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Summary of Contents for Brusa NLG664-U0
- Page 1 TECHNICAL INFORMATION AND START-UP On-board Fast Charger NLG664-U0 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. Any technical information, drawings and photos used are copyrighted and failure to respect this constitutes a punishable offence!
- Page 3 ALIDITY This manual is only valid for those devices listed in the following table: NLG664 – U0 – xxA – xxx * * x = applies for all models The decoding of the device designation is as follows: Technical information and start-up Fast Charger NLG6xx...
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Page 4: Table Of Contents
TABLE OF CONTENTS Foreword ..........................7 General characteristics ........................7 Labelling information, traceability and documentation of devices and components ......8 List of abbreviations ........................ 8 Safety and warning instructions .................... 9 Symbols and their meaning ......................9 Safety instructions and danger levels ................... 10 Generally applicable safety measures .................. - Page 5 About this device ........................23 Technical data ..........................23 Warnings on the device ........................ 25 Technical properties ........................26 Basic function ..........................26 6.4.1 Voltage-dependent control of 1-phase and 3-phase charging ..........27 6.4.2 PFC compensation ........................ 27 6.4.3 PRC compensation ....................... 27 Overview of the main structural components ................
- Page 6 7.4.4 Proximity Detection ....................... 52 7.4.5 Control Pilot........................... 52 7.4.6 Temperature derating ......................52 7.4.7 Output current limitation Iadem ..................... 52 7.4.8 Output voltage limitation Uadem.................... 52 Efficiency ..........................53 8.1.1 Level of efficiency 1-phase charging ..................53 8.1.2 Level of efficiency 3-phase charging ..................53 Installation / Start-up ......................
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Page 7: Foreword
Foreword Dear Customer! With the BRUSA NLG6 charger, you have purchased a versatile high-performance product. The device is a power electronics product which uses dangerous voltages and currents, thus special expertise with respect to handling and operation of such systems is required! Read this manual –... -
Page 8: Labelling Information, Traceability And Documentation Of Devices And Components
Labelling information, traceability and documentation of devices and components BRUSA Elektronik AG ensures a complete quality proof for all raw materials, manufacturing processes and products by means of suitable labelling and traceability measures. Traceability shall be organised in such a way that in the event of a defect the following characteristics can be identified at any time: ... -
Page 9: 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, certain specific symbols are used. -
Page 10: Safety Instructions And Danger Levels
Safety instructions and danger levels DANGER This instruction warns about severe irreversible risks of personal injury with possibly fatal consequences. Avoid this risk by adhering to these instructions! WARNING This instruction warns about the risk of severe but reversible injury! Avoid this risk by adhering to these instructions! CAUTION This instruction warns about a minor risk of injury! -
Page 11: 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 with country-specific and local guidelines. - Page 12 Prevent any penetration of fluids into the device (e.g. during assembly work)! Fluid ingress will lead to a short circuit and subsequently to damage to the device! In the case of any fluid ingression, do not start the device and immediately contact BRUSA Elektronik AG.
- Page 13 Therefore, always unwind the cable drum completely! INSTRUCTION The device is never to be opened! The opening of the device (sealed housing) directly leads to the forfeiture of any liability by BRUSA Elektronik AG! Refer to chapter 11 Liability INFORMATION When working on a HV system, the following 5 safety rules have to be strictly adhered to: ...
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Page 14: Safety Installations / Power Limitations
On the charger, each phase (L1, L2, L3, N) is protected by a 40 A fuse in order to protect the device and electric systems from damage due to overcurrent. If one of these fuses is blown, the charger must be returned to BRUSA Elektronik AG! Do not open the device – no user serviceable parts inside. 3.4.4 Overcurrent protection Overcurrent protection is integrated in the charger to avoid overload damage. -
Page 15: Overtemperature Protection (Derating)
