User Manual CPC Charger
Contents
1. LEAB Automotive CPC in this manual for information about attaching and releasing the plug type connections as well as assembly instructions for preparing new connection cables Starting charging Connect the mains plug to a Schuko socket in your building installation thus switching the CPC battery charger on After the device has been connected to the mains the operational LEDs start to flash red for 2 seconds while the battery charger checks whether or not a battery is connected If the LED lights up orange charging is taking place according to the set program Never switch the battery charger on until the connection to the battery has been a established Otherwise a fault message will be issued and the battery will not be charged No charging takes place as long as the red LED lights up or flashes Battery voltage 12 V one battery 2v After a few seconds the CPC starts in the selected program and automatically charges the connected battery until it is fully charged If the orange setting LED and the red Error LED are flashing alternately despite correct voltage please check the battery voltage If the voltage is less than 8 V the CPC will not start charging for safety reasons in order to avoid potential hazards caused by exhaustively discharged batteries As soon as the battery is fully charged the LED display changes from orange to green and the charging voltage is reduced to maintenance charging The battery c2. mobile energy CPC Compact Professional Charger Microprocessor controlled battery charger CPC 1215 CPC 1220 CPC 1230 CPC 1260 CPC 2415 CPC 2420 CPC 2430 CPC 2440 CPC 2450 CPC 2460 User M anual Ver 1 0en LEAB Automotive GmbH www leab eu LEAB Automotive CPC Important information about this documentation The technical data information and illustrations have been put together carefully and correspond to the production status at the time the documentation was prepared However the manufacturer retains the right to improve or modify the products specifications and documentation without notice at any time according to technical requirements and the latest development status The descriptions have been prepared in detail and with great care Nevertheless errors can never be ruled out entirely No liability will be accepted for errors of damage which could originate from these or from faulty interpretations The contents of this documentation may not be copied reproduced translated or forwarded to third parties in any other way without the express permission of LEAB Automotive GmbH Caution A Safety note non observance can lead to personal injury or material damage as well as impair the device function Caution Hazard through electric voltage A Safety note non observance can lead to injuries and death as well as damage or destroy the device Note Supplementary information on how to handle the de
3. CPC battery charger is mobile electrical operating equipment in the sense of the German accident prevention regulation BGV A3 or is subject to other regulations of the employers liability association depending on deployment and use This employers liability association regulation prescribes the regular testing of electrical devices for electrical safety usually once a year Please clarify with your employers liability association whether you are affected by this or any comparable regulation and take the measures necessary for the safety of your employees Your employers liability association or work accident insurance company will be able to provide more information A Check the battery charger and cable for damage before you use the device Do not used a damaged device or a device with damaged connection cables have it repaired without delay Have the device checked if it has been in contact with fluids Have the device checked regularly by a qualified electrician Always have any necessary repairs done exclusively by LEAB Spare parts accessories The following spare parts and accessories can be ordered from LEAB Service at bestellung leab eu or in the LEAB shop at http shop leab eu under specification of the article number 4 mainseaei sm Newiccnredor Sukopugd oona Table 3 Accessories also available in other lengths on request LEAB Automotive CPC 3 Specifications 3 1 Technical data
4. lever 1 towards you and turn into the jack on the back connection side of the the connector anti clockwise 2 as far as it will go LEAB CPC 1 and turn the connector clockwise 2 until you can pull the connector out of the jack 3 until you hear a quiet click indicating successful locking LEAB Automotive CPC If you require a longer mains connection cable or one with a plug other than the 250 V 16 A Schuko plug delivered with the device as standard please contact LEAB or your specialist dealer We can make customised connection cables for you at a favourable price We expressly advise against modifying the connection cable yourself fitting other plugs or making new cables The respective national guidelines e g VDE DIN in Germany or guidelines from the associations responsible accident prevention regulations for example must be followed when connecting the device to an existing 230 V installation This work may only be carried out by an appropriately trained electrician The LEAB CPC corresponds to protection class and requires a protective earth conductor to be connected For permanent installation we recommend a cable cross section of 3x 1 5 mm 4 6 Connection of remote display Fig 6 Remote display with connection cable There is also an LED remote display optionally available from LEAB for connection to the RJ45 jack on the back of the device refer also to the drawing in section 4 1 This remote display can be
