mm x 135 mm x 85 mm | 265 mm x 135 mm x 85 mm |
| Weight | 2.6 kg | 2.6 kg | 1.5 kg | 1.5 kg | 2.6 kg | 2.6 kg | 1.5 kg | 1.5 kg | 2.6 kg | 2.6 kg |
| AC wire | 1.5 m, 1 mm² | 1.5 m, 6 mm² | 1.5 m x 1 mm² | 2 m, 1.5 mm² | 1.5 m x 6 mm² | 1.5 m x 6 mm² | 1.5 m x 1 mm² | 1.5 m x 1 mm² | 1.5 m, 1 mm² | 1.5 m, 1 mm² |
| DC wire | 2 x 1.5 m, 25 mm² | 2 x 4 m, 6 mm², open | 2 x 2 m, 10 mm² | 2 x 2 m, 10 mm² | 2 x 4 m, 6 mm², open | 2 x 4 m, 6 mm², open | 2 x 2 m, 10 mm² | 2 x 2 m, 10 mm² | 2 x 1.5 m, 25 mm² | 2 x 1.5 m, 10 mm² |
| CBL connection | No | Yes | No | No | Yes | No | No | Yes | Yes | No |
| CTS/TS connection | Yes | Yes | Yes | Yes | No | Yes | Yes | Yes | No | Yes |
| Remote display connection | Yes | No | Yes | Yes | Yes | Yes | Yes | Yes | No | Yes |
| On/off switch | No | No | No | No | No | No | No | No | No | No |
6 Charging Characteristics
The ABC charger offers 15 different charging characteristics that can be selected before connecting to the battery. Charging is fully automatic and micro-processor controlled, utilizing a 3-stage IU₁U₂ characteristic curve for gentle and optimum battery charging.
A graphical representation of the charging characteristic curve shows voltage and current stages over time, illustrating the IU₁U₂ process. The available charging characteristics can be found in the appendix.
7 Setting Charging Characteristics
Notice: Battery defect due to incorrect charging. To protect the battery from damage, set a suitable charging characteristic before installation, following the battery manufacturer's instructions.
To set a charging characteristic:
- Turn the potentiometer to the desired position (refer to the characteristics sheet in the Appendix). The arrow in the middle of the potentiometer indicates the selected characteristic.
- To prevent accidental adjustment, affix the supplied sticker onto the potentiometer. Ensure the notch on the sticker is aligned above the LED.
The charging characteristic is now set.
Adjusting the Output Voltage
The output voltage can be adjusted using the potentiometer (±0.75 V).
Notice: Battery defect due to incorrect charge voltage. If using the fine adjustment, regularly check the charge voltage.
To adjust the output voltage:
- Turn the fine adjustment potentiometer until the desired charge voltage is reached.
The output voltage is now adjusted.
8 Assembly
To assemble the unit:
- Choose a cool, dry, and well-ventilated assembly site.
- Do not mount the unit directly next to or above batteries.
- Ensure adequate cooling by providing an unimpeded supply of cooling air.
- Fasten the assembly bracket to the unit using the 4 lateral holes (5 mm Ø).
The unit is now assembled.
9 Installation
9.1 Connecting the Battery
To connect the battery:
- Disconnect the battery from the vehicle power circuit.
- WARNING! Disconnect the negative cable first.
- Secure the positive cable of the device as close as possible to the vehicle battery with a suitable fuse.
- Connect the positive cable of the unit to the positive terminal of the battery.
- Connect the negative cable of the unit to the negative terminal of the battery.
- Reconnect the vehicle battery to the vehicle power circuit.
The battery is now connected.
9.2 Connecting the Unit to the 230 V Mains
To connect the unit to the 230 V mains:
- Connect the mains plug to a 230 V mains outlet.
The charger is now connected to the 230 V mains.
9.3 Connecting the Sensor Cable
The TS sensor cable measures the ambient temperature to optimize battery charging. The CTS sensor cable measures the battery temperature and voltage for optimal charging.
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 into the ABC chargers, which switches during charging. This can be used, for example, to implement an electrical start interlock with a 230 V connection or for charge monitoring.
Switching Function of the Changeover Contact:
- Pins 1 and 3 are connected when the charger is switched off.
- Pins 1 and 2 are connected when the charger is switched on.
9.5 Connecting the Remote Display
The remote display shows the battery's charge status via an LED.
To connect the remote display:
- Plug the connecting cable for the remote display into the charger's remote display connector.
The remote display is now connected.
10 Operation
10.1 Switching on the Unit
To switch on the unit:
- Connect the mains plug to a 230 V mains outlet.
- If your unit is equipped with an on/off switch, set the switch to position 'I'.
Charging starts automatically. The unit is switched on.
10.2 Charging the Battery
The ABC charger begins to charge the battery as soon as it is switched on.
10.3 LED Status Display on the Charger
| Status | Description | Action |
|---|---|---|
| Steady light, orange | Battery is charging. The charger is in the main charging 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. |
|
| Flashing, red | Timeout in the main charge phase, charging interrupted. |
|
11 Maintenance
Check the charger before each use:
- 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 secure.
NOTE: For battery maintenance, refer to the battery manufacturer's instructions.
12 Disposal
Dispose of the device in accordance with the Waste Electrical 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.
[WEEE symbol for disposal]
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
CE
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