LEAB 012-00022GF User manual

LEAB Automotive GmbH
Thorshammer 6
DE-24866 Busdorf
User manual
Version: V 2.0
Issue date: 16.09.2019
Lithium-Ion Battery
12 V-100 Ah, 24 V-100 Ah
With integrated battery management system
User manual

Installation instructions About this Manual
Page 1 of 18
Table of Contents
1About this Manual ............................................................................1
2General Safety...................................................................................2
3Technical Specifications ....................................................................3
4Package Contents..............................................................................5
5About the battery .............................................................................6
6Mounting ..........................................................................................8
7Installation ........................................................................................9
8Normal operation ...........................................................................16
9Error code display ...........................................................................17
10 Maintenance...................................................................................18
11 Disposal...........................................................................................18
12 EU Declaration of Conformity .........................................................18
1About this Manual
Read this manual carefully and keep it in a safe place. This manual is
intended for professionals in the automotive electrical field.
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:

Installation instructions General Safety
Page 2 of 18
Signal word
Meaning
DANGER
Warns of imminent danger resulting in death or
serious injury.
WARNING
Warns of a potentially dangerous situation that can
result in death or serious injury.
CAUTION
Warns of a potentially dangerous situation that can
result in moderate or minor injuries.
NOTICE
Warns of a potentially dangerous situation that can
result in material and environmental damage.
In this manual you will find the following symbols:
Shows you useful tips and information about the device.
Indicates a mandatory requirement for the following
instruction.
Shows the result of an instruction.
2General Safety
This manual supports safe handling of the batteries. Use the batteries solely
in accordance with its intended use:
Lithium-ion batteries are power sources with a particularly high energy
density in a closed metal housing.
Any modifications to the device or its components are prohibited and do
not conform to its intended use.
Lithium batteries are classified as hazardous to UN3480 Class 9. It is
essential to observe the relevant national and international standards and
guidelines as well as the instructions and notes in this manual during
installation.

Installation instructions Technical Specifications
Page 3 of 18
Observe the following safety instructions:
Check the battery for transport damage before installation.
Do not open battery housings, cells, or other system components.
Do not connect the lithium-ion battery in series.
Danger from damaged, frozen or deformed batteries: Before charging,
make sure that the battery is undamaged and the electrolyte is not
frozen.
Fully charge the lithium-ion battery before use.
Only charge batteries in well-ventilated rooms and away from ignition
sources.
Fully charge the lithium-ion battery every 6 months at the latest.
3Technical Specifications
Battery type
12 V / 100 Ah
24 V / 100 Ah
Part number
012-00022GF
012-00024GF
Available capacity
80 Ah
80 Ah
Rated voltage
12 V
24 V
Lower operating voltage
9.2 V
18.4 V
Charge voltage
15 V
30 V
Min. cell voltage
2.3 V
Max. cell voltage
4.2 V
Continuous discharge
current
100 A
Max. pulse discharge
current
10 min.
200 A (temperature controlled)
5 s.
>500 A
10 µs
>1000 A
Continuous charge
current
100 A
Rated charge and
discharge current
50 A
Cycle life
80 % DOD
>3000
Cycle life
70 % DOD
>5000

Installation instructions Technical Specifications
Page 4 of 18
Battery type
12 V / 100 Ah
24 V / 100 Ah
Part number
012-00022GF
012-00024GF
Rated temperature
-40 °C … 50°C
Cooling
Controlled fan
Inputs
3
Outputs
2
Communication
CAN (SAEJ1939) –CP Single Wire
Parallel connection
1 …20
Internal consumption per
month (sleep mode)
<3 %
Internal consumption
350 mA
180 mA
Internal consumption
(Sleep mode)
< 2 mA
IP rating
IP20
Connection
Screws, M8
Weight
16.52 kg
31.22 kg
Dimension (L x W x H)
302 mm x 192 mm x
274 mm
558 mm x 192 mm x
274 mm
Parallel connection / CAN bus connection parameters
Pin
Signal
Parameter
Value
1
CAN
WakeUp
Output voltage
Battery voltage
Output impedance
10 kΩ
Maximum input voltage
60 V
Trigger voltage (high/low)
3.5 V
Input impedance
4.7 MΩ
2
CAN GND
Maximum current
250 mA
Rated fuse size
300 mA (thermal)
3
CAN High
Connection speed
125 kbps
Connection protocol
>MΩ
Output impedance
SAE J1939-11
4
CAN Low
Connection speed
125 kbps
Connection protocol
>MΩ
Output impedance
SAE J1939-11