5. soiled LEAB Automotive CPC Annex A Mains connection plug 230V The following non interchangeable connector is used for the 230V mains connection cable e ACinput connector type Neutrik NAC3FCA blue The connector is available as a spare part from LEAB under the article number 0205900023 Operation of Neutrik connector engagement separation Fitting the Neutrik connector Coding A Type Color coding blue NAC3FCA A type coding blue Cable preparation Connections Insert Clamping piece Union nut LEAB Automotive CPC Annex B Use of lead acid batteries Handling lead acid batteries can be hazardous These batteries produce explosive Ay gases If metal tools are used for work on batteries it is important that the plus and minus terminals can never be touched at the same time A short circuit through a solid metal tool can lead to the battery exploding If acid splashes onto the skin and eyes in particular rinse the parts affected with clear water and seek medical advice immediately The installation location for batteries must be well ventilated Smoking and naked flames are prohibited during work on batteries Regular recharging and maintenance will extend the service life Battery maintenance Lead batteries including ones which are not currently in use must be recharged and serviced regularly This should take place at least once a month during the warm seasons and every thr
6. the voltage increases to up to 15 6 31 2 V at reduced charging current As soon as this phase has been completed the battery charger switches to phase 4 Maintenance charging with reduced voltage U3 phase LED lights up green The charging voltage is reduced to 13 6 27 2 V setting wet cell or 13 8 27 6 V setting gel AGM to keep the battery fully charged over an unlimited time Physical self discharge is compensated and the battery is kept fully charged until it is disconnected During the maintenance phase LEAB CPC battery chargers can operate connected consumers up to the full capacity of the battery charger without any undesired return to main charging The values specified are for 12 V charging setting values for 24 V in brackets LEAB Automotive CPC 2 2 Operation The correct charging characteristic must be set on the CPC battery charger before installation and connection to the battery There are 15 charging characteristics and one test setting stored in the internal battery charger memory these can be requested via a 16 level rotary potentiometer Use the table on the characteristic sheet delivered with the battery charger to choose the appropriate setting for your application depending on battery type and capacity and adjust the charger to this position by turning the potentiometer Potentiometer 1600 W 600 800 W Fig 1 Position of the potentiometer and front display STATUS Attach the enclosed sticke
7. used to display the status of the built in LED providing an additional display of the status of charge and charging parameters for a permanently installed battery charger Refer to section 2 5 for details of the display and appearance of different LED states Article number and type for the remote display can be found in the spare parts and accessories list in section 2 7 of this manual LEAB Automotive CPC 4 7 Connection of sensor cable There is also two sensor cables optionally available from LEAB for connection to the RJ 45 jack on the back of the device refer also to the drawing In section 4 1 CTS cable Sensor for temperature and voltage This sensor cable is used to measure the temperature in the battery environment as well as the voltage directly at the battery terminal and then transmit this to the CPC battery charger The CPC corrects the charging voltage depending on the temperature in order to achieve optimum efficiency and yet gentle battery charging at all times no matter the temperature By measuring the voltage at the battery terminals the CPC can compensate the drop in voltage on the charging cable thus making faster and more efficient charging possible even with long charging cables We recommend the use of the combined CTS sensor cable where charging cables longer than 3 m are used ay TS cable Sensor for temperature This sensor cable can be used to measure the temperature in the direct e
