HAWE Hydraulik PDU 4 Assembly Instructions Manual

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Power Distribution Unit type PDU

Assembly instructions

High-voltage distribution unit with shield housing for

connecting battery packs type IEP to electrical systems.

PDU 4: For connecting up to 4 HAWE Mattro batteries

PDU 8: For connecting up to 8 HAWE Mattro batteries

(Translation of the original instructions)

B 6150

04-2024 -1.0 en

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Summary of Contents for HAWE Hydraulik PDU 4

Page 1 Power Distribution Unit type PDU Assembly instructions High-voltage distribution unit with shield housing for connecting battery packs type IEP to electrical systems. PDU 4: For connecting up to 4 HAWE Mattro batteries PDU 8: For connecting up to 8 HAWE Mattro batteries (Translation of the original instructions) B 6150 04-2024 ...
Page 2 HAWE Hydraulik respects these legal provisions in all cases. HAWE Hydraulik cannot provide individual guarantees that the stated circuits or procedures (including in part) are not subject to the intellectual property rights of third parties.
Page 3: Table Of Contents
Functional test..............................27 Maintenance..............................28 Service................................28 7.1.1 Visual check: electrics (cables, connections, plugs)....................29 7.1.2 Cleaning and visual check for damage.........................29 7.1.3 Replacing the fuses............................29 Disassembly and disposal..........................31 Troubleshooting..............................32 HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 3/46...
Page 4 Example integration diagram..........................34 10.2.1 PDU0101H00BS02_PDU_example_schematics......................35 10.3 Documents...............................39 10.3.1 Declaration of incorporation..........................39 10.3.2 Declaration of conformity..........................39 10.3.2.1 DeclarationofConformityPDU..........................40 10.3.2.2 240325_PDU_Not-CE-Declaration.........................41 10.4 System - parts list............................43 Glossary................................. 44 4/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 5: About These Instructions
Draws your attention to a hazardous situation that can indirectly lead to light to moderate injury if not avoided. Notice to prevent environmental and material damage. Information to ensure the correct use of the product. HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 5/46...
Page 6 Wear safety goggles to protect your eyes against chemical and mechanical hazards. Protective clothing Wear tted clothing without protruding parts. Follow the safety data sheet of the hydraulic uid. 6/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 7: Applicable Documents
2014/35/EU Low Voltage Directive EN 60 664-1 Insulation coordination for equipment within low-voltage supply systems Documents PDU 4x_04_A2 Dimensional drawing for PDU 4 PDU 8x_04_A2 Dimensional drawing for PDU 8 PDU0101H00BS02 Example integration diagram, "enclosed in appendix" Spare parts list "Enclosed in appendix"...
Page 8: For Your Safety
Use of the product in environments with intensive electrostatic elds and where strong electromag- ■ netic procedures are present must be avoided. NOTICE Only ever use identical battery types together, otherwise the system will switch to Error mode for safety reasons. 8/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 9: Residual Risks
Due to their technical training, knowledge and experience, specialists are able to assess and carry out the Specialist personnel assigned work and can independently recognize possible dangers. HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 9/46...
Page 10: Personal Protective Equipment
In the instructions, safety instructions with mandatory symbols indicate the wearing of special protective equipment for special activities. The supply of PPE, and instruction in its proper use, is carried out by the operator. 10/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 11: About This Product
Communication with the charger ■ Calculation of the overall state across all active batteries ■ The product design is shown in: Overview of design Dimensional drawing, see page 7 ■ HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 11/46...
Page 12: Functions
HV interlock, outputs with various fuse sizes and the optional Insulation Monitoring Device (IMD). The fuses of the outputs are congurable. The product is available in the following versions: PDU 4: parallel circuit with up to 4 batteries ■ PDU 8: parallel circuit with up to 8 batteries ■...