3.4.5 Overtemperature protection (derating) INSTRUCTION Continuous operation at the temperature limit will inevitably lead to a higher level of wear of the components! The charger protects itself through temperature dependent derating. If the charger reaches a defined temperature limit, it reduces the power (derating) to protect the charger from damage due to overheating. The power is reduced according to the temperature increase in order to keep the temperature within the target range. -
Page 16: Hv Interlock Acc. To Lv123
3.4.6 HV Interlock acc. to LV123 The interlock is a protective loop in the vehicle which monitors the drive components. It also allows monitoring of HV side plug connections at the charger. Wiring of the interlock pins does not influence the functionality of the charger, but in order to ensure safety, we strongly recommend that an interlock system is employed! These interlock pins can carry +/-48VDC nominal to Gnd, at 10mA (max. -
Page 17: Proximity Detection Acc. To Iec 61851
3.4.7 Proximity Detection acc. to IEC 61851 Proximity defines an additional resistor attached to the connector of the charging cord, which indicates the maximum ampacity of the cord. This resistor is measured by the charger and defines the amount of current that the cord is allowed to conduct. -
Page 18: Requirements On The Start-Up Personnel
Requirements on the start-up personnel All courses of action described in this manual may only be carried out by a qualified electrician! Specialist staff are defined as electricians who have had specific professional training, have knowledge and experience in the field of electronics / electric mobility, ... -
Page 19: General
Scope of the documentation INFORMATION In order to successfully commission the charger, you need this manual and the software manual, and possibly further software. BRUSA will be happy to provide this so-called (documentation-) “customer package” by download links. Scope of delivery... -
Page 20: Optional Scope Of Delivery
Optional scope of delivery INFORMATION These accessories can be obtained optionally from BRUSA Elektronik AG. Meaning Type Illustration 1. NLG6 CEQ 4-part cable set, assembled on one side 13198 2. Quick connection cooling water ports 90° Norma PS3 MHAA776 (required inner diameter of cooling water tube = 18 mm) 3. -
Page 21: Use And Limitations Of The Product
Use and limitations of the product Proper use The BRUSA Fast Charger NLG6xx is suitable for the integration into vehicles for charging different battery types such as Li-ion batteries, NiCd batteries or LeadAcid batteries. In case you plan to use it for other purposes, please contact the company BRUSA Elektronik AG in advance at the manufacturers address as given in chapter 4.6. - Page 22 Technical information and start-up Fast Charger NLG6xx...
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Page 23: About This Device
About this device Technical data AC input NLG664 Unit Min. Input voltage 1-phase Max. input voltage 1-phase Min. input voltage 3-phase Max. input voltage 3-phase Max. input current 3-phase (each phase) Max. input current 1-phase Voltage HV battery for automatic activation 1-phase charging when starting the charging <... - Page 24 Wiring system interface AUX NLG664 Unit Wiring system voltage 6 - 16 Max. wiring system current (without locking motor operation) µA Wiring system standby current (without pin HW_WakeUp) @ U = 12 V Thermal / Cooling system NLG664 Unit Amount of coolant in device 0.21 External diameter of cooling water connection ports Quick connection PS3...
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Page 25: Warnings On The Device
Warning signs are installed on the device 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. To get an original label, please contact BRUSA support at the manufacturing address given in chapter Technical information... -
Page 26: Technical Properties
Technical properties High charging power up to 22 kW 1-phase and 3-phase charging supported Galvanic isolation between mains and HV battery No DC-fault current possible, therefore the use of a Class A Ground Fault Interrupter is sufficient ... -
Page 27: Voltage-Dependent Control Of 1-Phase And 3-Phase Charging
6.4.1 Voltage-dependent control of 1-phase and 3-phase charging The NLG6 enables 3-phase charging for battery voltage of ≥ 310 V to ≤ 430 V at max. 22kW. Outside this range, single-phase-charging is performed at max. 7kW. A hysteresis is programmed for this switchover threshold defining the following switchover point: If the battery voltage is <... -
Page 28: Overview Of The Main Structural Components
Charging modes (Mode2 and Mode3 charging) INFORMATION By default, the NLG6 supports Mode2 and Mode3 charging. Mode 2: Alternating current (AC) charging at a local standard socket or CEE socket, by using an In Cable Control Box (ICCB) integrated in the charging cable. The ICCB ensures a correct charging procedure controlled by safety signals and -equipment according to the respective standards. -
Page 29: Dimensions And Installation Information
Dimensions and installation information For the installation of the charger, the following must be adhered to: The charger must be installed at a secure location out of reach of the user of the vehicle. This is to prevent dangers such as accidental touching of HV components or skin burns on the hot housing. ... -