8. 00 Ah 150 600 Ah Ripple lt 3 M ain charging 14 2 14 4 V 28 4 28 8 V Equalisation charging 15 6 V 31 2 V M aintenance charging 13 6 13 8 V 27 2 27 6V Input voltage nominal values 230V 50Hz 8A Input voltage range 90 270 V lt 200 V reduced charging current Input frequency range 0 400 Hz Standby current from the lt 2 mA battery Switching frequency 100 kHz Recommended mains fuse B16 A or C16 A protection faassofpotecion length x width x height OO OO Table 5 Technical data CPC 1600W EQ charging only with charging characteristic for traction batteries option LEAB Automotive CPC 3 2 Dimensional drawing Fig 3 Dimensions CPC 600W 800W left and CPC 1600W right 4 Installation The LEAB CPC has been designed primarily as a built in battery charger but it can also be used as a transportable service battery charger The sturdy rubber corners make stable yet vibration absorbing attachment possible allowing it the be set down or mounted to sensitive surfaces without causing any damage However since the charging cables do not have an additional strain relief fixture we recommend changing to the type LEAB PWC if you wish to use the device permanently as a service battery charger The device feet have suitable seats for attachment bolts for permanent installation allowing the CPC to be attached vertically or horizontally to a wall or table see section 4 2 4 1 LEAB Aut
9. ELVICE ccccceccceecceeeeeeeeseeeseeeceueeeeeeseeesseeseeeseueeseeeseeeseeeseeeesueeseeeseeeseeesanes 13 3 DDECIICAIIONS aae E E A A A EA 14 3 1 Technical gt ee 14 32 WNMCMSIONIAN Gl AWING cuacencovatonosenoset cunsetnnosetanotenmempanetatsintssaisnaianmianciansiansiabstabsinsatobataeutessheratannss 16 4 DIYS TAO IN cscri aaia Aaaa 16 ee CPO CONNECCION eenen 17 A2 WS TAEAUNO MO CANON essa a ante duin hulu cece cadednieaeanpucuiss 17 AD DVICE STAM AON ceis ce atresia ances cpa hunteaean aerate 18 4 4 Conversion of charging cable CPC 600W and 800W only cccceeeeeceeeeeeeeeeeeeeeeesaeeeesaaaees 19 4 5 Connection and conversion of the mains CONNECTION cable ccceccseceseeeceeeceeeeeeeeneeeseeeeaees 19 46 GOnnection Or rem Ole CIS Olay iste stsssepee ee eeee ee 20 4 7 Connection of sensor cable cccccccecccceeeeceeeeceeeeceeeeseeecee cess cece eeseueeseeessueeseueeseneeseueeseneesees 21 4 8 Connection of CBL control relay 600 800W Only ccccecceceeccseeeeseeeeseeeeseeeeseeeeseueeseeeseeeesees 21 ANDOK A a E E E A E E A 23 Mains COMNMECUION DING 230V ircstccccesecenccenesenacdvectconteeuacsuseqeaccesaqeccneceesncswacquecqeacaundeendeetdcuscausveusdausceuseeads 23 PANG D eor E EE 24 Use of ledd acid Daro S E eee nna e eo enon enn manor env em yae Tarr 24 BRENO ANC O eenn nere rise sbumboaamone pamini sane nbammooannesebua mbes mba voumbban moat oanhsinbeanenneoubereeuaneanbans 24 DS a aS NS See
10. Mod CPC 1215 CPC1220 CPC1230 CPC2415 CPC2420 CPC 2430 Article number Type of battery Open and sealed lead acid lead gel AGM batteries Charging characteristic Choice of 15 characteristics see characteristic sheet Rec battery capacity 50 150 Ah 60 200 Ah 90 300 Ah 50 150 Ah 60 200 Ah 90 300 Ah Ripple lt 3 Main charging 14 2 14 4 V 28 4 28 8 V Equalisation charging 15 6 V 31 2V Maintenance charging 13 6 13 8 V 27 2 27 6V Input voltage nominal values 230V 50Hz 4A Input voltage range 90 270 V lt 200 V reduced charging current Input frequency range 0 400 Hz Standby current from the lt 2 mA battery Switching frequency 100 kHz Recommended mains fuse B16 A or C16 A protection Class of protection Operating temperature range 30 60 C IP protective rating IP 20 Housing dimensions 264 x 127 x 86 mm length x width x height Weight without cable 1 5 kg Connection cable Twinflex charging cable 2x6 mm length 1 5 m M ains cable 1 5 m Neutrik connector Schuko plug Weight accessories Charging cable 1 5 m 0 2 kg M ains cable 1 5 m 0 2 kg Table 4 Technical data CPC 600W 800W LEAB Automotive CPC Mod CPC 1260 CPC 2440 CPC 2450 CPC 2460 Article number Type of battery Open and sealed lead acid lead gel AGM batteries Charging characteristic Choice of 15 characteristics see characteristic sheet Rec battery capacity 150 600 Ah 120 400 Ah 140 5
11. an now be disconnected or remain connected to the battery charger until it is used The CPC ensures that the battery remains fully charged in the meantime independently of the time involved Only with charging program with start voltage gt 0 V Choose the correct battery type Standard for wet cell batteries or Gel AGM for sealed lead batteries using gel or AGM technology Your battery will only be charged correctly in this case Individual batteries with a voltage of less than approx 8 V will no longer be charged in the charging setting of the CPC for safety reasons Exhaustively discharged batteries must be pre charged for several hours using a power supply charging program with start voltage 0 V even charges exhaustively discharged batteries LEAB Automotive CPC Battery voltage 24 V two batteries in series After a few seconds the CPC starts in the selected program and automatically charges the connected battery until it is fully charged If the orange setting LED and the red Error LED are flashing alternately despite correctly set voltage please check the voltage of the batteries If the voltage is less than 20 V the CPC will not start charging for safety reasons in order to avoid potential hazards caused by exhaustively discharged batteries Please pre charge the batteries separately As soon as the battery is fully charged the LED display changes from orange to green and the charging voltage is reduced to maintenance ch