Page 13 All messages from the BCU to the user, from the user to the BCU and reserved messages on the customer CAN can be retrieved using a dbc le. With respect to the distribution of power cables and power connections, observe the following plan of Power distribution terminal connections: HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 13/46...
Page 14: Automatic Detection Of Batteries Used
Discharge mode 1. Set the signal “DischargeCommand” to True via CAN to switch the Power Distribution Unit PDU to discharge mode. 14/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 15: Alive Counter
Even if the Power Distribution Unit PDU is used in a system of <60 VDC (not HV), the HVIL is still evaluated and the BCU still responds accordingly to any interruptions. HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en ...
Page 16: Insulation Monitoring
Faults on the product must not trigger any hazard and must be able to be safely rectied. ■ There must be no hazard from failure of the electric power supply to the product. ■ People cannot reach into the hazard zone of the product. ■ 16/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 17 Load circuit faults cannot trigger any hazard and can be safely rectied. ■ Load circuit power supply failure will not result in danger. ■ HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 17/46...
Page 18: Transport And Storage
Claims for damage can be accepted only if submitted within the applicable claim periods. HAWE cannot accept liability for later claims. 4.3 Storage NOTICE Property damage from incorrect storage Incorrect storage can lead to damage. Refer to the technical data. 18/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 19 Store the product and its individual components as follows: Do not store outdoors ■ Store in an area that is dry and free of dust. ■ Storage temperature: -25°C to +60°C ■ HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 19/46...
Page 20: Assembly And Installation
3. Install the four M6 cylinder head screws from the inside. Fasten them either to a mounting plate or directly to designated attachment points. NOTICE The pressure equalisation membrane must not face upwards as standing water in this location could cause a malfunction. 20/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 21: Electrical Connection
Electrical and electronic components must only be replaced and connected by trained specialist personnel. Comply with the relevant electrical safety regulations. Only connect electrical lines when the system has been de-energized. HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 21/46...
Page 22 Do not expose components to moisture or an aggressive environment. To avoid overheating, always keep ventilation openings (if any) open to allow sufcient air circula- tion. PPE (insulated tool) CAT III or IV voltage tester ■ 22/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 23: Cable Tting And Cable Lugs
Tubular cable lugs tested for minimum creepage distance and minimum clearance (according to IEC 60664-1_2022): M8 up to 70 mm² - Klauke 7R8 (PDU 4 M8 only up to 50 mm² - Klauke 6R8) ■ M6 up to 35 mm² - Klauke 5R6 ■...
Page 24: Start-Up
Preconditions for parameter setting CAN connection set up via LV/communication interface ■ USB-to-CAN adapter (Peak) ■ HAWE Visual Tool ■ Certain BCU parameters can be modied before the commissioning work starts. 24/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 25 Error and derating limits These parameters overwrite the standard error and derating limits. The limits stored in the BMS of the batteries are not overwritten. They cannot be changed. HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 25/46...
Page 26: Grounding
M6 threaded hole on the housing CAN interface via HDSCS Only qualied electricians are permitted to make the connection. connector 1. Observe the following pin assignment: Pinout Function Battery_CAN_H_in Battery_CAN_L_in Battery_CAN_GND Battery_HVIL_OUT 26/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 27: Functional Test
Mating LV connector: TE Connectivity: 1-1563759-1 6.4 Functional test 1. Turn on the supply voltage 2. Check the circuitry and functionality of the switch outputs in accordance with the information in Chapter 3.3, "Functions". HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 27/46...
Page 28: Maintenance
Congure the access to the higher-level system such that the user cannot access hot surfaces. Allow the higher-level system to cool down before performing maintenance measures or disassembly work. 28/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 29: Visual Check: Electrics (Cables, Connections, Plugs)
Use suitable, calibrated voltage testers (CAT III or IV) to test the voltage. b) Open the Power Distribution Unit PDU and take a measurement between the HV + and HV - rail to check that it is de-energized. HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 29/46...
