LEAB Clayton Power CLP 600 User manual

LEAB Automotive GmbH
Thorshammer 6
DE-24866 Busdorf
User Manual
Version: V1.2
Issue date: 04.05.2020
Charge Booster from
CLP 600
Bidirectional DC-DC converter with charging characteristics
User Manual

User Manual About this Manual
Page 1 of 11
Welcome
With the LEAB Charge Booster from Clayton Power, you have opted for a
bidirectional DC-DC converter with charging characteristics. Read this
manual carefully before installing and commissioning, and retain it for
future reference.
If you have any suggestions or comments about this manual, please let us
know by email: [e-mail].
Our website, www.leab.eu, contains further information on the device
(including data sheets and installation videos) as well as the latest version
of the manual. Here you will also find information about optional
accessories or variants of your device.
Table of Contents
1About this Manual............................................................................2
2General Safety..................................................................................3
3About the Device..............................................................................4
4Package Contents.............................................................................5
5Technical Specifications ....................................................................5
6Charging Characteristic.....................................................................6
7Assembly..........................................................................................6
8Installation .......................................................................................7
9Normal Operation ............................................................................8
10 Emergency Start Function.................................................................8
11 Operating Status...............................................................................9
12 Disposal ...........................................................................................9
13 EU Declaration of Conformity ...........................................................9
14 Connection Diagram: Lithium Battery from Clayton Power ..............10
15 Connection Diagram: Lead-acid Battery...........................................11

User Manual About this Manual
Page 2 of 11
1About this 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 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:
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.
It is prohibited to copy, duplicate, translate or otherwise pass on the
content of this manual to third parties without the express written
permission of LEAB.

User Manual General Safety
Page 3 of 11
2General Safety
This manual supports safe handling of the device. Use the device solely in
accordance with its intended use:
The CLP 600 charge 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 on-board power supplies 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.
Any modifications to the device or its components are prohibited and do not
conform to its intended use.
Observe the following safety instructions:
Danger from damaged, frozen or deformed batteries: Before charging,
make sure that the battery is undamaged and the electrolyte is not
frozen.
Device defect due to incorrect installation: Install the device in a dry
and cool location.

User Manual About the Device
Page 4 of 11
3About the Device
Number
Details
1
Data connection (M12)
2
Output (+)
3
Ground (GND)
4
Input (+)
5
“Setup” button






User Manual Package Contents
Page 5 of 11
4Package Contents
5Technical Specifications
Package Contents
Amount
Charging booster
x1
User Manual
x1
Data adapter, M12
x1
Nut, M6
x3
Spring washer, M6
x3
Cable lug
16 mm²
x3
Screw, 16 mm
x4
CLP 600 charge booster
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 … 85°C
IP rating
IP21
Connections
x3 bolts M6 (input and output)
x1 data connection, 5-pin, M12
Dimensions (L x W x H)
222 x 111 x 40 mm
Weight
620 g
Assembly
Screws (x4)

Installation Instructions Charging Characteristic
Page 6 of 11
6Charging Characteristic
The charging of lead-acid batteries is fully automatic with a five-stage
charging 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
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.
7Assembly
To mount the device, perform the following steps:
Choose a cool, dry and well-ventilated mounting site.
Do not mount the device directly next to or above batteries.
1. Fasten the device to the 4 lateral holes (5 mm Ø).
The device is mounted.

Installation Instructions Installation
Page 7 of 11
8Installation
Fitting the Data Adapter
Connection
1 –single wire
2 –wake-up signal (D+)
3 –ground
4 –CAN high
5 –CAN low
It is not possible to operate the device without a wake-
up signal.
A CAN connection must also be established in order to
charge lithium batteries.
Connecting Batteries
To connect the batteries (starter battery and additional battery), perform the
following steps:
1. Disconnect the batteries from the on-board power supply.
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 on-board power supply.
The batteries are connected.

Installation Instructions Normal Operation
Page 8 of 11
9Normal Operation
Switching on the Device
The charging process starts automatically when a wake-up signal (pin 2) is
applied.
It is not possible to operate the device without a wake-
up signal.
If a lead-acid battery is charged, the status LED "LEAD"
illuminates green. If a lithium battery is charged, the
status LED "LITHIUM" illuminates green.
Switching off the Device
The device switches off automatically if no wake-up signal (pin 2) is applied.
10 Emergency Start Function
To activate the emergency start function, perform the following step:
A wake-up signal is applied to the device.
1. Press the “Setup” button for 3 seconds.
To end the emergency start function, perform the following step:
1. Press the “Setup” button for 3 seconds.
The starter battery is charged for a maximum of 5
minutes from the additional battery.
The status LED flashes red and green simultaneously.
The emergency start function ends, the charge booster returns to
normal operation.

Installation Instructions Operating Status
Page 9 of 11
11 Operating Status
The status LED shows the operating status of the device.
Status
Description
Green, steady light
Charging process completed, additional
battery fully charged
Green, flashing (1 Hz)
Battery is charged, charging status > 80%
Green, flashing (4 Hz)
Battery is charged, charging status < 80%
Green/red, steady light
Emergency start function, starter battery
fully charged
Green/red, flashing (1 Hz)
Emergency start function,
charging status > 80%
Green/red, flashing (4 Hz)
Emergency start function,
charging status < 80%
Red, flashing, x1
Input voltage too low / too high
Red, flashing, x2
Temperature too high
Red, flashing, x3
Error at DC output
Red, flashing, x4
Current too high / short circuit
Red, flashing, x5
No CAN connection
Red, flashing, x6
Other errors
12 Disposal
Dispose of the device in accordance with the Waste Electrical and Electronic
Equipment Regulations (WEEE).
The device must not be disposed of with household waste.
Take it to a recycling point or send it to your point of sale.
13 EU Declaration of Conformity
The CLP 600 charge booster from Clayton Power
complies with the requirements of the following
directives:
2014/30/EU: EMC
2011/65/EU: RoHS