12. arging The battery can now be disconnected or remain connected to the battery charger until it is used The CPC ensures that the battery remains fully charged in the meantime Only with charging program with start voltage gt 0 V Choose the correct battery type Standard for wet cell batteries or Gel AGM for sealed lead batteries using gel or AGM technology Your battery will only be charged correctly in this case Depending on the state of charge and size of the battery to be charged it can take up to 18 hours for the batteries to be fully charged again Batteries which are connected up to 24 V and have been exhaustively discharged to under 20 V must always be charged individually to avoid any further damage use a 12 V battery charger for this If sealed lead batteries gel or AGM are charged for longer periods with excessively high voltage they can gas and dry out thus destroying the battery Open wet cell batteries consume water during charging Water must thus be refilled regularly If you are not sure how to charge your batteries please contact your specialist dealer Discharged batteries must be recharged without delay otherwise they can be destroyed LEAB Automotive CPC 2 4 Power supply function CPC batteries chargers with a charging program with start voltage 0 V can also be used without a battery to supply DC consumers up to the maximum capacity of the battery charger In this case it must be noted that the o
13. e LEAB will either repair the device free of charge or replace it at their own discretion New or repaired parts of equal value can be used for replacement A warranty claim cannot be recognised under the following circumstances e The device was not used in accordance with the recommendations given in this manual e The device was used for purposes other than general automotive solar industrial or maritime applications without prior agreement with LEAB e The device was repaired or modified without express permission from LEAB e The device shows signs of damage caused by excess charge penetration of humidity water oil acid mechanical force excess or insufficient voltage or any other non intended use Pre conditions for warranty payments Warranty claims can be made to your specialist dealer or LEAB directly The following documents are required e Invoice or delivery note e Model description or type e Serial number e Detailed description of the fault and installation if appropriate Procedure If the device cannot be put back into operation perfectly according to the instructions in this manual or if the fault persists contact your dealer s Service department or LEAB directly If this is no help either please request a processing form and processing number RM A number as well as a free UPS pick up sticker free UPS pick up service unfortunately only possible without Germany by calling 49 0 4621 97860 120 or sendin
14. ected directly The charging output is protected against inverse polarity the battery or the CPC will not be damaged If you mix up the battery connections charging is not possible with inverse battery connections Sparks can fly if the charging cable is connected to a battery with the battery charger Switched on Make sure there is a good electrical contact clean the battery terminals before connection if necessary All round rubber edges protect any sensitive surfaces the device is set down on Keep the rubber feet in particular clean of dirt and solvents so that this protection effect is not jeopardised Always connect the charging cables to the battery terminals first before you connect the device to the mains in order to avoid sparking Always select the charging program to match the type and size of battery on the CPC the wrong selection can lead to the battery not being charged correctly or becoming damaged due to excess charge Protect the battery charger from water and humidity Check the battery charger regularly for damage and replace any faulty or worn connection cables immediately Do not open the device there are no components the user can operate inside the device Clean the device feet regularly and do not expose them to acids oil and aggressive cleaning agents When charging refillable lead acid batteries open the cover so that any gases produced can escape Clean the air inlets and outlets regularly if heavily
15. ee months in the cold seasons Older and poorly maintained batteries should be checked every two weeks Open batteries The fluid level in open batteries should be checked and the acid density measured using an acid siphon They must be recharged if necessary A clean and dry battery surface will lead to a longer service life Soiling and any acid marks should be removed carefully This can be done using warm water and a soda solution Then rinse off with clear water and dry carefully M ake sure that the ventilation caps have been fitted cleanly and correctly In addition the connection terminals must be checked for a tight fit The terminal screws should always be tightened Make sure that the cell grids are covered with acid Only distilled water may be used for topping the battery up Never use normal drinking water Do not fill up with too much water this would reduce the acid density and thus the battery capacity heed manufacturer instructions Sealed batteries Sealed batteries are low maintenance The acid is bound through gel or in a fleece AGM and can therefore not evaporate Testing is limited to measuring the battery voltage To achieve a plausible result the battery must not have been charged for several hours prior to testing However simply testing the voltage is not necessarily sufficient since sulphating can increase voltage even if capacity is reduced More accurate conclusions can only be drawn by using a suitable ba
