LEAB BPC 12-12/40 User manual

www.leab.eu
USER MANUAL
VERSION 3
07/04/2021
CHARGE BOOSTER
BPC 12-12/40
LEAB Automotive GmbH Thorshammer 6 24866 Busdorf

Table of Contents
1 About this Manual................................................................................................................ 3
2 General Safety........................................................................................................................ 4
2.1 Intended Use............................................................................................................... 5
2.2 Foreseeable Misuse.................................................................................................. 5
3 About this Product............................................................................................................... 6
4 Technical Specifications.................................................................................................... 7
5 Package Contents................................................................................................................. 8
6 Preparation............................................................................................................................. 8
7 Assembly.................................................................................................................................. 9
8 Installation.............................................................................................................................. 10
8.1 Connecting an External LED.................................................................................. 11
8.2 Establishing CAN Communication...................................................................... 11
9 Operation................................................................................................................................. 11
9.1 Switching the Device On/Off................................................................................ 11
9.2 Changing the Output Voltage............................................................................... 11
9.3 Checking the Set Output Voltage........................................................................ 12
9.4 Operating Status........................................................................................................ 12
10 Error Codes and Error Descriptions.............................................................................. 13
11 Maintenance........................................................................................................................... 14
12 Disposal.................................................................................................................................... 14
13 EU Declaration of Conformity.......................................................................................... 15
LEAB Automotive GmbH