Installation instructions Package Contents
Page 5 of 18
Signal contact parameters
Pin
Parameter
Value
Output 1
Output 2
Maximum drain voltage
45 V
Maximum current
300 mA
Rated fuse size
300 mA (thermal)
Design
Open collector
Input 1
Input 2
Maximum input voltage
45 V
Input voltage level (High/Low)
TTL range
Input impedance
4.7 MΩ
Input 3
Maximum input voltage
45 V
Input voltage level (High/Low)
3.8 V
Input impedance (at +5 VDC)
2 MΩ
SW DATA
Connection speed
9600 Baud
Output impedance (at +12 VDC)
1 kΩ
Rated fuse size
300 mA (thermal)
SW GND
Maximum current
300 mA
Rated fuse size
300 mA (thermal)
GND
Maximum current
300 mA
Rated fuse size
300 mA (thermal)
4Package Contents
Package Contents
No.
User manual
1
CAN communication cable
1
Lithium-ion battery
1
M8 spacer (plastic)
1
M8 screw
1
M8 snap ring
1
M8 washer
1
Phoenix connector, 3 pin
1
Phoenix connector, 5 pin
1
Fuse (CF8, 150 A)
1

Installation instructions About the battery
Page 6 of 18
5About the battery
Front of lithium ion battery
No.
Part Name
1
Positive terminal
2
Negative terminal
3
DIP switch
4
Status indicator (for more information see page 7)
5
Status contacts (for more information see page 7)
6
CAN bus sockets (RJ10)







Installation instructions About the battery
Page 7 of 18
Detail view of status indicator and signal contacts
Status indicator (left)
Signal contacts (right)
LED
Indicator
Status
Power (blue)
Steady light
Device on
Flashing
Charging
Failure (red)
See page 17
100% (green)
Steady light
> 90 %
Flashing
80 % …90 %
80 % (green)
Steady light
> 70 %
Flashing
60 % …70 %
60 % (green)
Steady light
> 50 %
Flashing
40 % …50 %
40 % (green)
Steady light
> 30 %
Flashing
20 % …30 %
20 % (red)
Steady light
> 10 %
Flashing
0 % …10 %
Signal contact
Description
Output 1
External alarm controller (active at <10% SOC)
Output 2
Protection against overload by an external charger
(active at > 4.1 V cell voltage)
Input 1
Wake-up signal for vehicle ignition
(active operating voltage, D+ signal)
Input 2
Wake-up signal for remote control signal
(active operating voltage)
Input 3
Wake-up signal for 230 V network (active at low range)
ground. Do not apply 230 V AC voltage.
SW data
Communication port for external device
SW GND
Communication port to ground
GND
Ground connection

Installation instructions Mounting
Page 8 of 18
6Mounting
To mount the lithium-ion battery, perform the following step:
Use screws to secure the device to the 4 holes on the underside of the
battery (5 mm Ø).
The device is mounted.
Choose a cool, dry and well-ventilated mounting site.
Always mount the lithium-ion battery upright or lying on its
side, never upside down.
Make sure the air circulation is unobstructed at the radiator.
12 V /100 Ah
24 V /100 Ah

Installation instructions Installation
Page 9 of 18
7Installation
The lithium-ion battery can be used in a variety of ways. This chapter
describes the most common installations.
Single operation with APP power supply
To connect the lithium-ion battery in single operation to 12V or
24 V consumers, you need a suitable power pack. LEAB recommends an
APP series power pack. To connect the APP and the
12 V or 24 V consumers, perform the following steps:
For installation you need an installation relay. LEAB
recommends the Eltako R12-110-230V relay
(part no.: 9905043791).
Before installing, make sure that the power pack is turned
off.
The wiring diagram shows the lithium-ion battery connected to a
power pack.