16. g a mail to service leab eu You can send the defective device to us together with these documents We will then examine it and repair it if necessary LEAB Automotive CPC CE Declaration of Conformity The product LEAB CPC with the types CPC 1215 CPC 1220 CPC 1230 CPC 1260 CPC 2415 CPC 2420 CPC 2430 CPC 2440 CPC 2450 CPC 2460 complies with the requirements of the directives 2006 95 EC 2004 104 EC and 2005 83 EC The following harmonised standards were used EN 60335 2 29 1996 A11 97 IEC335 2 29 2002 modified EN 60335 1 1994 A11 95 A1 96 A12 96 A13 98 A14 98 A15 00 A2 00 A16 01 as well as EN 61204 3 2000 EN 50366 2003 Al Busdorf 01 07 2013 Kg QJ D Bart Westerkamp M anaging Director LEAB Automotive CPC LEAB Automotive GmbH Thorshammer 6 D 24866 Busdorf Germany Fon 49 0 4621 97860 110 Fax 49 0 4621 97860 260 Email anfrage leab eu www leab eu semen o 5 D Ras 0 200 ISO O LEAB is certified to ISO 9001 2008 and 14001 2004 Mi Mil a
17. g mechanisms on the cable terminals which are used to attach the charging cables to the charging output and pull the old charging cables out Push the stripped ends of the new charging cables completely into the terminal guides To do this twist the ends of the wires slightly and release the locking mechanism using a screwdriver before pushing the ends in Pull the screwdriver out when the cables have been pushed in completely so that the locking mechanism can grip tightly Pull the new charging cable firmly a few times to check whether the locking mechanism holds Note the polarity specifications on the label next to the charging output Connect the red charging cable to the left hand output marked and the blue or black charging cable to the right hand output marked 4 5 Connection and conversion of the mains connection cable When the LEAB CPC is mounted on the wall or used as a transportable battery charger the 1 5 m mains connection cable delivered with the device may not always be sufficient and may need replacement To make this modification easier for you the mains connection cable is connected to a Neutrik connector system See Annex A of this manual for instructions on fitting the Neutrik connector To insert and remove the mains connection cable to and from the battery charger please proceed as follows i engagement separation Engagement Separation Insert the blue Neutrik connector on the mains cable Pull the silver locking
18. indicates the different operating and fault statuses The different statuses are indicated by permanent or flashing light See section 2 2 on the position of the LED LED display on the battery charger Permanent light Battery is being charged the CPCis in none orange the main charging phase Permanent light Battery fully charged the CPCisinthe The battery charger can be unplugged and the green maintenance charging phase battery used Permanent light No battery connected or connected Check the battery connection measure the battery battery exhaustively discharged voltage pre charge the battery using the power supply Flashing Time exceeded in the main charging Battery faulty Check battery red phase charging interrupted Battery too large for the battery charger choose larger battery charger Parallel consumers too large Switch consumers off during charging Table 1 LED display on the CPC battery charger Pre charging Is not necessary for programs with start voltage 0 V LED display on the optional remote display If you have the optional LED remote display installed see section 4 5 the CPC statuses will also be displayed there in the same way as described above 2 6 Troubleshooting LEAB Automotive CPC If your LEAB CPC is not working as it should please try to localise the fault using the following procedure first If this is not successful please contact your specialist dealer or LEAB Have the serial number a
19. istic set incorrectly The battery can become damaged LEAB Automotive CPC e Dry well ventilated and dust free installation location e Keep the distance to the batteries as short as possible to achieve short cable lengths e Do not install the device directly next to or above the batteries e The device must be protected from the effect of dust and humidity e Make sure that the fan can intake cooling air freely e Do not install the device directly next to or above inflammable materials 4 3 Device installation Install the device on a level horizontal or vertical surface The four recesses on the rubber feet are for attachment Use screws with a diameter of 5 mm installation Dimensional drawings can be found in section 3 2 The built in fan guarantees optimum cooling independently of the direction of Vertical installation option Attachment screws 5 mm Fig 5 Attachment CPC LEAB Automotive CPC 4 4 Conversion of charging cable CPC 600W and 800W only Depending on the application it can be necessary to replace the charging cable fitted to the LEAB CPC This can be due to cable damage or in order to fit a cable of a different length than the one already fitted Standard electric cables of the corresponding cross section can be used as replacement cables To remove the charging cable disconnect the LEAB CPC from the mains and from the battery Use a slim screwdriver to carefully release the two clamp lockin
