CLAYTON POWER Li-G4 Lithium Power Supply Instruction Manual

CLAYTON POWER Li-G4 Lithium Power Supply

Specifications

• Product Name: Li-G4
• Classification: Class 9 dangerous goods (UN3480)
• Chemistry: Lithium iron phosphate (LiFePO4/LFP)
• Variants: 100Ah and 280Ah
• Nominal Voltage: 12.8V
• Features: Control, Synchronization, Data logging, Firmware update
• Protection Mechanisms: Short-circuit protection, Overcurrent protection, Internal fuse

Product Usage Instructions

Installation and Safety

• Ensure that the installation of the Lithium Power Supply complies with national safety regulations, enclosure requirements, and IP54 ingress protection. It is recommended to have installations performed by authorized professionals.
• Before making any connections, switch off the system and check for hazardous voltages. The Lithium Power Supply should only be serviced by trained personnel.

Getting Started

Product Box Contents:

• 1x Li-G4 battery
• 2x M12 connectors
• 2x M8 bolts (With washers)
• 1x M4 bolt

Product Details:

Front View:

1. Terminal (+)

2. Terminal (-)

3. Power button

4. SOC indication

5. Wake-up (M4 terminal)
   Rear View:

6. Type plate

7. Pressure valve

Product Usage
The Li-G4 is a module-based lithium iron phosphate battery known for its safety and reliability in energy storage. It comes in two variants with different capacities to suit various applications. The integrated battery management system ensures cell protection from deep discharge, overcharge, and overheating.

FAQ

• Q: How often should the unit be charged if not used?
  A: The unit must be charged every 6 months if not in use to maintain optimal performance.

Manual and safety instructions
The Li-G4 range

SAFETY INSTRUCTIONS – UN3480

• The Li-G4 is classified as Class 9 dangerous goods according to UN3480, a power source with high energy density and hazardous materials in a sealed metal cabinet.
• Installation must follow national safety regulations in accordance with the requirements for enclosure, installation, creepage, clearance, marking and segregation requirements for the end-use application. We recommend that  installations are performed by authorised professionals. Switch off the system and check for hazardous voltages before changing any connections!
• The Lithium Power Supply must only be serviced by trained personnel.
• The lowest ingress protection rating for Li-G4 is IP54. Ensure that the installation of the Lithium Power Supply complies with IP54 requirements.

Observe the following:

• Do not open the Li-G4.
• Do not discharge a new Li-G4 until it has been fully charged.
• Charge only within the specified limits.
• Make sure the Li-G4 is switched off when it is moved and during installing.
• Do not mount the Li-G4 upside down or on its side.
• Check if the Li-G4 has been damaged during transport.
• Do not leave outside exposed to the elements.
• Do not use at altitudes above 2,000 metres (6,562 feet)
• Do not allow children or animals to come in contact with the device or connected power supplies.

Danger in case of fire:

• Danger of explosion with dust particles.
• Decomposition due to fire or heat development emits toxic and corrosive gases.
• Combustion gases which strongly irritate the eyes and respiratory organs.
• General precautions the driver should observe if these hazards occur:
• Switch off the motor.
• Place a warning sign on the road to warn others.
• Inform others of the dangers and advise them to stay away from the wind direction.
• Contact the police and fire brigade immediately and inform them that there are lithium batteries  (UN3480) onboard.
• Instruction for fire extinguishing:
• Extinguish fire with water. If possible, submerge the Li-G4 completely in water.
• Extinguishing with water produces fluoride, phosphate, fluoride-oxide and carbon monoxide. Alternatively, extinguish with a CO2 fire extinguisher.

NON-SPILL LI-ION BATTERY

UNIT MUST BE CHARGED EVERY 6 MONTHS IF NOT USED

 GETTING STARTED

Product Box Contents

Product Details

DESCRIPTION
1| Terminal ( + )| 8| Type plate
2| Terminal ( – )| 9| Pressure valve
3| Power button| |
4| SOC indication| |
5| Wake-up (M4 terminal)| |
6| M12 – Data/IO connector ( Isolated )| |
7| M12 – Data/IO connector ( Isolated )| |

NOTE: The wake-up (M4 terminal) provides remote control for the battery’s output. The battery turns on at voltages above 4V and turns off when the voltage falls below 3V.

