LEAB CLP 600 Charge Booster User Manual

LEAB CLP 600 Charge Booster User Manual

1 About the manual

This user manual is a supplement to the original operating manual from manufacturer Clayton Power. 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 accessories.
Throughout the manual, you will be alerted to warnings and safety notices about potential hazards associated with handling the device. The colors and signal words indicate the severity of the hazard:

Notice
Possibility of property damage The signal word Notice indicates that there is a possibility of material damage. To avoid material damage, follow the instruction.

CAUTION

Danger that can lead to minor injuries A safety instruction with the signal word CAUTION denotes a hazard with a low degree of risk which, if not avoided, can result
in minor or moderate injury. Read the safety information carefully and follow the instructions to avoid it.

WARNING

Hazards that can lead to severe injuries or death A safety instruction with the signal word WARNING indicates a hazard with a medium level of risk which, if not avoided, can
result in death or serious injury. Read the safety information carefully and follow the instructions to avoid it.

DANGER

Danger that will lead to severe injury or death A safety instruction with the signal word Danger indicates a hazard with a high degree of risk which, if not avoided, will result
in death or severe injury. Read the safety information carefully and follow the instructions to avoid it.

You will find notes at some points in the manual. These appear as follows:

TIP Note

A note gives useful tips and information about the product.

2 General Safety

This manual aids safe handling of the device. Use the device solely in accordance with its intended use. Observe the safety instructions.

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 undamaged and the electrolyte is not frozen.

Notice

Device defects from incorrect installation Incorrect installation can result in device defects.

1. Install the device in a dry and cool location

2.1 Intended use

The CLP 600 booster has been developed for permanent installation in vehicles for charging additional batteries (lead and lithium). The device may be used in both 24 V and 12 V vehicle power circuits and charges batteries with nominal voltages of 12 V and 24 V. The emergency start function allows the starter battery to be charged briefly (max. 5 min.) from the additional battery to enable the vehicle to start.
At the output, the unit supplies a DC voltage of 14.4 V or 28.8 V, depending on the charging characteristic, and thereby supplies consumers with power permanently or for a short time. The input voltage is 12 V or 24 V. The device is designed for an operating temperature of -25°C … +80°C.

2.2 Foreseeable misuse

The device is designed for interior use only. Do not mount the device outside the vehicle.

3 About the product

Fig. 1: CLP 600

1. Data connection (M12)
2. Output (+)
3. Ground (GND)
4. Input (+)
5. Jump start button (emergency start)

LEAB Automotive GmbH

Fig. 2: CLP600 dimensional drawing in mm

4 Technical Specifications

5 Package Contents

6 Charging Characteristic

The charging of lead-acid batteries is fully automatic with a five-stage charging characteristic for optimum battery charging.

(Level 1)

| 40 A| 20 A
Stage 2| Constant voltage

(Level 1)

| 14.0 V| 28.0 V
Stage 3| Constant current

(Level 2)

| 10 A| 10 A
Stage 4| Constant voltage

(Level 2)

| 14.4 V| 28.8 V
Stage 5| Charge retention| 13.5 V| 27.0 V

– Level 2 has a time limit of 8 h.
– The charging process restarts in phase 1 when the current in the charge retention
exceeds 10 A.

7 Assembly

To mount the device, perform the following steps:

TIP

Do not mount the device directly next to or above batteries.
Choose a cool, dry and well-ventilated mounting site.
1. Fasten the device to the 4 lateral holes (5 mm Ø). ð The device is mounted.

8 Installation

Fitting the Data Adapter

Fig. 3: Data adapter connectors

Notice

Device defect due to excessive tightening torque
The connection bolts of the device can be damaged by an excessive tightening torque.

1. Apply between 5.5 Nm and 6 Nm tightening torque to each nut.
2. Do not overtighten the nuts.

To connect the batteries (starter battery and additional battery),

perform the following steps:

1. Disconnect the batteries from the vehicle power circuit. WARNING! Disconnect the negative cable first.
2. Secure the positive leads as close as possible to the batteries with suitable fuses (50 A).
3. Connect the outputs (2) and (4) of the device to the positive terminals of the batteries.
4.  Connect the common ground (3) of the device to the negative terminals of the battery.
5. Connect the vehicle batteries to the vehicle power circuit. ð The batteries are connected.

9 Normal Operation

9.1 Switching on the Device

Charging starts automatically when a wake-up signal (pin 2) is applied.

TIP

It is not possible to operate the device without a wake-up signal (Ignition switch, terminal 15).

9.2 Switching off the Device

The device switches off automatically if no wake-up signal (pin 2) is applied.

9.3 Operating Status

The LEDs indicate the operating status of the device.

battery fully charged
| Green, flashing (1 Hz)| Battery charging, charge status lead acid battery

80 %, lithium battery

95%

| Green, flashing (4 Hz)| Battery charging, charge status: lead acid battery <80 %, lithium battery

<95%

Charge| Red, flashing, 1x| Current too high / short circuit.
IN and OUT| | Device requires restart.
| Red, flashing, 2x| Temperature too high. Device auto- matically restarts.
| Red flashing, 3x| Other errors
Jump start| Green, steady light| Emergency start completed.
(Emergency start function)| Green, flashing (4 Hz)| Emergency start active. Starter bat- tery charging.
| Red, flashing| Error, emergency start not possible.
Data| Green, steady light| CAN connection active, device is controlled.
| Green, flashing (1Hz)| CAN connection active, device is not recognised.
IN/OUT 12 V| Green, steady light| 12 V charging active
IN/OUT 24 V| Green, steady light| 24 V charging active

LEAB Automotive GmbH

10 Emergency Start Function

To activate the emergency start function, perform the following step: ü A wake-up signal (Ignition switch, terminal 15) is applied to the device.

1. Press the jump start button for 3 seconds.
   ð The starter battery is charged for a maximum of 5 minutes from the auxiliary battery. The jump start LED (emergency start) flashes green. Do not start the vehicle yet.
   ð The jump start LED (emergency start) is lit green. The starter battery is charged, you can start the vehicle. To end the emergency start function, perform the following step:

2. Press the jump start button.
   ð The emergency start function ends, the charge booster returns to normal operation.

11 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 send it to your point of sale.’

12 EU Declaration of Conformity

The The CLP 600 charge booster from Clayton Power complies with the requirements of the following directives:
– 2014/30/EU: EMC
– 2011/65/EU: RoHS

13 Connection diagram: Lithium battery from Clayton Power

14 Connection diagram: Lead-acid battery

It is prohibited to copy, duplicate, translate or otherwise pass on the content of
this guide to third parties without the express written permission of LEAB.

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