Brusa EVB1-350-40-HP Technical Data And Start-Up Download

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Technical data

and start-up

EVB1-350/400-40-HP

Use and Limits of the Product

5.1

Proper Use

The product Batterie EVB1-400/350-40-HP is designed for the following uses - bearing in mind the limits given in

chapter

5.2



Installation in a drive train for hybrid vehicles



Installation in a drive train for electric vehicles



Installation in a drive train for fuel cell vehicles



Use in high-performance driving (motor-racing sector)



Installation in a drive train for electric motorbikes



Installation in a drive train for utility vehicles (electric and hybrid)



Installation in a drive train for electric motorboats



Test stand applications

For planned uses in areas outside of those previously defined, the buyer undertakes to agree on these with the

manufacturer and to obtain written clearance for this.

INFORMATION

This equipment is a custom built evaluation kit destined for professionals to be used solely at
research and development facilities for such purposes.

Summary of Contents for EVB1-350-40-HP

Page 1: ...A Elektronik AG Neudorf 14 CH 9466 Sennwald 41 81 758 19 00 info brusa biz www brusa biz EVB1 400 40 HP EVB1 350 40 HP TECHNICAL DATA AND START UP Translation of the original German operating instruct...

Page 2: ...velopment of our products we reserve the right for structural changes Any changes will be disclosed in the relevant manuals through the replacement of the relevant pages and or a revision of the elect...

Page 3: ...3 Technical data and start up EVB1 350 400 40 HP VALIDITY This manual is valid only for the following devices EVB1 400 40 A02 HP EVB1 350 40 A03 HP Decoding of the device designation is as follows...

Page 4: ...s 14 3 4 Safety installations power limitations 15 3 4 1 Temperature Monitoring Derating 15 3 4 2 Current Monitoring Derating 17 3 4 3 Monitoring of Cell Voltages 19 3 4 4 Main Fuse of the Battery 20...

Page 5: ...onents 38 6 8 Dimensions and Installation Information 39 6 8 1 Fixing Points 39 6 8 2 Dimensions 40 6 8 3 Installation Position 40 6 9 Regulation and Control System 41 6 9 1 Control via Terminal 15 wi...

Page 6: ...Inlet Temperature 5 C 58 8 3 2 Cooling Behaviour at Cooling Water Inlet Temperature 15 C 58 8 3 3 Cooling Behaviour at Cooling Water Inlet Temperature 25 C 59 8 3 4 Cooling Behaviour without Active C...

Page 7: ...d start up EVB1 350 400 40 HP 10 6 Carrying Out Firmware Updates 85 11 CAN Matrix 89 11 1 CAN Signals Messages 89 11 2 CAN Signals Errorand Warning Messages 91 12 Warranty 96 13 Instructions for Dispo...

Page 8: ...other work on it 2 List of abbreviations Throughout this manual some specific technical abbreviations are used You will find an overview as well as their meaning in the following table ABBR MEANING AB...

Page 9: ...n the following table PROHIBITION SYMBOLS SYMBOL MEANING SYMBOL MEANING General prohibition Warning high voltage Touching forbidden Switching on forbidden WARNING SYMBOLS SYMBOL MEANING SYMBOL MEANING...

Page 10: ...uction warns against serious irreversible risks of injury Avoid these dangers by observing these instructions CAUTION This instruction warns against serious irreversible risks of injury Avoid these da...

Page 11: ...not exceed 20 C At temperatures higher than this the cooling water to battery Delta T does not reach high enough a level to have a cooling effect Furthermore we recommend the use of a climate compres...

Page 12: ...implications for the battery This can lead to the cell structures being destroyed and this can then lead to short circuiting or fire INSTRUCTION A high cooling water temperature reduces the life span...

Page 13: ...f this is the case the battery cannot be switched on again In this case a return to service can be carried out only by BRUSA experts In general make sure that the SoC level is at around 50 before prol...

Page 14: ...must be ensured Even when the HV supply is switched off a turning motor can still produce voltage INFORMATION Adhere strictly to the following 5 safety rules when working on a HV grid Disconnect syst...

Page 15: ...efault values of the battery are not adhered to the battery is immediately disconnected from the DC intermediate circuit Further information on temperature measurement can be found in chapter 6 6 3 Te...

Page 16: ...rating begins and reducing the current from 600 A to 320 A BATT_CurrentDischargeMax at a rate of 128 A C To inform you the CAN signal BMS_MODE_TP is emitted 5 C before reaching the limit of temperatur...

Page 17: ...CAN BATT_Current_Act Alongside this a second measurement is taken continually at 125 ms intervals this has a poorer resolution due to the shorter measurement time 6 A This parallel measurement makes a...

Page 18: ...e derating mode enters immediately and reduces the discharge current gradually down to 320 A discharge cont With a discharge current 320 A the battery can recover The longer the recovery period the lo...