M12 PINOUT

#| FUNCTION| FRONT VIEW
1| Single Wire|
2| I/O Signal
3| GND
4| CAN High
5| CAN Low

NOTE : All ports of the M12 connector are isolated and do not have any voltage potential reference to terminal voltage or terminal ground.

PRODUCT USAGE

Li-G4 is a module-based lithium iron phosphate battery (LiFePO4/LFP) which is a safe and reliable chemistry for energy storage. The product is available in 2 variants with capacities of 100Ah and 280Ah to satisfy demanding applications. The nominal voltage of a Li-G4 module is 12.8V. The Li-G4 series has an integrated battery management system to protect the cells from deep discharge, overcharge and overheating. The product features:

• Safe battery technology – LiFePO4.
• Integrated Battery Management system.
• Integrated power switch.
• Designed for heavy duty environments and requirements.
• Metal frame and flame-retardant enclosure.
• CAN bus communication (compliant with SAE J1939) which is used for:
  • Control
  • Synchronization (System configuration)
  • Data logging
  • Firmware update

Ensuring the safe installation of lithium batteries is mandatory to prevent any potential hazards. The battery comes equipped with built-in protection mechanisms, including short-circuit and overcurrent protection, as well as an internal fuse that is not user-replaceable.

ATTENTION:
It is mandatory to add an additional fuse as close as possible to the positive terminal, with a rating that aligns with your power requirements.

Interface
The battery is equipped with a button and LED for operation and indication. The battery is considered off when no LED is illuminated in the State of Charge (SoC) indication bar. When the device is turned on, the SoC indication bar will display the remaining battery capacity in 20% increments. Following table explains normal operation and warnings that are indicated by the SoC indication bar:

State of Charge.
Red LED| Solid| Battery is nearly empty (<10% SOC)
Flashing| Battery is empty and disconnected

The SoC indication bar also serves to display error codes. An error will trigger a red flashing SoC indication bar, with the number of flashes corresponding to the specific failure. You can find a list of error codes on chapter 3.1. Errors can be cleared by turning the battery off and on, depending on the type of error.

System configuration – Standalone (Charge from accumulator)
The Li-G4 can be used as a standalone power source for auxiliary appliances. The following diagram illustrates how to connect the battery to an accumulator for charging during a drive. To control the charging process, a Clayton Power DC-DC converter (PN: CD1804) is used. This converter prevents the system from draining the accumulator and only charges it when the voltage is within specified limits and a wake-up signal (Pin 2 – M12 connector) is present.

Connect appliances to the terminals of the battery and use an appropriate cable thickness with fuse (F3) that supports the appliances current.

ATTENTION:

• M8 bolts must be torqued to 12Nm
• M4 bolts must be torqued to 1.5Nm
• Do not connect the CAN Bus to the vehicle’s CAN communication system.
• Place fuses as close to the source as possible.

System configuration – Capacity extension for LPS II
Li-G4 can be used to extend the capacity of LPS II series. Use Clayton Power DC-DC converter between the batteries and the LPS. Connect according to image:

Use 16mm2 cable gauge fused with 60A fuse as close to the source as possible.
If the LPS is used to run heavy equipment that requires constant high power, a larger DCDC converter can be used to enable power transfer between the batteries and the LPS to keep up with the consumption. Using PN: CD1804, the power transfer is limited to 45A, while PN: CD2402 allows power transfer up to 90A. The installation using PN: CD2402 is illustrated in the following diagram:

The communication / signal harness for both configurations is the same and is premade (PN: AL2401) and is constructed according to following table:

DESCRIPTION| Data LPS Front (Pin #)| Data DCDC (Pin #)| DATA Li-G4 (Pin #)| Wake- up Li- G4| Data LPS Back (Pin #)
---|---|---|---|---|---
Charge| 2| 1| –| –| –
Discharge| –| 2| 2| –| 2
GND| –| 3| 3| –| 3
CAN High| –| 4| 4| –| 4
CAN Low| –| 5| 5| –| 5
Wake-up| –| –| 2| Terminal| –

ATTENTION:

• M8 bolts must be torqued to 12Nm
• M4 bolts must be torqued to 1.5Nm
• Do not connect the CAN Bus to the vehicle’s CAN communication system.
• Place fuses as close to the source as possible

Configuration on LPS:
To enable the capacity extension, you must change a setting on the LPS through its interface/display. Go to:
Main Menu → General → System Configuration and set the configuration to “Capacity Extension”. This will enable the capacity extension functionality. To disable the capacity extension functionality select “None”.