20. nd date of purchase on hand as well as an accurate description of the fault so that we can help you as quickly as possible LED display on the battery charger The figures refer to the corresponding chapters in this manual Lock Neutrik connector Insert mains plug Switch the mains fuse on no no Battery is not being charged Is the LED lit green Maintenance charging check voltage no Main charging Check charging program 2 3 Check battery voltage Battery faulty Is the LED lit orange no ye Connect battery 2 3 Is the LED Check voltage flashing red Select power supply function 2 4 Check charging no cable Is the LED lit red Connect battery 2 3 Check voltage Select power Is the Neutrik connector lankad supply function 2 4 Check charging ye cable Is the mains Is the mains fuse OK ye Contact LEAB Service LEAB Automotive CPC 2 7 Maintenance and service Regular tests Check the battery charger before every use as follows e Arethe mains cable and mains plug undamaged e Arethe charging cable and connections undamaged e isthe charging cable fixed safely to the battery charger e isthe outside of the battery charger undamaged and not opened e Has the battery charger been in contact with water oil or other fluids When used for commercial applications the LEAB
21. nd the use of a safety fuse in the plus cable with the following values Type c cpcazzo crci230 CPC2415 CPC2a20 Cross 6 mm 6 mm 6 mm 6 mm 6 mm section Type CPC2430 CPCI260 CPC2440 CPC2450 CPC2460 Fuse o 50A A TSA A TSA A O a A eo A a a mm Taa mm T mm ee mm T mm section The cross sections of the charging cables must not be reduced We recommend keeping the charging cables as short as possible and not extending them There are three sockets on the back of the CPC battery charger only 2 sockets on the CPC 1600W which can be used to connect additional devices see section 4 6ff Assignment is as follows Remote display Temperature voltage sensor CBL relay not CPC 1600W 2 3 2 Battery outside the vehicle Connect the two charging cables to the battery terminals as follows e red end of the cable to the plus terminal of the battery marked e blue end of the cable to the minus terminal of the battery marked Only use suitable battery terminal clamps and protective pole caps such as the ones you can find In our range at http shop leab eu 230V mains connection There is a connection socket for the 230V mains cable on the back of the CPC battery charger The plug system of the type Neutrik can be locked thus guaranteeing safe and vibration resistant contact in every vehicle yet providing maximum flexibility during installation and removal Please refer to Annex A
22. nvironment of the battery and transmit this to the CPC battery charger The CPC corrects the charging voltage depending on the temperature in order to achieve optimum efficiency and yet gentle battery charging at all times no matter the temperature We recommend the use of the TS temperature sensor cable where charging cables up to 3 m in length are used Available versions can be found under Accessories in section 2 7 4 8 Connection of CBL control relay 600 800W only There is a potential free changeover contact installed in the battery charger versions of the LEAB CPC series 600W and 800W which switches during charging operation There is a suitable adapter cable set with RJ45 connector and three open cable ends available for more straightforward connection This option can be used for example as an electrical ignition interlock for a 230 V connection or for charging monitoring green Pin 3 Switching function contact changeover Technical Data Isolation Load max values black Pin 1 l Battery charger off Pin 1 connected to Pin 3 Output against housing 500 V 24 VDC 0 5A Battery charger on Pin 1 connected to Pin 2 Output against ground 120 V 120 VAC 0 5 A red Pin 2 Fig 7 Connection assignment and technical data for switched output CBL LEAB Automotive CPC General notes The charging output is short circuit proof no hazardous state occurs for the device even when the charging cable is conn
23. omotive CPC CPC connections Cn DOOOOUOMOOORNOO JUEEBEEH Neutrik connection 230V Connection Connection RJ45 RJ45 RJ45 plus minus connection CBL connection connection charging charging relay not sensor cable remote display cable cable 1600W Fig 5 View of CPC from the back connection side 4 2 Installation site The following environmental conditions must be given if you want to install the battery charger for stationary use A Choose a dry and dust free spot not too hot for installation The LEAB CPC can be attached horizontally to a level panel as well as horizontally or vertically to a wall Optimum cooling is achieved with the LED side facing downwards Make sure there is sufficient and unobstructed cooling air flow so that the heat produced can be dissipated safely Do not install the device directly next to or above inflammable materials Never install the battery charger in the direct vicinity of open wet cell batteries The acid vapours produced during charging can corrode and thus destroy the PCB and other components Do not use a charging cable with a cross section smaller than the one delivered with the device Protect your battery charger from excessive heat impact This reduces performance and can shorten the service life Heed the installation guidelines for other devices e g radio controlled devices to avoid mutual influence Never charge with the charging character