Page 19: ...d 1 kHz The values measured are identified with an index and relayed one after another via CAN CCU_Cell The following factors are included in this index Number of cells CCU_Number Current index CCU_In...

Page 20: ...eded If the cell voltage reaches 4 20 V the battery will always be disconnected from the DC intermediate circuit immediately The error message or the CAN signal BMS_Err_OverCharge is emitted If this i...

Page 21: ...ion in the passenger compartment area The operator driver must be able to reach the emergency stop button in any situation The emergency stop switch must be installed in such a way that it influences...

Page 22: ...he company BRUSA Elektronik AG 4 2 Scope of the Entire Documentation INFORMATION To start up the battery successfully you will need the entire documentation as well as various types of software With t...

Page 23: ...ew GND pre assembled 1 6 Hose clips 3 7 Cable gland 9 16 mm with extension pre assembled 2 8 Serrated lock washer M8 for M8 x 10 screw pre assembled 1 9 M8 hexagonal nut pre assembled 2 10 M8 washer w...

Page 24: ...monitoring unit 200214 2 Power distribution unit PDU254 00147 4 5 EU Guidelines This manual has been produced under application and consideration of the EC guidelines national laws and harmonised stan...

Page 25: ...in high performance driving motor racing sector Installation in a drive train for electric motorbikes Installation in a drive train for utility vehicles electric and hybrid Installation in a drive tr...

Page 26: ...t may not be used outside these limits Operation outside the defined limits can lead to life threatening situations EVB1 350 40 HP EVB1 400 40 HP UNIT Permitted voltage range 290 400 324 448 V Max cha...

Page 27: ...108 Rated voltage 350 400 V Max voltage 400 448 V Min voltage 290 324 V Cont discharging current cont 320 112 320 128 A kW Peak discharging current specified derating 600 120 600 240 A kW Cont chargin...

Page 28: ...HANICAL DATA EVB1 350 40 HP EVB1 400 40 HP UNIT Weight without cooling water ca 130 ca 145 kg Length without BMS with BMS 662 770 736 844 mm Width 515 515 mm Height without fastening bars with fasteni...

Page 29: ...g signs are attached to the battery to warn the operator of possible dangers Should one of these warning signs be missing or become illegible due to wear and tear it must be renewed immediately To get...

Page 30: ...n INSTRUCTION The installation of a PDU is imperative to protect the battery as well as any peripheral devices from voltage peaks short circuit situations and the serious damages resulting from these...

Page 31: ...SA Elektronik AG 4 6 6 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 32: ...corresponding signal immediately via CAN to the higher level control If this is not reacted to accordingly then the battery disconnects itself from the DC intermediate circuit to ensure the battery s...

Page 33: ...33 Technical data and start up EVB1 350 400 40 HP 6 6 1 EVB1 400 350 40 HP Block Circuit Diagram...

Page 34: ...ging resistor is heated up by a succession of repeated 3 4 times periods of pre charging If overheating occurs then further pre charging is temporarily not possible In this case the pre charging resis...

Page 35: ...temperature monitoring takes place in three steps Step 1 Warning If a defined temperature value is reached or exceeded the warning message or CAN signal BMS_War_OverTemperature or BMS_War_UnderTemper...

Page 36: ...difference of 20mV is not possible here In general the lower the difference the higher the capacity of the battery When balancing is being activated a lower limit 0 1 V under maximum cell voltage is...

Page 37: ...unction the Ah meter would constantly shift because the battery loss could not be factored into the calculation despite being picked up by the Ah meter Auto reset is carried out after a short discharg...

Page 38: ...00 40 HP 38 6 7 Overview of the Main Structural Components 1 HV connections 2 Control connector 3 Cooling water connections 4 Square profile 40 x 20 x 3 mm 5 Grounding screw GND 6 Pressure balance mem...

Page 39: ...its installed state Under no circumstances should objects of any kind be placed or mounted on the cover This can lead to the malfunction of the battery 6 8 1 Fixing Points INSTRUCTION The battery mus...

Page 40: ...he battery in a horizontal direction A maximum gradient of 10 degrees on each side is permitted here see diagram Installation positions deviating from this hold additional dangers and lead to damage t...

Page 41: ...ON In principle the battery can be switched on independently by the vehicle control system via terminal 15 or via CAN bus If the battery is switched on via terminal 15 the ID of the parameter Rx_CMD m...

Page 42: ...Technical data and start up EVB1 350 400 40 HP 42 6 9 2 Control via Terminal 15 with Driving via CAN...

Page 43: ...types and diameters in chapter 6 1 Technical Data 1 Ground GND chapter 7 2 Ground GND 2 High voltage HV Plus 3 Control connector chapter 7 2 Ground GND 4 High voltage HV negative 5 Cooling water outle...