System configuration – Battery w. Combi
The Li-G4 can be used with a G3 Combi for 230VAC applications. Using a Clayton Power DC/DC converter (PN: CD1803) between the Li-G4 and the vehicle battery allows charging during driving. The battery can be charged using the Combi (Blue Neutrik) or from an accumulator. 16mm2 Use 50mm2 cable gauge with a 200A fuse between Li-G4 and Combi. Use 16mm2 cables with 60A fuses between Li-G4, DCDC converter and accumulator. Place the fuses as close to the source as
possible.

Wire the communications / control signals according to following table:

DESCRIPTION| Data Combi (Pin #)| Data Li-G4 (Pin #)| Neg. Term. Li- G4| Wake- up Li- G4| Data DCDC (Pin #)
---|---|---|---|---|---
Single Wire| 1| 1| –| –| –
Wake-up| –| –| –| Terminal| 2
GND| –| 3| Terminal| –| –

ATTENTION:

• M8 bolts must be torqued to 12Nm
• M4 bolts must be torqued to 1.5Nm
• Do not connect the CAN Bus to the vehicle’s CAN communication system.
• Place fuses as close to the source as possible

TROUBLESHOOTING

Error List
The battery uses its LEDs for error indication. An error list shows the cause of failure and how to solve the error. If the solutions provided below are unable to resolve the error or if the error code is not listed, contact your retailer.

it to a place with a higher / lower ambient temperature
3| Overload, Short Circuit or Pre-charge failure| Disconnect the load and restart the battery to confirm operation. Check for short circuits in installation or defective connected equipment
4| IO Terminal is overloaded or is short circuited| Disconnect connector and check connector or cable for damage
5| Blown internal fuse or defective internal switch| Contact your retailer for assistance
6| Other failures| Contact your retailer for assistance

Errors can be cleared by turning the battery off and on, depending on the type of error.

SPECIFICATIONS

IFpP/73/175/208/[4S]M/- 30+60/90
Communication| CAN Bus (SAE J1939)
I/O ports| 2 x I/O and 1 x Input
I/O input voltage| 0 – 60 V
I/O output voltage| 0 – 12 V
I/O output current| 400mA (Over current protected)
I/O connector type (M12)| Type A – 5-way
I/O connector type (Terminal)| M4
IP classification| IP54
Maximum altitude| 2,000 m
Product weight| 12 kg| 28 kg
Product size (H x W x L)| 187 x 197 x 343| 243 x 197 x 438
Gross weight| 14 kg| 30 kg
Package size (H x W x L)| 240 x 260 x 450 mm| 400 x 260 x 545 mm

CHARGE PROFILE AND SETTINGS

The recommended charging parameters for the charging sources are:

• Li-G4 2S (100Ah): 50A constant current (Max. 100A – 1 cycle/day), 14.4V constant voltage.
• Li-G4 2S (280Ah): 56A constant current (Max. 140A – 1 cycle/day), 14.4V constant voltage.

For more information on the charge settings of the individual chargers or inverters/chargers, please refer to the manuals on the respective product page.

SAFETY AND FUSES
These measures ensure the safe and secure operation of the electrical system

• Correct orientation – Do not place the battery upside down.
• Incorrect cable size or bad cable connection can cause thermal issues or short circuits.
• Make sure the Li-G4 battery is turned off before starting the installation and do not connect any active wakeups before the installation is finished.
• Do not combine Li-G4 batteries with other brands.

ATTENTION : DC terminals are protected with 400A fuse in Li-G4 2S. The internal fuse cannot be replaced by user and requires service. Place a correctly dimensioned fuse as close as possible to the Li-G4 to prevent high current short-circuits and internal fuse to blow.