Installation instructions Installation
Page 10 of 18
Connect the negative terminal of the battery to a common ground.
Secure the positive lead of the battery with the CF-8 fuse supplied.
Connect the negative terminal of the power pack to a common
ground.
Connect the positive terminal of the battery to the positive terminal of
the power pack.
To enable automatic charging of the battery, connect the input 3 of
the battery to the terminal 1 of the relay with a signal cable.
Connect the terminal 3 of the relay to ground.
Connect the L conductor of the AC wire of the power pack to the +A1
terminal of the relay.
Connect the N conductor of the AC wire of the power pack to the +A2
terminal of the relay.
Bridge the SW GND connection of the battery with the GND
connection of the battery with a signal line.
Connect the negative lead of the 12 V or 24 V consumers to a ground.
Connect the positive lead of the 12 V or 24 V consumers to the
positive terminal of the battery.
In single operation the battery is connected to the power pack
and the 12 V or 24 V consumers.
When installing the 12 V or 24 V consumers, pay attention to the
manufacturer information.

Installation instructions Installation
Page 11 of 18
Single operation with CLP combi
In order to connect the lithium-ion battery in single operation with 230 V
consumers, you need a suitable inverter. LEAB recommends the CLP combi
inverter. To connect the CLP combi and the
230 V consumers, perform the following steps:
For installation you need an installation relay.
LEAB recommends the Eltako R12-110-230V relay
(part no.: 9905043791).
Before installation, make sure that the combi is switched
off.
The wiring diagram shows the lithium-ion battery connected to
CLP combi.

Installation instructions Installation
Page 12 of 18
Connect the negative terminal of the battery to a common ground.
Connect the negative terminal of the combi to a common ground.
Secure the positive lead of the battery with the CF-8 fuse supplied.
Connect the positive terminal of the battery to the positive terminal of
the combi.
Connect the SW data connector of the battery to a signal cable to the
SW data connector of the combi.
To enable automatic charging of the battery, connect the input 3 of
the battery to the terminal 1 of the relay with a signal cable.
Connect terminal 3 to the ground.
Connect the L conductor of the AC wire of the combi to the + A1
terminal of the relay.
Connect the N conductor of the AC wire of the combi to the + A2
terminal of the relay.
Bridge the SW GND connection of the battery with the GND
connection of the battery with a signal line.
Connect the 230 V consumer to the output of the combi.
Connect the negative lead of the 12 V or 24 V consumers to a ground.
Connect the positive lead of the 12 V or 24 V consumers to the
positive terminal of the battery.
In single operation the battery is connected to the CLP combi
and the consumers.
When installing the 230 V consumers, pay attention to the
consumer manufacturer’s information and to the combi
manufacturer’s information.
When installing the 12 V or 24 V consumers, pay attention to the
manufacturer information.

Installation instructions Installation
Page 13 of 18
Optional: Connecting the remote display
To connect the remote display (part no.: 0200600001), perform the
following steps.
Connect the GND port of the remote display to a ground.
Connect the ‘+Batt’ port of the remote display to the positive terminal
of the starter battery.
Connect the remote port of the remote display to the input 2 of the
lithium-ion battery with a signal cable.
Use a signal cable to connect the SW data port of the remote display
to the SW data port of the lithium-ion battery.
The remote display is connected.
The wiring diagram shows the remote display connected to the
lithium-ion battery with CLP combi.
When installing the 12 V or 24 V consumers, pay attention to the
manufacturer information.

Installation instructions Installation
Page 14 of 18
Optional: Connecting the charger booster (12 V / 24 V)
To charge the lithium-ion battery via the alternator, you need a suitable
charge booster. For the 12 V battery you need a 12 V DC-DC charge
booster, LEAB recommends the BPC 12-12 (part no.:1041003001). For the
24 V battery you need a 24 V DC DC charge booster, LEAB recommends the
PP 12/24 DC/DC converter (part no .: 1042004326) or the 12 V/29 V charge
booster (part no.: 0404002424).
To connect the charge booster, perform the following steps:
Connect the negative terminal of the charge booster to a common
ground.
Connect the positive terminal of the charge booster to the positive
terminal of the starter battery.
Connect the other positive terminal of the charge booster to the
positive terminal of the battery.
For the charge booster 12/12: Connect the CAN terminal of the charge
booster to the CAN terminal of the battery with a signal cable.
For the 12/24 charge booster: use a signal wire to connect the D +
signal connector to the vehicle D + signal.
The charge booster is connected.
The wiring diagram shows the connection of a charge booster for
the 24 volt lithium-ion battery. The lithium-ion battery is also
connected to the remote display and the CLP combi.