1 About this Manual
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 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 material damage
The signal word Attention 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 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.
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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:
NOTE
A note provides useful tips and information about the product.
Read the note carefully and follow the instructions where
applicable.
2 General Safety
This manual will help you to handle the device safely. Use the device solely in
accordance with its intended use. Observe the safety instructions.
WARNING
Risk of burns from hot surfaces
During continuous operation, the surface of the device can reach
temperatures of up to 70 °C.
1. Avoid physical contact with the device during operation.
WARNING
Burns from escaping acid
Acid can leak out when handling batteries.
1. Wear acid-proof clothing when handling batteries.
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WARNING
Risk of fire from overheated battery
Flammable gases can escape if the battery overheats.
1. Always charge batteries in well-ventilated rooms and away
from ignition sources.
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 BPC charge booster is an active DC-DC converter which charges the addi-
tional battery from the on-board supply system. Using the voltage at the input,
the modern voltage converter generates a regulated charging voltage for fast
recharging of lead batteries (wet, gel and AGM batteries) or lithium batteries
during travel.
At the output, the system supplies an adjustable DC voltage between 14.1V
and 15V and thereby provides consumers with power permanently or for a
short time. The input voltage is 12V.
The device is designed for an operating temperature of -20 °C ... +50 °C. A re-
duced output current is generated from surface temperatures of 70 °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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3 About this Product
Fig.1: BPC charge booster
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12
4
3
5679 810
1 DC output (Out) 2 DC input (In)
3 LED Status 4 LED Failure
5 LED Com 6 Program button
7 Port for D+signal 8 Port for ground (GND)
9 Port for external LED 10 Port for CAN communication
4 Technical Specifications
Part no. 1041003001
Modell BPC 12-12/40
Input voltage 12 V (11.5 V … 15 V)
Output voltage 14.1 V/14.5 V/15 V (adjustable)
Output current, max. 40 A, reduced output current from 70
°C surface temperature
Input current, max. 55 A
Standby current, max. < 10 mA
Degree of efficiency > 95 %
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Part no. 1041003001
Operating temperature -20 °C … +50 °C
International Protection (IP class) IP21
DC connector Bolt, M8 (max. 15 Nm)
Operating display LED
Dimensions (L x W x H) 170 mm x 137 mm x 70 mm
Weight 900 g
5 Package Contents
No.
BPC charge booster 1x
Insulating caps (red) 2x
User manual 1x
6 Preparation
NOTE!If you are using a Clayton Power lithium battery and CAN communica-
tion, there is no need to set the output voltage as it is detected automatically.
Before you install the BPC charge booster, the required output voltage must
be set. To do this, perform the following steps:
Connect the 12 V battery (DC Input)
To connect the starter battery, perform the following steps:
1 Disconnect the starter battery from the on-board supply system.
WARNING!Disconnect the negative cable first.
2 Secure the positive cable as close as possible to the starter battery with a
suitable fuse (60 A).
3 Connect the positive terminal of the starter battery to the DC input of the
device with a cable (25 mm2).
CAUTION!First connect the charge booster and then the starter battery.
NOTE!Loosen only the top nut.
4 Connect the negative terminal of the starter battery to the port for the
ground (GND) of the device with a cable (2.5 mm2).
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ðThe device is ready for operation (‘LED Status’ flashes green).
5 Connect the starter battery to the on-board supply system.
ðThe BPC charge booster is connected to the starter battery.
Setting the Output Voltage
The BPC charge booster provides 3 different output voltages:
– 14.1 V for wet batteries
– 14.5 V for gel and AGM batteries
– 15 V for lithium batteries
An output voltage of 14.1 V is set at the factory.
To set the output voltage, perform the following steps:
6 Press the program button (approx. 6 seconds) until 'LED Failure' and 'LED
Status' illuminate green.
7 Press the program button for a further 3 seconds.
8 To choose between the output voltages, press the program button.
–LED Com: 14.1 V
–LED Failure: 14.5 V
–LED Status: 15 V
9 To store an output voltage, press the program button for 3 seconds until all
LEDs illuminate red.
ðThe output voltage is set. To check the set output voltage, see Checking the
Set Output Voltage [ } 12] .
7 Assembly
Notice
Device defect due to the effects of dust and moisture
The effects of dust and moisture can cause device defects
1. Choose a cool, dry and well-ventilated assembly site.
2. Protect the device from the effects of dust and moisture.
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To assemble the device, perform the following steps:
üAssemble the device on a flat and heat conductive surface.
1 Fasten the device with screws to the 4 lateral holes (Ø 4mm).
ðThe device is assembled.
8 Installation
To install the device, perform the following steps:
1 Disconnect the starter battery from the on-board supply system.
WARNING!Disconnect the negative cable first.
2 Secure the positive cable as close as possible to the starter battery with a
suitable fuse (60A).
3 Connect the positive terminal of the starter battery to the DC input of the
device with a cable (25 mm2).
CAUTION!First connect the charge booster and then the starter battery.
NOTE!Loosen only the top nut.
4 Connect the negative terminal of the starter battery to the ground port
(GND) of the device with a cable (2.5mm2).
ðThe device is ready for operation.
5 Connect the positive terminal of the additional battery to the DC output of
the device with a cable (25 mm2).
NOTE!Loosen only the top nut.
6 Connect the negative terminal of the additional battery to the shared
ground with a cable (25mm2).
7 Connect the D+signal of the vehicle (e.g. terminal15 or terminal51) with the
port for the D+ signal of the device.
NOTE!When used with lithium batteries from Clayton Power, the vehicle's D +
signal can also be transmitted via the device's CAN communication connec-
tion.
8 Connect the starter battery to the on-board supply system.
ðThe device is installed.
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8.1 Connecting an External LED
To connect an external LED, perform the following steps:
1 Connect the anode lead of the external LED to the DC input of the device.
2 Connect the cathode lead of the external LED to the of external LED port on
the device.
ðThe external LED is connected.
8.2 Establishing CAN Communication
The BPC charge booster is used to facilitate easy charging of lithium batteries
from Clayton Power. The BPC charge booster is switched on and off via CAN
communication. In addition, the charge booster automatically detects the re-
quired output voltage.
To activate CAN communication, perform the following steps:
1 Connect one end of the CAN communication cable to a CAN bus connector
on the Clayton Power lithium battery.
2 Connect the other end of the CAN communication cable to the CAN con-
nector on the charge booster.
ðCAN communication is established automatically during operation.
9 Operation
9.1 Switching the Device On/Off
The BPC charge booster switches on automatically when the following condi-
tions are fulfilled:
– D+ signal is present (connection for D+ or CAN communication).
– Charge booster is in standby mode.
The BPC charge booster switches off automatically when one of the conditions
is not fulfilled.
9.2 Changing the Output Voltage
NOTE!If you are using a Clayton Power lithium battery and CAN communica-
tion, there is no need to set the output voltage as it is detected automatically.
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The BPC charge booster provides 3 different output voltages:
– 14.1 V for wet batteries
– 14.5 V for gel and AGM batteries
– 15 V for lithium batteries
To change the output voltage, perform the following steps:
üThe device is ready for operation and is not charging a battery.
1 Press the program button (approx. 6 seconds) until 'LED Failure' and 'LED
Status' illuminate green.
2 Press the program button for a further 3 seconds.
3 To choose between the output voltages, press the program button.
– LED Com: 14.1 V – LED Failure: 14.5 V – LED Status: 15 V
4 To store an output voltage, press the program button for 3 seconds until all
LEDs illuminate red.
ðThe output voltage is set.
9.3 Checking the Set Output Voltage
To check the set output voltage, perform the following steps:
üThe device is ready for operation.
1 Press the program button (approx. 6 seconds) until 'LED Failure' and 'LED
Status' illuminate green.
2 Press the program button for a further 3 seconds.
ðLEDs illuminate in a chase string. LED for the set output voltage illuminates
green.
9.4 Operating Status
The BPC charge booster indicates the operating status via the LEDs on the
charge booster. In addition, an external LED can be connected.
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LEDs on charge booster
LED Status Meaning
LED Status Does not illuminate Device inactive (no input voltage)
LED Status Illuminates green Battery is charged
LED Status Illuminates red Reduction in charging current, overheating
protection (from 70 °C surface temperature)
LED Status Flashes green Device is ready for operation
LED Status Flashes alternately
red and green Device in normal operation, charging current is limited
LED Com Illuminates yellow CAN communication active
LED Com Does not illuminate CAN communication inactive
LED Failure Flashes red See Error Descriptions table in the Error
Codes and Error Descriptions [ } 13] section
Tab.1: LEDs on charge booster
With External LED
LED Status Meaning
External
LED Does not illuminate Battery is not charged
External
LED Flashes Error exists (see ‘LED Failure’ on device)
External
LED Illuminates Battery is charged
Tab.2: With External LED
10 Error Codes and Error Descriptions
Displaying Stored Error Codes
To display error codes, perform the following steps:
1 Press the program button until 'LED Com' and 'LED Failure' flash green.
2 The error codes are indicated by the flashing of ‘LEDFailure’ (see Error De-
scription table)
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ðThe error codes are displayed.
NOTE!The first error code displayed is the most current error code. The
device stores up to 5 error codes.
Error Description
LED Meaning
The temperature is too high.
The temperature is too low.
The output voltage is too high.
The input voltage is too high.
The input voltage is too low.
The output voltage is too low.
The output current is too high.
Tab.3: Error Description
11 Maintenance
Maintain the device at regular intervals:
– Ensure that the wiring between the batteries and the charge booster is se-
cure.
– To remove dirt, clean the device from the outside with a dry cloth.
12 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 return it to your
point of sale.
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13 EU Declaration of Conformity
The BPC 12-12/40 charge booster complies with the re-
quirements of the following directives:
– 2014/30/EU: EMV
– 2011/65/EU: RoHS
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LEAB Automotive GmbH
Thorshammer 6
DE-24866 Busdorf
Tel: [phone]
Fax: [phone]
[email protected]
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.