Battery operation is monitored by the battery management system to ensure safe operation. The integrated battery management system disconnects the power line in case of any abnormalities.

| Li-G4 2S (100Ah)| Li-G4 2S (280Ah)
---|---|---
Overvoltage| Overvoltage warning for each cell| 3.60 V
Overvoltage protection for each cell| 3.65 V
Overvoltage release for each cell| 3.55 V
Overvoltage recovery method| Automatically when cell voltage falls below release voltage
Undervoltage| Undervoltage warning for each cell| 2.70 V
Undervoltage protection for each cell| 2.50 V
Undervoltage release for each cell| 2.80 V
Undervoltage recovery method| Automatically when cell voltage rises above release voltage
Cell balancing| Cell balancing method| Passive Balancing
Cell balancing current| 1 A
Over current| Charge over current protection (Time delayed)| >100 A|

140A
Discharge over current protection (Time delayed)| >175 A| >200A
Battery temperature| Over temperature protection for each cell| 65°C
| Under temperature protection for each cell| -30°C

 CERTIFICATIONS AND COMPLIANCE

Low Voltage Directive 2014/35/EU EN62368-1, EN62133
EMC 2014/30/EU
EN61000-6-2, EN61000-6-3
RoHS Directive 2011/65/EU
EN 63000
E-Marking
UN-ECE Regulation 10, E5 10R – 06 0488

 BATTERY MAINTENANCE

To ensure optimal battery performance, fully recharge the battery every month (100%). If the battery has not been fully charged for a long period, maintenance charge can be prolonged to several days.

STORAGE
The battery can be stored at temperatures between -20⁰C and 45⁰C. For long term storage (>1 month), the battery should be fully charged and stored at temperatures between 0⁰C and 35⁰C. The battery needs to be charged every 6 months if not used. Do not store the battery upside down.

TRANSPORTATION
Lithium batteries are classified as Class 9 hazardous materials (UN3480) and must always be transported in compliance with all applicable local, national, and international regulations. Proper packaging is required during transportation, and packaging instructions (PI965) must be respected. The batteries should not be turned upside down during transportation.

DISPOSAL
To ensure proper disposal and reduce potential hazards, discharge the battery completely before placing it in a designated battery recycling bin. Improper disposal, such as throwing it in regular rubbish bins, is strictly prohibited as the product contains batteries with potentially harmful chemicals. Adhere to local laws and regulations for battery recycling and disposal.

WARRANTY

IMPORTANT AND WARNING:
DO NOT USE OR ATTEMPT TO USE THIS PRODUCT UNTIL YOU HAVE READ THE USER MANUAL IN ITS ENTIRETY. IMPROPER INSTALLATION OR USE OF THIS DEVICE MAY BE DANGEROUS AND MAY CAUSE DAMAGE TO OTHER ELECTRICAL EQUIPMENT AND WILL VOID THE WARRANTY.
Warranty. The company guarantees that products and associated services are free of significant defects in design, material and execution for 24 months after delivery.
Exceptions. The company’s warranty does not include defects caused by:

• ordinary wear and tear,
• storage, installation, use or maintenance against the company’s instructions or ordinary practice,
• repair or change carried out by others than the company, and
• other conditions for which the company has no responsibility.

Examination. Within a reasonable period of time after receiving a complaint from the client about defects and examining the claim, the company will inform the client about whether or not the defects are covered by the warranty. After the request, the client must ship defect parts to the company. The client covers the expenses and risks of the parts during transport to the company. The company covers the expenses and risks for return of parts during transport, only if the defects are covered by the warranty.
Register a complaint. If the client discovers defects within the period of warranty, which the client wishes to invoke, it must be communicated immediately in writing. If defects, which the client discovers or should have been discovered, are not immediately communicated to the company in writing, it cannot be effectuated at a later time. The client must provide the company the requested information about the registered defects.

Instructions for Obtaining Warranty Service for Clayton Power Devices
To obtain warranty service, contact the store where you have bought the product and provide the following:

• Sales receipt
• Device model number
• Device serial number
• Brief description of the application and problem, including any error codes displayed on the device.
• Obtain an authorisation number from the Clayton Power dealer before shipping the device. Carefully pack the device and ship it (freight paid) to the Clayton Power dealer. Note that the device contains lithium batteries and  must be shipped as dangerous goods according to UN3480 lithium-ion batteries’ regulations.

Sales: sales@claytonpower.com
Service: service@claytonpower.com
Phone: +45 4698 5760

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