Summary of Contents for Brusa PDU254 Series
- Page 1 TECHNICAL DATA AND START-UP PDU254 Translation of the original German operating instructions BRUSA Elektronik AG Neudorf 14 CH–9466 Sennwald +41 81 758 19 00 www.brusa.biz info@brusa.biz...
- Page 2 The content of this document may not be passed on to third parties without the written authorisation of the company BRUSA Elektronik AG - not even in extracts. All technical information, drawings and photos used in this document are protected by copyright and any infringement constitutes a...
- Page 3 ALIDITY This manual is only valid for the devices listed in the following table: PDU254-A01 PDU254-A02 The decoding of the device designation is as follows: Technical data and start-up PDU254...
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Page 4: Table Of Contents
TABLE OF CONTENTS Foreword ..........................6 List of abbreviations ......................6 Safety and warning instructions ..................7 Symbols and their meaning ......................7 Safety instructions and danger levels ..................8 Generally applicable safety measures ..................9 3.3.1 Safety instructions for handling and operation ..............9 3.3.2 Safety instructions for electrical systems ................ - Page 5 Basic principle of vehicle installation ..................23 Dimensions and installation information ................... 24 6.7.1 Fixing points ........................24 6.7.2 Housing dimensions ......................25 6.7.3 Interface dimensions ......................25 6.7.4 Fully assembled view ......................26 Type plate ..........................26 Connections ........................27 Input side ..........................
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Page 6: Foreword
Foreword Dear customer! With the BRUSA PDU254, you have obtained a very capable and versatile product. As this is a power electronics product, specialist knowledge is required for dealing with it as well as operating it! Read this manual – in particular the chapter Safety and warning instructions– carefully before installing the battery... -
Page 7: Safety And Warning Instructions
Safety and warning instructions In this chapter, you will find safety instructions applying to this device. These instructions refer to the assembly, start-up and the running operation in the vehicle. Always read and observe these instructions in order to protect people's safety and lives and to avoid damage to the device! Symbols and their meaning Throughout this manual, some specific technical symbols are used. -
Page 8: Safety Instructions And Danger Levels
Safety instructions and danger levels DANGER This instruction warns against serious, irreversible risks of personal injury with possibly fatal consequences! Avoid these risks by observing these instructions! WARNING This instruction warns against serious but reversible risks of injury! Avoid these risks by observing these instructions! CAUTION This instruction warns against a minor risk of injury! Avoid these risks by observing these instructions! -
Page 9: Generally Applicable Safety Measures
Generally applicable safety measures The following safety measures have been developed based on the knowledge of the manufacturer. They are incomplete as they can be supplemented by local and/or country-specific safety instructions and guidelines for accident prevention! The system integrator and/or distributor of the device must therefore supplement the present general safety instructions by country-specific and local guidelines. -
Page 10: Safety Instructions For Electrical Systems
3.3.2 Safety instructions for electrical systems DANGER High voltage! Danger to life! Do not touch the HV wires or connections without ensuring the absence of voltage beforehand! The PDU may only be connected by a qualified electrician! Safety installations must not be by-passed or avoided! Any resulting malfunctions could have life threatening consequences! ... -
Page 11: Safety Installations
Safety installations 3.4.1 Interlock switch The interlock switch (1) protects the operator from injuries from the HV connections. The interlock switch (1) is automatically activated as soon as the service cap is opened. Technical data and start-up PDU254... -
Page 12: Shorting Link
3.4.2 Shorting link In order to put the PDU into a safe state for assembly work, a shorting link (1) is included in the delivery. After the service cap has been opened, the interlock switch (2) is automatically activated. By means of the interlock switch (2), the HV circuit is immediately disconnected from the voltage supply. -
Page 13: Safety Concept For Vehicle Installation
Safety concept for vehicle installation INFORMATION This safety concept is a recommendation of the company BRUSA Elektronik AG and is a general requirement for the safe operation of electric vehicles! 3.5.1 Principle of operation Interlock The interlock switch (1) is closed if the corresponding interlock condition of each devices is met (closed service cover, plugged HV connections ...). -
Page 14: Requirements Regarding The Start-Up Personnel
The operational and safety instructions given must be adhered to in order to ensure the ongoing optimum functioning of the device and to meet the warranty requirements of the company BRUSA Elektronik AG. Scope of the entire documentation INFORMATION To start up the PDU254 successfully, you will need the entire documentation. -
Page 15: Scope Of Delivery
Scope of delivery MEANING PIECES ILLUSTRATION 1. High voltage distribution unit PDU254 2. Fuse FWH-300 A / 500 VDC for main connections 3. Fuse FWH-100 A / 500 VDC for range extender / DC quick charger 4. Fuse 20 A / 600 V for small-scale energy users 5. - Page 16 MEANING PIECES ILLUSTRATION 15. Washers for fuse 300A installation 16. Screw M8x22 for fuse 300A installation 17. Serrated lock washers for cable lug connection 18. Screw M4x8 for cable lug connection Technical data and start-up PDU254...