24. onnection to the battery by a Constant current Constant voltage mantenance a selected one of the 15 characteristic curves a stored in the device Charging with constant current I phase LED lights up orange Depending on the battery s state of charge maximum charging current is used in order to store as much energy as possible in the battery as quickly as possible If an exhaustively discharged battery is connected for charging the battery charger starts charging at reduced current to prevent damage to the battery After the set main charging voltage has been reached 14 2 28 4 to 14 4 28 8 V depending on the battery type the battery charger switches to the next charging phase Charging with constant voltage U phase LED lights up orange The actual full charging of the battery takes place in this phase The voltage is kept contact at a value of 14 4 28 8 V setting gel AGM or 14 2 28 4 V setting wet cell As the battery charge increases the current drops continually and approaches a lower limit which depends on the type and size of the battery As soon as the value drops below this limit or a set minimum charging time has been exceeded the battery charger switches to phase 3 Equalisation charging U phase LED lights up orange only with the program for traction batteries Following the main charging phase the electrolyte is stabilised any sulphating of the plates is degraded Depending on the battery type set
25. our order by email to bestellung leab eu Overview of available types To make presentation easier we distinguish between three series of CPC battery chargers depending on the capacity of the power supply The basic properties such as dimensions weights and electrical equipment are identical within one such group Compare the technical data listed in Chapter 3 Series 600W Series 800W Series 1600W CPC 1215 CPC 1230 CPC 1260 CPC 1220 CPC 2420 CPC 2440 CPC 2415 CPC 2430 CPC 2450 CPC 2460 LEAB Automotive CPC 2 Performance characteristics and operating functions The portable battery charger LEAB CPC has been developed both for mobile use and stationary installation in vehicles for the charging of all types of lead batteries Thanks to their compact design high capacity and very good interference suppression LEAB battery chargers have been used for years wherever optimum mobile battery charging is essential Custom charging programs are available for special applications and also provide a suitable solution for special applications such as the charging of traction or lithium batteries 2 1 Charging procedure Battery charging takes place completely Voltage automatically and controlled by micro processor with a three stage IU 0U gt charging characteristic for optimum and gentle battery treatment The charging parameters can be adapted to the type and capacity of the batteries to be charged during installation and before c
26. r in such a way that it covers the setting potentiometer and a the recess is over the multi colour LED Refer to section 2 5 of this manual for details of the LED status display and the meaning of the colour code of the three colour LED Fig 2 LED status sticker Choose the correct battery type Standard for wet cell batteries or Gel AGM for sealed lead batteries using gel or AGM technology from the characteristic sheet Your batteries will only be charged perfectly when the correct setting has been made See your battery data sheet for information on battery charging or ask your battery Supplier If you have any questions about the correct charge setting please contact LEAB or your battery manufacturer Other charging programs for special applications are available on request impaired and the battery will not reach its capacity The wrong charging characteristic can damage or destroy the battery A If batteries are charged using an unsuitable characteristic their performance can be LEAB Automotive CPC 2 3 Connection If you want to use the LEAB CPC as a mobile battery charger please continue with section 2 3 2 2 3 1 Battery in the vehicle Connect the two charging cables fixed to the LEAB CPC as follows e red end of the cable to the plus terminal of the battery marked e black end of the cable to the minus terminal of the battery marked or an earth contact point provided near the battery We recomme
