Clayton Power LEAB CLP 600 User manual
Table of Contents
1 About the manual................................................................................................................. 3
2 General Safety........................................................................................................................ 4
2.1 Intended use............................................................................................................... 5
2.2 Foreseeable misuse................................................................................................. 5
3 About the product................................................................................................................ 6
4 Technical Specifications.................................................................................................... 8
5 Package Contents................................................................................................................. 8
6 Charging Characteristic...................................................................................................... 9
7 Assembly.................................................................................................................................. 10
8 Installation.............................................................................................................................. 10
9 Normal Operation................................................................................................................. 11
9.1 Switching on the Device......................................................................................... 11
9.2 Switching off the Device......................................................................................... 12
9.3 Operating Status........................................................................................................ 12
10 Emergency Start Function................................................................................................. 13
11 Disposal.................................................................................................................................... 13
12 EU Declaration of Conformity.......................................................................................... 13
13 Connection diagram: Lithium battery from Clayton Power................................ 14
14 Connection diagram: Lead-acid battery...................................................................... 15
Table of Contents LEAB Automotive GmbH
1 About the manual
This user manual is a supplement to the original operating manual from man-
ufacturer 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 elec-
trics.
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 ac-
cessories.
Throughout the manual, you will be alerted to warnings and safety notices
about potential hazards associated with handling the device. The colours 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.
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LEAB Automotive GmbH 1 About the manual
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 accord-
ance 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 un-
damaged 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.
4 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
2 General Safety LEAB Automotive GmbH
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 24V and 12V vehicle power circuits and charges batteries with
nominal voltages of 12V and 24V. 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 14.4V or 28.8V, depending on
the charging characteristic, and thereby supplies consumers with power per-
manently or for a short time. The input voltage is 12V or 24V.
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.
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LEAB Automotive GmbH 2 General Safety
3 About the product
1
2
34
5
Fig.1:
CLP 600
1 Data connection (M12) 2 Output (+)
3 Ground (GND) 4 Input (+)
5 Jump start button (emergency
start)
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3 About the product LEAB Automotive GmbH
Fig.2:
CLP600 dimensional drawing in mm
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LEAB Automotive GmbH 3 About the product
4 Technical Specifications
Part no. 1041004001
Modell CLP 600
Input voltage 12 V / 24 V (11.5 V … 32 V)
Input current, max. 45 A
Output voltage 14.4 V / 28.8 V (with characteristic
curve)
Output current, max. 40 A
Operating display LED
Internal consumption (standby) < 1.6 W
Wakeup voltage (D+) 4 V … 36 V
Operating temperature -25 °C … +80 °C
International Protection (IP class) IP21
Dimensions (L x W x H) 222 mm x 111 mm x 40 mm
Weight 830 g
5 Package Contents
No.
CLP charging booster 1x
User manual 1x
Data adapter, M12 1x
Nut, M6 3x
Spring washer, M6 3x
Cable lug, 16 mm23x
Screw, 16 mm 3x
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5 Package Contents LEAB Automotive GmbH
6 Charging Characteristic
The charging of lead-acid batteries is fully automatic with a five-stage char-
ging characteristic for optimum battery charging.
Phase Description 12 V 24 V
Stage 1 Constant current
(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
– Level2 has a time limit of 8h.
– The charging process restarts in phase 1 when the current in the charge re-
tention exceeds 10 A.
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LEAB Automotive GmbH 6 Charging Characteristic
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 (5mmØ).
ðThe device is mounted.
8 Installation
Fitting the Data Adapter
Fig.3: Data adapter
connectors
No. Connection
1 Single wire
2 Wake-up signal (Ignition switch, terminal 15)
3 Ground
4 CAN High
5 CAN Low
TIP
It is not possible to operate the device without a wake-up signal
(Ignition switch, terminal 15).
A CAN connection must also be established in order to charge
lithium batteries.
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8 Installation LEAB Automotive GmbH
Connecting Batteries
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.
ðThe 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).
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LEAB Automotive GmbH 9 Normal Operation
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.
LED Status Description
Power Green, steady light Device active, wake-up signal active
Green, flashing, 1x Device in standby mode, wake-up
signal active
Charge OUT Green, steady light Charging process completed, addi-
tional 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
IN and OUT
Red, flashing, 1x Current too high / short circuit.
Device requires restart.
Red, flashing, 2x Temperature too high. Device auto-
matically restarts.
Red flashing, 3x Other errors
Jump start
(Emergency start
function)
Green, steady light Emergency start completed.
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
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9 Normal Operation LEAB Automotive GmbH
LED Status Description
IN/OUT 12 V and 24
VGreen, steady light Automatic input voltage detection
active
IN/OUT 12 V or 24 V Red, flashing Input voltage too low / too high
10 Emergency Start Function
To activate the emergency start function, perform the following step:
üA wake-up signal (Ignition switch, terminal 15) is applied to the device.
1. Press the jump start button for 3 seconds.
ðThe 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.
ðThe 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.
ðThe emergency start function ends, the charge booster returns to normal
operation.
11 Disposal
Dispose of the device in accordance with the Waste Elec-
trical 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 com-
plies with the requirements of the following directives:
– 2014/30/EU: EMC
– 2011/65/EU: RoHS
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LEAB Automotive GmbH 12 EU Declaration of Conformity
13 Connection diagram: Lithium battery from Clayton Power
14 LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
13 Connection diagram: Lithium battery from Clayton Power LEAB Automotive
GmbH
14 Connection diagram: Lead-acid battery
15LEAB Automotive GmbH Thorshammer 6 24866 Busdorf
LEAB Automotive GmbH 14 Connection diagram: Lead-acid battery
LEAB Automotive GmbH
Thorshammer 6
DE-24866 Busdorf
Tel: +49 (0) 4621 9 78 60-0
Fax: +49 (0) 4621 9 78 60-260
We make energy
mobile.
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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