CLAYTON POWER 600W Bidirectional DC and DC Converter User Manual
- June 12, 2024
- CLAYTON POWER
Table of Contents
600W Bidirectional
DC/DC Converter
User Manual
In the box
Tools for installation
T20 Screwdriver
10mm socket wrench
10-120mm² crimp tool
Specification
| Electrical Parameter | Value |
|---|---|
| Supply Voltage | 10,9V – 32V |
| Input Current | 0-45A |
| Output Voltage | 14,4V or 28,8V |
| Output Current | 0-40A |
| Output Control | 5 stage charge |
| Wakeup Input Range | 0-36V |
| Wakeup Input (Deactivate) | <3,0V |
| Wakeup Input (Activate – Delayed 15sec) | >4,0V |
| Power consumption (Idle): | <1,6 W |
| Power consumption (Sleep): | <1 mW |
| Operating temperature range: | -25 to 50 °C |
| Weight: | 620 g |
| Dimensions: | 222 x 110,5 x 40 mm |
| DC Input Operation Parameter | Value (12V) |
| --- | --- |
| Under Voltage (1sec) | 11,5V¹ |
| Under Voltage (30sec) | 12,0V¹ |
| Under Voltage Recover | 12,2V |
| Over Voltage (1sec) | 17,0V |
| Over Voltage (30sec) | 16,0V |
| Over Voltage Recover | 15,0V |
¹- Voltages are compensated by current coming into the DC-DC Converter with a predefined impedance of 15mΩ. (ex: 40A *15mΩ = 600mV Compensation)
| Input | Value | Output | Value |
|---|---|---|---|
| 12V | 0-45A | 12V | 0-40A |
| 12V | 0-45A | 24V | 0-20A |
| 24V | 0-20A | 12V | 0-40A |
| 24V | 0-20A | 24V | 0-20A |
Standards and approvals
Low Voltage Directive 2014/35/EU
EN62368-1:2014
EMC 2014/30/EU
EN61000-6-2:2005, EN61000-6-3:2007 / A1:2011
EN50498:2010 (UNECE Regulation 10)
E13 10R-05 14880 (E-mark)
RoHs Directive 2011/55/EU
EN50581:2012
LED Codes
The LED indications all have same individual behavior:
| LED | Behavior | Indication |
|---|---|---|
| Power | Green | Solid |
| Green | 1 Flash | Standby – wakeup signal active |
| Charge IN or OUT | Green | Solid |
| Green | Flash 1Hz | Constant voltage – (Lead: >80%) – (Lithium: >95%) |
| Green | Flash 4Hz | Constant current – (Lead: <80%) – (Lithium: <95%) |
| Charge IN & OUT | Red | 1 Flash |
| Red | 2 Flash | Temperature too high – recovers automatically |
| Red | 3 Flash | All Other failures |
| Jumpstart | Green | Solid |
| Green | Flash 4 Hz | Jumpstart in progress – do not start the vehicle yet |
| Red | Flash | Jumpstart not able to run. |
| Data | Green | Solid |
| Green | Flash 1Hz | CAN active – unknown device |
| IN/OUT 12V | Green | Solid |
| IN/OUT 24V | Green | Solid |
| IN/OUT 12V & 24V | Green | Solid |
| IN/OUT 12V / 24V | Red | Flashing |
Charge Algorithm
The Charge algorithm is a 5-stage charge cycle with level 1 charging the
battery with high current allowing active loads to be in parallel.
Level 2 is performing the absorption charging at lower current avoiding gas
voltage.
The Level 2 state is time limited avoiding infinite charging if loads absorb
the charge energy.