Installation instructions Installation
Page 15 of 18
Parallel connection
To switch several lithium-ion batteries in parallel, note the following:
To switch several lithium-ion batteries in parallel, perform the following
steps.
For installation you need an installation relay.
LEAB recommends the Eltako R12-110-230V relay
(part no.:9905043791).
You have connected the CLP combi.
You have connected a charge booster.
Make sure all devices are turned off before installation
Connect a maximum of 20 lithium-ion batteries in parallel
Never connect the lithium-ion batteries in series
Do not connect lithium-ion batteries from other
manufacturers to the lithium-ion battery
The wiring diagram shows the lithium-ion battery connected to
CLP combi, a booster and a remote display.

Installation instructions Normal operation
Page 16 of 18
Connect the negative terminals of the batteries to a common ground.
Connect the positive terminals of the batteries to a busbar.
Connect the CAN bus sockets of the batteries to CAN communication
cables as shown in the circuit diagram.
For batteries with only one CAN communication cable connected, set
the upper DIP switch to 'ON' and the lower to 'OFF'.
For the batteries with two CAN communication cables connected,
switch both DIP switches to 'OFF'.
The batteries are connected in parallel.
8Normal operation
Switching on the battery
The lithium-ion battery switches on as soon as a wake-up signal is present
for a wake-up input.
The lithium-ion battery switches off as soon as all wake-up signals are
removed.
Charging the battery in sleep mode
To charge the lithium-ion battery, connect a suitable charger and start
charging within 30 seconds.
The lithium-ion battery protects itself against deep discharge by
disconnecting the power ports and starting sleep mode. In this mode, the
lithium-ion battery can be activated for 30 seconds to starting charging with
min. 1 A.
Charging a deeply discharged battery
To charge a deeply discharged lithium-ion battery, connect a suitable
charger and start the battery within 3 seconds with min. 1 A.
Make sure that the cable lengths are identical. The maximum
tolerance of the cable lengths among each other is ± 20%.
Depending on the cable length, the following cable cross
sections result:
35 mm2
< 2 m
50 mm2
< 3 m
70 mm2
< 5 m

Installation instructions Error code display
Page 17 of 18
9Error code display
Failure (red LED)
Error
Error Description
Flashing x 1
Battery
discharged
Restart battery and apply
charge current (>1 A) within 30
s
Flashing x 2
Battery
temperature
too high
Wait until the battery has
cooled down
Flashing x 3
Battery
overload or
short circuit
Battery starts in 'Sleep Mode'
after 30 s, remove load and
restart.
Flashing x 4
Precharge error
Battery starts in 'Sleep Mode'
after 30 s, remove load and
restart
Flashing x 5
Battery
overloaded
Check charger, battery is in
compensation mode
Flashing x 6
Internal error:
Cell voltage
monitor
Battery starts in 'Sleep Mode'
after 30 s, contact dealer
Flashing x 7
Internal error:
Cell
temperature
monitor
Battery starts in 'Sleep Mode'
after 30 s, contact dealer
Flashing x 8
Internal error:
Communication
error
Battery starts in 'Sleep Mode'
after 30 s, contact dealer
Flashing x 9
Internal error:
other
Battery starts in 'Sleep Mode'
after 30 s, contact dealer

Installation instructions Maintenance
Page 18 of 18
10 Maintenance
Check the battery as follows each time before using it:
Check the battery for external damage.
Ensure that the wiring between the charger cable and the charger
is secure.
11 Disposal
Dispose of the lithium-ion battery in accordance with the Waste Electrical
and Electronic Equipment Regulations (WEEE).
The lithium-ion battery 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 lithium-ion battery
types 12 V-100 Ah and 24 V-100 Ah
complies with the requirements of the following
directives:
2014/30/EU: EMC
2014/35/EU: NRL
2011/65/EU: RoHS

LEAB Automotive GmbH
Thorshammer 6
DE-24866 Busdorf
Germany
Tel.: [phone]
Fax: [phone]
Email: [email protected]
Web: www.leab.eu