Page 30 See “Torque limit values” table below for the torques Thread size Torque to be used 3 Nm 16 Nm Only use fuse ratings that were dened when designing the system. 30/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 31: Disassembly And Disposal
HAWE Mattro GmbH for advice.) Dispose of electronic components at approved collection points or via approved waste disposal companies in accordance with the local regulations. Dispose of metal via approved waste disposal organisations. HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 31/46...
Page 32: Troubleshooting
The number of batteries has been dened manually and not all batteries have been found on the CAN bus 16-31 Battery CAN timeout (battery 1 – 16) CAN timeout for the “BatteryControl” message or Alive Counter is incorrect 5x 32/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 33: Annex
At 40°C: max. 50% At 20°C: max. 90% Operating altitude Max. 2000 m Operation in explosive atmosphere 10.1.2 Weight Weight without fuses PDU 4 7.5 kg PDU 8 13.5 kg 10.1.3 Electrical data Max. permissible voltage Max. 500 VDC Max. possible fuse ratings Max.
Page 34: Example Integration Diagram
Total nominal current PDU 4: 800 A PDU 8: 1600 A Supply voltage LV 12 VDC Max. Current consumption LV 15 A Corresponds to 200 A per battery; the current values only apply to the maximum configuration and if all batteries are active. The maximum possible current depending on the particular state is permanently transferred via CAN.
Page 35: Pdu0101H00Bs02_Pdu_Example_Schematics
DCDC User System Battery 1 LV (+) KL30 Power Distribution Unit CAN L in LV (-) KL31 GND CAN H in (Input) GND CAN in Battery_CAN_H_in Customer_HVIL_OUT Interlock return (Output) CAN L out Battery_CAN_L_in Customer_HVIL_IN Interlock (9-32V) CAN H out Battery_CAN_GND Battery_CAN_H_out 120 Ohm...
Page 36 DCDC User System Battery 1 LV (+) KL30 Power Distribution Unit CAN L in LV (-) KL31 GND CAN H in (Input) GND CAN in Battery_CAN_H_in Customer_HVIL_OUT Interlock return (Output) CAN L out Battery_CAN_L_in Customer_HVIL_IN Interlock (9-32V) CAN H out Battery_CAN_GND Battery_CAN_H_out 120 Ohm...
Page 37 DCDC User System Battery 1 LV (+) KL30 Power Distribution Unit CAN L in LV (-) KL31 GND CAN H in (opt.) (Input) GND CAN in Battery_CAN_H_in Customer_HVIL_OUT Interlock return (opt.) (Output) CAN L out Battery_CAN_L_in Customer_HVIL_IN Interlock (9-32V) CAN H out Battery_CAN_GND Battery_CAN_H_out (opt.)
Page 38 DCDC Battery 1 LV (+) Power Distribution Unit CAN L in LV (-) CAN H in GND CAN in Battery_CAN_H_in Customer_HVIL_OUT (opt.) (opt.) CAN L out Battery_CAN_L_in Customer_HVIL_IN CAN H out Battery_CAN_GND Battery_CAN_H_out (opt.) GND CAN out Battery_HVIL_OUT Battery_CAN_L_out (opt.) LV Connector Start Battery_HVIL_IN...
Page 39: Documents
10.3 Documents 10.3.1 Declaration of incorporation 10.3.2 Declaration of conformity HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 39/46...
Page 41: 240325_Pdu_Not-Ce-Declaration
No-CE-Declaration for HAWE-Mattro Power Distribution Unit (PDU) • Why does the Richtlinie 2006/42/EG not apply: This directive applies for machines doing mechanical work. Since our PDUs have basically no moving part this directive cannot be applied for PDUs. According to the definition of a machine stated in the RICHTLINIE 2006/42/EG DES EUROPÄISCHEN PARLAMENTS UND DES RATES vom 17.
Page 42 • EMC and why the Richtlinie 2014/30/EU is considered but not certified. Testing the EMC is a complicated matter and must be done in a sophisticated EMC laboratory. Testing single components of a machine (like e.g. a battery or Power Distribution Unit) is often not very significant, because the EMC depends strongly on how the component is integrated.
Page 43: System - Parts List
AE2 10x38mm 500V 20A AE22200605 AE2 10x38mm 500V 25A AE22250605 AE2 10x38mm 500V 30A AE22300605 AE2 10x38mm 500V 35A AE22350605 AE2 10x38mm 500V 40A AE22400605 AE2 10x38mm 500V 50A AE22500605 Table: Fuses HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 43/46...
Page 44: Glossary
External charger Charger that is located outside machines or vehicles. Charges the battery independently of the application. Derating Adjustment of the power load in line with the current battery state. 44/46 B 6150 - 04-2024 - 1.0 en HAWE Hydraulik SE...
Page 45 Optional signal line that ensures that all relevant components in an application have been properly connected Cell temperature Temperature of the battery cells. Not to be confused with the ambient temperature. HAWE Hydraulik SE B 6150 - 04-2024 - 1.0 en 45/46...
Page 46 Further information HAWE Hydraulik SE is a responsible development partner with application expertise and experience in more than 70 areas of mechanical and plant engineering. The product range includes hydraulic power packs, constant and variable pumps, valves, sensors and accessories.

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