After the battery is fully charged float charge will keep the battery full
even if loads are active. Charging will restart if loads absorb more than
allowed during float.
| Stage | Description | Value (12V) | Value (24V) |
|---|---|---|---|
| Stage 1 | Level 1 Constant current | 40A | 20A |
| Stage 2 | Level 2 Constant voltage | 14,0V | 28,0V |
| Stage 3 | Level 1 Constant current1 | 10A | 10A |
| Stage 4 | Level 2 Constant voltage1 | 14,4V | 28,8V |
| Stage 5 | Float charge2 | 13,5V | 27,0V |
- Level 2 stage is time limited to 8h and hereafter the battery is considered full.
- If the current overpass 10A during float charge charging is restarted at stage 1.
Installation of an extra lead auxiliary battery
Lead Starter Battery to Lead Aux Battery
DC-DC Converter in a system with Lead Acid start battery and lead acid
Auxiliary battery.
The converter can operate with either a 12V or 24V input battery and a 12V or
24V output battery.
The converter will during start up automatically detect if one or the other
configuration has been selected and all four configurations are possible.
Step 1 – DC Cables
Secure the power cable lug to the terminal studs, first with the spring
washer, then with the nut.
Apply between 5.5 Nm (49 lb-in.) and 6 Nm (53 lb-in.) of torque to each nut.
Do not overtighten the nut.
CAUTION: The maximum torque rating of the terminal studs on the DCDC
Converter is 6.5 Nm (58 lb-in). The terminal studs may be damaged if excessive
torque is applied.
Step 2 – DATA Connection
For automatic charging when the engine turns on.
Not For Production Connect a 0,75 mm² wire to PIN 2 in the M12 connector
- Single Wire
- D+ Ignition Signal
- GND
- CAN High
- CAN Low
Jump start
The DC/DC Converter can provide reverse charge current into the starter
battery giving start aid option. The DC/DC Converter will reverse charge into
the starter battery for 5 min. then the user should be able to start the
vehicle.
To activate jump start
Turn Car Key on.
Push 3 sec on the SETUP button on the DC/DC Converter.
This will activate reverse charging for 5 min. Reverse charging can be
terminated at any time by pushing the select button again.
| 
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Warranty
CAUTION & WARNING:
DO NOT USE OR ATTEMPT TO USE THIS PRODUCT UNTIL YOU HAVE READ THIS USER’S
MANUAL IN ITS ENTIRETY. IMPROPER INSTALLATION OR USAGE OF THIS DEVICE MAY BE
HAZARDOUS AND MAY CAUSE DAMAGE TO OTHER ELECTRICAL EQUIPMENT AND WILL VOID
WARRANTY.
Clayton Power warrants, to the original purchaser only, for a period of 24
months from the date of purchase, that the Clayton Power device will be in
good working order when properly installed and operated as described in this
manual.
If the device fails within this period of time under normal use, Clayton Power
will, free of charge, at a place of Clayton Power’s choosing, repair or
replace the device – with new or reconditioned parts or a new or reconditioned
device as Clayton Power deems necessary.
This warranty is not valid in cases of:
Usage against the recommendations of this manual.
Usage in applications outside of general automotive, solar, industrial or
marine applications without the consent of Clayton Power.
Device modification or repair without written authorization from Clayton
Power.
Reverse polarity, excessive overloading, general abuse, neglect, wear & tear,
ingress of liquids (water, oil, acid, or otherwise), foreign objects,
lightning strikes, over or under voltage, RFI/EMI, etc.
Obtaining Warranty Service
To obtain warranty service, please contact the outlet at which you purchased
your product. Do not contact Clayton Power directly. For warranty service
provide the following:
- Proof of purchase
- The unit model number
- The unit serial number
- A brief description of the application and problem including any failure codes displayed on the unit.
- Contact your Clayton Power dealer for an authorization number prior to dispatch – do not send without authorization.
- Once this number has been obtained, please carefully pack your unit and send (freight paid) to the Clayton Power dealer.
Copyright
The information contained within this document remains the sole property of
Clayton Power. No part of this document may be copied or reproduced in any
form or by any means, and the information contained within is not to be
communicated to third parties, without the prior written consent of Clayton
Power.