27. s se cen cg sine scansasencacaccesceesaacsaaescacacausscascasaaaesaacacauaacsseasaceesaceacaasasssessaceessseacaasasssaacs 24 ealed Da MOr a ere ne ee nee 24 BS Sl a Sate eect EEE EE E E E E E cece dare te cece Secs ead dtd ite eds dn rude us E E E E 25 ANNER arn EEEN ants ce cle ee ees ee ewe ee ce te ee ee ec ee ee 26 EUS IO VV ANNU Species E E otis sale sence suet een nus usa us esse se 26 CE Declaration OF COMIOnMNY saciseiveseawinrreserteriiesere enn eerie een eee eee 27 LEAB Automotive CPC 1 Scope of supply With the LEAB battery charger CPC you have purchased a high quality battery charger that you can use both permanently installed in vehicles and in mobile workshop applications Please check before you use the charger whether the following items are included in the box e Battery charger CPC of the required voltage and output see specifications on the rating plate e Mains connection cable 230VAC 1 5 m long with Schuko plug e Battery charging cable 2x 6 10 mm2 1 5 m long permanently attached e English manual this document If the scope of supply does not correspond to these items or the charger or connection cable are damaged please contact your dealer or LEAB directly If you should require a further copy of the manual you can download this in PDF format from www leab eu free of charge If you should require spare parts or accessories for your LEAB battery charger CPC please see section 2 7 of this manual and send y
28. ttery tester e g Midtronix M DX for tests LEAB Automotive CPC Summary of maintenance points e Make sure that batteries are always fully charged only use suitable high quality battery chargers such as LEAB CPC Do not part charge batteries if possible e Regular charging reduces the risk of irreversible permanent sulphating e Open wet cell batteries must be topped up regularly using distilled water e Battery surface and terminals must be dry and clean e The connection terminals must be covered with terminal grease e Do not expose batteries to a hot environment e Check the connection terminals for a tight fit at least once a year e Replace any batteries which bulge are cracked or leaking Battery storage e Store batteries in a cool but frost free and dry environment e Never store batteries in a discharged state They should be charged to at least 75 e f batteries are stored for longer periods check their state of charge at regular intervals and recharge if necessary e In very cold environments continuous maintenance charging prevents the battery freezing LEAB Automotive CPC Annex C Extent of Warranty Providing installation has been carried out professionally and the devices are used according to their intended purpose LEAB offers mandatory warranty over a period of 24 months after the date of purchase If any defects of faulty functions should occur during this period under normal conditions of us
29. utput voltage is reduced after a short time from the higher main charging voltage to the lower maintenance charging voltage This allows vehicles to be supplied with voltage even when the battery has been removed thus avoiding the time consuming and tedious re programming of customer settings in the on board computer and radio system LEAB can equip all CPC battery chargers with the suitable power supply program for exclusive use as a power supply Please contact LEAB Service in this case Charging programs must be stated in your order for the CPC battery charger so that they can be installed in the battery charger Optional extra Power supply function is only available for devices with start voltage 0 V or with Special power supply program The power supply output is resistant to short circuit and overload but longer short circuit should still be avoided to prevent the charging cable and LEAB CPC becoming too hot The optional power supply program is also suitable for pre loading exhaustively discharged batteries which are no longer detected by a battery charger for a few hours or for regenerating them If you would like to use the LEAB CPC in combination with diode distributors or the charging current distributor LEAB CDB you must always choose a charging characteristic with 0 V start voltage LEAB Automotive CPC 2 5 Control display and fault descriptions The control lamp three colour LED on the front of the device
30. vice LEAB Automotive GmbH Thorshammer 6 D 24866 Busdorf Germany www leab eu Important note on using the device To avoid operational errors you should read this manual carefully before installation and before initial use and always follow the respective instructions Please keep this manual near the charger for future reference so that operators can use it to find out about the device s functions LEAB Automotive CPC Contents Page Important note on using the device ace ets ct cso ei ce es rene cs we ce 2 1 SCOPE OF SUDD roche etre ecteecteec E EEEE stew sensor sesveeseess 4 2 Performance characteristics and Operating functions c cccceseeeeeeeeeeeeeeeeneeeneeenesenseeeneseaes 5 2am GNO DOCE 0 e ee ee ec ee a ec 5 2R 1 621 6 Ren ee nn nen eee 6 2S GONNE 61416 PREM Rene ee eee ee ee ne eee ee eee ee ee 7 2 3 1 Battery in the VENICIC cccccceccsecceeeseeeeeeneeeeeeseeeneeeeeeseeesseceeeseeeseeseeeseeesueseeseeesueseeeseeeaueneeenass 7 2 3 2 Battery outside the vehicle cece ceccceeccseceeeeeceeeeeeeeaeeeaeeeseeeseueceeeseeeseueeseeeseeeseeeseueeeeeseeeseeess 7 2A POWT UPYA ION errore A EEE EREE E 10 2 5 Control display and fault descriptions cece eeccceeeeceeeeeeeeesaeeeseeeeeeeeeeeeeesaeeessaeesseesaeeeeaeeeas 11 20 WVOPNDIS SIO OMI sss cae scacacatascecenaacaescacacasacseecsasccescasncatsacteaaceasasacaaeasseatsaaceaacaasascnassacssaueaesacsesssans 12 2 7 Maintenance ANd S
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