Page 30: Fixing Points
6.6.1 Fixing points Device mounting Holes for attachment of fir tree clips M8 x 20 screw Torque = 25 Nm Technical information and start-up Fast Charger NLG6xx... -
Page 31: Dimensions
6.6.2 Dimensions 6.6.3 Installation position INSTRUCTION The charger should be installed horizontally (housing cover aligned horizontally). Maximum tilting of 60° on graphically displayed sides is permitted. Deviating installation positions may lead to insufficient cooling performance and damage to the charger! Due to the position of the pressure compensation membrane, the charger should be installed inclined upwards as shown on the right. -
Page 32: Vehicle Installation Basic Principle
Vehicle installation basic principle Technical information and start-up Fast Charger NLG6xx... -
Page 33: Block Diagram
Block diagram Technical information and start-up Fast Charger NLG6xx... -
Page 34: Type Plate
Type plate Manufacturer address Series number and date of production Supplier number (specified by the customer) Space for customer specific labels 3D bar code 2D bar code IP protection class not connected IP protection class fully connected Max. DC side charging capacity Max. -
Page 35: Connections
Connections Electrical INFORMATION Information about required mating plug types can be found in the chapter of the respective plug, or on the charger drawing. Grounding screw GND (equipotential bonding) DC plug (code A) for M6 x 20 screw refer to chapter 7.1.2 Pin assignment DC plug Torque = 12.5 Nm (Code A, device side) -
Page 36: Earthing / Grounding Screw (Equipotential Bonding)
7.1.1 Earthing / Grounding Screw (equipotential bonding) WARNING Sparking! Fire hazard! Ensure that Ground / Protective Earth is connected correctly! A loose ground connection can lead to sparking and subsequent fires! INFORMATION The device is equipped with three ground connections. For safe operation, at least one ground connector needs to be connected! ... -
Page 37: Pin Assignment Dc Plug (Code A, Device Side)
7.1.2 Pin assignment DC plug (Code A, device side) 1. HV Batt+ 2. HV Batt- HV battery plus HV battery minus 3. DC_HVIL_in HV interlock loop input 4. DC_HVIL_out HV interlock loop output Technical information and start-up Fast Charger NLG6xx... -
Page 38: Pin Assignment Ac Mains Plug (Code A, Device Side)
7.1.3 Pin assignment AC mains plug (Code A, device side) 1. PE Protective earth conductor 2. L3 Phase 3 3. L2 4. L1 Phase 2 Phase 1 5. N 6. AC_HVIL_out HV interlock output Neutral conductor 7. AC_HVIL_in HV interlock input Technical information and start-up Fast Charger NLG6xx... -
Page 39: Pin Assignment Lv Plug Vehicle 12-Pole (Code A, Device Side)
7.1.4 Pin assignment LV plug vehicle 12-pole (Code A, device side) 1. Kl30 +12 V (plus wiring system) 2. EV_CAN_H EV CAN high 3. Kl30C 4. HVIL_out Kl30 Crash HV interlock loop output 5. --- not connected 6. --- not connected 7. - Page 40 7.1.4.2 Pin 2 EV_CAN_H / Pin 8 EV_CAN_L INFORMATION These two pins must be connected to the CAN bus of the vehicle. This enables control of the charger. This CAN bus offers WakeUp, see chapter 7.3.1 WakeUp via CAN (CAN for Vehicle Control Unit (VCU)) Internal wiring...
- Page 41 >5 V conforms to no Crash Technical information and start-up Fast Charger NLG6xx...
- Page 42 7.1.4.4 Pin 4 HVIL_out / Pin 9 HVIL_in Internal wiring Pin 9 Connector HVIL_IN 49kΩ Pin 4 HVIL_OUT 49kΩ The (externally created and evaluated) interlock signal is transmitted over the DC plug. As a result, the correct connection of the DC plug is constantly monitored. If the DC plug is disconnected or not properly locked, the charger and battery should immediately be switched off by the external interlock system, so dangerous situations can be avoided.
- Page 43 INFORMATION The Debug-CAN bus is designed for troubleshooting. Therefore, its data are only relevant for the company BRUSA. If an error occurs on the charger, the data of this CAN bus can also be logged by the customer.
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Page 44: Pin Assignment Lv Plug Charging Socket 12-Pole (Code B, Device Side)
7.1.5 Pin assignment LV plug charging socket 12-pole (Code B, device side) 1. POS_S Locking system feedback signal 2. PROX_D Proximity Detection Resistor 3. LED_Green 4. LED_Blue Output LED green Output LED blue 5. RELAY_L1 Plug locking 6. RELAY_L2 7. TEMP_Con Input PT1000 temperature sensor 8. - Page 45 Technical information and start-up Fast Charger NLG6xx...
- Page 46 7.1.5.2 Pin 2 PROX_D Via input pin 2 PROX_D the proximity resistor of the charger is measured an interpreted. The charger assumes that a 4.7 kΩ resistor is installed in the Charge Coupler in addition to the proximity resistor (see chapter 3.4.7.
- Page 47 7.1.5.4 Pin 5 RELAY_L1 / Pin 6 RELAY_L2 / Pin 8 RELAY_U2 / Pin 10 RELAY_U1 Internal wiring Pin 8 / Pin 10 Kl30 / internal Relais U TLE 8209- Pin 5 / Pin 6 Relais L Pin 5 RELAY_L1 / Pin 10 RELAY_U1 ...