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Page 17: Optional Delivery Contents
This manual has been produced under application and consideration of the EC guidelines, national laws and harmonised standards (EN) valid at the time of production relevant to the product PDU254. Contact information of the manufacturer BRUSA Elektronik AG Neudorf 14 9466 Sennwald... -
Page 18: Use And Limits Of The Product
Use and limits of the product Proper use The product PDU254 has been designed for the following uses, taking into consideration the limit values indicated in chapter Installation in a drive train for hybrid vehicles Installation in a drive train for electric vehicles ... -
Page 19: About This Device
About this device Technical data BASIC ELECTRICAL DATA PDU254 UNIT Operating voltage 200...500 Peak inrush current, contactors Voltage for control signals (Pin = high) 7 to 15 Interlock current Max. permissible voltage drop via interlock loop Recommended cable diameter for main connection 300 A and cascading Recommended cable diameter for range extender or air conditioning compressor Recommended cable diameter for small-scale energy users (up to max. -
Page 20: Technical Properties
Warning signs are installed on the PDU to warn the operator of possible dangers. Should one of these warning signs be missing or become illegible due to wear and tear, it is to be renewed immediately! In order to obtain an original label, please contact the BRUSA support at the manufacturer's address provided in chapter Technical data... -
Page 21: Overview Of The Main Structural Components
Overview of the main structural components Service cap Connections, input side see chapter 7.1 Input side Pressure compensation membrane Control connector Chap. 7.4 Pin assignment of control connector (device side) Housing Earth GND Chap. 7.3 Earth GND Fuse 100 A Interlock switch see chapter 3.4.1 Interlock switch... -
Page 22: Basic Function Pdu254
DC quick charger with up to 100 A can additionally be connected. The cascading connections can be used in order to connect two PDU254 with each other. For small-scale energy users, a total of six 20 A fuses is available (e.g. BRUSA charger NLG5, BRUSA on-board converter BSC6, air conditioning compressor etc.). -
Page 23: Basic Principle Of Vehicle Installation
Basic principle of vehicle installation Technical data and start-up PDU254... -
Page 24: Dimensions And Installation Information
Dimensions and installation information For the installation of the PDU, the following points must be strictly adhered to: Despite the IP protection provided, the PDU should be installed in a dry location, protected from splashing water. When bringing the device into its installation position, make sure that the connection sides are positioned as horizontally as possible. -
Page 25: Housing Dimensions
6.7.2 Housing dimensions 6.7.3 Interface dimensions Technical data and start-up PDU254... -
Page 26: Fully Assembled View
6.7.4 Fully assembled view Type plate Classification Version Serial number Date of production (dd.mm.yy) Admissible voltage range HV battery Fuse protection output DMC1, DMC2 (admissible maximum current) see chapter 7.2 Output side Fuse protection output RXT (admissible maximum Fuse protection output BSC, NLG, AUX (admissible current) maximum current) see chapter... -
Page 27: Connections
Connections Input side You will find the required cable types and cable diameters in chapter 6.1 Technical data Battery input 1+ (HV plus) Battery input 1- (HV minus) Battery input 2+ (HV plus) Battery input 2- (HV minus) Cascading output + (HV plus) Cascading output - (HV minus) Output for the connection of a second PDU Output for the connection of a second PDU... -
Page 28: Output Side
Output side You will find the required cable types and cable diameters in chapter 6.1 Technical data Output AUX Output BSC Fuse protection 20 A Fuse protection 20 A Output NLG Output RXT+ (HV plus) Fuse protection 20 A Fuse protection 100 A Output RXT- (HV minus) Output DMC2+ (HV plus) Fuse protection 100 A... -
Page 29: Earth Gnd
Earth GND INFORMATION The grounding screw (1) must be connected with the earth of the vehicle and/or test bench. We generally recommend to guide the earth cables of all drive components to one earth point altogether. This minimises the risk of potential differences which may cause malfunctions of individual drive components! ... -
Page 30: Pin Assignment Of Control Connector (Device Side)
Pin assignment of control connector (device side) Earth (minus wiring system, 2. --- terminal 31) Enable (power ON, terminal 15) 4. DO0 Digital output 1 Digital output 2 6. --- Digital output 4 8. --- 10. --- 11. --- 12. --- 13. - Page 31 7.4.1 Pin 1 GND Internal wiring Pin 1 GND housing Earth connection to control unit. 7.4.2 Pin 3 EN Internal wiring Pin 3 1,5A AUX safe 100μF Internal Supply The control unit of the PDU is only supplied via this connection. ...