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Page 48: Cooling Water Connections
Cooling water connections INSTRUCTION When the cooling system is connected, attention must be paid that the cooling water inlet and outlet are connected correctly! Swapping the connections may lead to malfunctions in the cooling systems and consequently to overheating of the device! Cooling water inlet Cooling water outlet (for connection of Normaquick PS3*) -
Page 49: Wakeup Mechanism
Wakeup mechanism INFORMATION The NLG6 features several WakeUp mechanisms to wake up the device from sleep. The following chapters contain an overview and descriptions of the various WakeUp mechanisms. For a successful WakeUp, AUX voltage must always be between 9 and 16 V. 7.3.1 WakeUp via CAN As soon as there is any communication on the CAN bus, the charger wakes up. -
Page 50: Wakeup Via Proximity
7.3.2 WakeUp via Proximity As soon as a charging cable is connected to the charging socket of the vehicle (Charge Coupler), the charger detects the proximity resistor and wakes up. Also refer to chapter 3.4.7 Proximity Detection acc. to IEC 61851 7.3.3 WakeUp via Pin HW-WakeUp The charger wakes up as soon as voltage at this pin exceeds 4.2 V (edge-controlled event). -
Page 51: Power Limitations / Limiting Controller
Power limitations / Limiting controller INFORMATION To protect the charger and connected peripherals (e.g. HV battery, charging cable, Wallbox) from damage due to overload, several load limits must be considered. The charger continuously monitors whether all operating values are within the permissible range, and reduces charging power if required (derating). -
Page 52: Input Power Limitation Pndem
7.4.2 Input power limitation Pndem The charger permanently monitors the charging power and limits it to a max. of 22 kW. In a 3x230V/400V grid, this corresponds to a phase current of 32 A. The maximum mains capacity is country-specific and directly influences the available charging power. -
Page 53: Efficiency
Efficiency 8.1.1 Level of efficiency 1-phase charging Efficiency vs. charging power single phase charging, at different battery voltages (200VDC / 300VDC). 8.1.2 Level of efficiency 3-phase charging Efficiency vs. charging power three phase charging, at different battery voltages (310VDC, 340VDC, 400VDC) Technical information and start-up Fast Charger NLG6xx... -
Page 54: Installation / Start-Up
Prior to installation, visually check the packing material and particularly the device itself for damage. Each device undergoes a strict quality and function test at BRUSA before distribution. However, we do not have any influence on shipping and loading of our products. - Page 55 Procedure step Illustration / Other Information Carefully install the charger at its installation location. Fasten the screws (1). If mounting plates (adapter plates) are to be used, these must be attached to the charger first. Torque = 20 Nm +/- 2 Nm Remove covers (1) of the cooling water connections.
- Page 56 Procedure step Illustration / Other Information Establish earth connection to the chassis. The charger is equipped with three earth connections (1), (2) and (3). At least one earth connector must be connected! Torque = 12.5 Nm +/- 1.5 Nm For information on earth connection refer to chapter 7.1.1 Grounding Screw (equipotential bonding)
- Page 57 INFORMATION The charger is now ready for operation. Customer specific configurations are already carried out before shipping by BRUSA Elektronik AG. Technical information and start-up Fast Charger NLG6xx...
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Page 58: Removing The Charger
Removing the charger DANGER High voltage! Danger to life! If the HV battery is activated, HV cables carry high voltage! Under no circumstances carry out work on the device without first ensuring that there is no voltage in the HV system! High voltage! Danger to life! After disconnecting the mains and DC connections, the charger requires approx. - Page 59 Procedure step Illustration / Other Information 4. Disconnect the mains plug (1) from the charger. 5. Wait at least 5 seconds before performing the following steps. Capacitors are discharged 6. Disconnect the LV plugs (1) and (2) from the charger. 7.
- Page 60 Procedure step Illustration / Other Information 8. Disconnect the cooling water connections (1) and (2) from the charger. These connections are achieved with PS3 quick connections. 9. Attach the covers (1) to the cooling water connections. 10. Remove all cables attached to the charger, e.g. at the fir tree clips (1).
- Page 61 Charger weight = 12 kg INFORMATION If the device is to be sent to BRUSA Elektronik AG for repairs, always use appropriate packaging! Should you have any questions regarding this, please contact BRUSA customer support at the address specified in chapter...
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Page 62: Precharge Output Capacitor
Precharge output capacitor HINWEIS In order to avoid the formation of sparks (and/or damage to the device) when connecting the charger to the battery, the internal capacity of 24.5 uF must always be pre-charged from the battery’s DC-link via a pre-charging resistor! When using a PTC as pre-charging resistor, the latter may heat up in case of multiple subsequent pre- charging attempts. -
Page 63: Operation
Warranty and Guarantee 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 regarding disposal A basic requirement for the re-use and recycling of used electronic devices is the correct disposal. -
Page 64: Index
Index Block diagram LED pin assignment ..............44 Installation into the vehicle ..........32 Level of efficiency ..............51 NLG6xx .................. 33 Notes on assembly ..............13 CAN specification ............... 24 Notes on life span ..............13 control connector LV Code A ...................
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