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Page 32: Pin 4 Do0
7.4.3 Pin 4 DO0 Internal wiring Pin 4 This output indicates the state of the interlock generator. This pin becomes active (= low) as soon as LV is applied and the interlock circuit is closed. As soon as the interlock circuit is opened, this pin becomes inactive (= high). Now, the LV supply voltage is applied to this pin. -
Page 33: Pin 7 Do3, Pin 16 Di0
7.4.5 Pin 7 DO3, pin 16 DI0 Internal wiring Pin 16 Pin 7 On the one hand, pin 16 DI0 is used to supply the main contactors of the HV bus and, on the other hand, to supply the internal logic of the active intermediate circuit discharge. ... -
Page 34: Installation / Initial Start-Up
Installation / initial start-up DANGER High voltage! Danger to life! If the battery is switched on, high voltage is applied to the HV connections which also includes HV cables that have already been connected! Therefore, do not connect any HV cables before making absolutely sure that the device is de-energised! Before carrying out any work on the PDU, follow strictly the safety instructions, chap.3.3.2 Safety... - Page 35 PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 1. Make sure that all of the HV cables to be connected are de-energised. 2. Connect the cables to the control connector. See chapter 7.4 Pin assignment of control connector (device side) 3. Connect the HV supply and the ground wiring. See chapter 8.1 Connecting the HV lines 4.
- Page 36 PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 7. Unscrew the cable fitting union nut (1) on both sides. For this, we recommend the special key for HV cable fitting type: RAAA041 See chapter 4.4 Optional delivery contents 8. Unscrew the screws (1). Remove the serrated lock washers (2) and the washers (3).
- Page 37 PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 10. Guide the prepared HV cables through the housing openings on both sides. For building the HV lines cabels See chapter 8.1 Connecting the HV lines Place the cable lug (1) on the connector pin on both sides.
- Page 38 PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 12. Bring the washers (3) and then the serrated lock- washers (4) in position and tighten the screws (5). The order must always be observed as shown! (1) = Cable lug (2) = Fuse (3) = Washer (4) = Serrated lock-washer (5) = Screw M8 x 22...
- Page 39 PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 14. For install output side connections with fuse protection 20 A, connect the cables with lugs, serrated lock-washer and tighten the screws (1). Torque of screws M4 x 8 = 2.5 Nm 15. Assemble the service cover. Make sure that the service cap is correctly fitted.
- Page 40 INFORMATION The cable connection has been established. Repeat the procedure for all required cable connections. Unused cable entries and exits must be closed using the supplied blanking plugs! Close the service cap afterwards. Technical data and start-up PDU254...
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Page 41: Connecting The Hv Lines
Connecting the HV lines The building of the HV wiring must be carried out in accordance with the following instructions. Here it is important that no strands are damaged and that none stick out at the sides on the assembled cable. So check that the screw connections are correct for each completed cable and that the cable lug is fixed properly (pull test). - Page 42 PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 3. Lead the HV cable (1) through the union nut (2). Lead the HV cable (1) through the terminal insert (3). 4. Place the terminal insert (1) with the front edge flush with the cable insulation (2). 5.
- Page 43 INSTRUCTION If you have to reassembly the cable you have to use a new terminal insert. Otherwise it can cause a leakage. The terminal inserts can be ordered from BRUSA Elektronik AG or directly from hummel.com. Technical data and start-up...
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Page 44: Warranty
Warranty The warranty corresponds to the regulations in our currently valid general terms and conditions see under www.brusa.biz/en/support/terms-conditions.html. Instructions for disposal The correct disposal is a basic requirement for the re-use and recycling of used electronic devices. With the implementation of the electric and electronic device regulation (ElektroG), since 24 March 2006, electronic devices may no longer be disposed of along with ordinary household waste but must be separately collected and recorded by a specialist service. -
Page 45: Index
Index Principle of operation............13 Block diagram Installation into the vehicle ..........23 Limit values ................18 PDU basic concept ..............22 Minimum wiring (unsafe operation!) ......... 30 Cable connections Instructions and cross-sections ..........19 Customer package ..............14 Operating ranges ............... 18 Designation of the device PDU254 Decoding .................