Page 44: ...ting bay We generally recommend connecting the grounding wires of all drive components collectively to one ground pin This minimises the risk of potential differences which can lead to the dysfunction...

Page 45: ...15 4 PWML PWM out External fan 5 PWMP PWM out External pump 6 CAN2L Reserve 7 CAN2H Reserve 8 APG Analogue Protected Ground RS232 9 CAN1L CAN1 low 10 CAN1H CAN1 high 11 RS232T RS232 Transmit 12 RS232...

Page 46: ...ve for self protection and constitute a defined connection 7 3 2 Pin 2 AUX INFORMATION We recommend using a 15 A fuse for this pin on the 12 V battery LV supply The voltage range for pin 2 AUX high is...

Page 47: ...vice logic is only fed if pin 3 is EN high Pin 3 EN has the function of terminal 15 7 3 4 Pin 4 PWML PWM out INFORMATION This PWM controlled outlet may be charged with 4 A max at 12 V Programming is c...

Page 48: ...is controlled by the BMS Desired temperature thresholds switching on switching off along with the output can be configured in the software PARAM see chapter 10 3 Changing the CAN Parameters with PARA...

Page 49: ...n 12 RS232R INFORMATION This interface is NOT intended for general use It is designed for firmware updates Should you have any questions please contact BRUSA support at the manufacturer address given...

Page 50: ...n 3 EN must also be high for this In normal operation pin 13 PRO may not be wired or it must be directly connected with terminal 31 An open circuit can lead to a reset of the battery The voltage range...

Page 51: ...in the contactor This way whether the contactors are open or closed can be constantly monitored The signals can be analysed by the customer accordingly for this monitoring Internal wiring 10nF Pin 17...

Page 52: ...tocoupler is installed INFORMATION The battery does not react automatically to the interlock signal This function must be implemented by the customer by connecting and assessing both pins pin 19 IL1 a...

Page 53: ...place via this pin The supply from pin 21 NAUS must temporarily provide 10 A to switch the contactors The peak inrush current for the HV contactors is 3 7 A each You can find instructions on the func...

Page 54: ...r temperature flow 15 C Constant discharging of the battery 8 1 1 Charging 120 A EVB1 400 40 HP CHARGING 120 A 8 1 2 Discharging 80A EVB1 400 40 HP DISCHARGING 80 A 150 200 250 300 350 400 450 500 140...

Page 55: ...ging 600 A peak EVB1 400 40 HP DISCHARGING 600 A 150 200 250 300 350 400 450 500 0 50 100 150 200 250 300 350 400 0 0 5 1 5 2 2 5 3 3 5 4 4 5 5 5 5 6 6 5 7 VOLT AMPERE Zeit in min Current A Voltage V...

Page 56: ...DISCHARGING 80 A 150 200 250 300 350 400 450 140 120 100 80 60 40 20 0 20 0 2 4 6 8 10 12 14 16 18 20 VOLT AMPERE Zeit in min Current A Voltage V 250 300 350 400 450 250 200 150 100 50 0 0 3 6 9 12 15...

Page 57: ...charging 600 A peak EVB1 350 40 HP DISCHARGING 600 A 150 200 250 300 350 400 450 0 50 100 150 200 250 300 350 0 0 5 1 1 5 2 2 5 3 3 5 4 4 5 5 5 5 6 6 5 7 VOLT AMPERE Zeit in min Current A Voltage V 25...

Page 58: ...ehaviour at Cooling Water Inlet Temperature 5 C COOLING WATER INLET TEMPERATURE 5 C 8 3 2 Cooling Behaviour at Cooling Water Inlet Temperature 15 C COOLING WATER INLET TEMPERATURE 15 C 0 30 60 90 120...

Page 59: ...g Circuit Deactivated COOLING CIRCUIT DEACTIVATED 0 30 60 90 120 150 0 10 20 30 40 50 0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 Time in min Ampere Celsuis Temperatur C Strom A 0 30...

Page 60: ...end connecting it interlock and emergency stop via the PDU INFORMATION Make visual checks on the packing material and the device itself in particular for damages before installation Each device underg...

Page 61: ...ll the provided software PCANview This software is recommended by BRUSA Customer specific software can of course be used as an alternative for this 7 Install the provided software PARAM PARAM msi See...

Page 62: ...If all the battery data is OK switch pin 15 to low e g switch off ignition key in vehicle If the battery data is not OK there is a fault Should you have any questions please contact our support servic...

Page 63: ...ering 1 off 18 Ensure that the HV contacts 1 are not live using a suitable multimeter DANGER High voltage Danger to life The HV protector 2 is a safety installation and may under no circumstances be d...

Page 64: ...epared HV cable 1 through the cable gland 2 in the BMS You must ensure that the washers are positioned on the HV contacts before you attach the cable lugs See procedure step 20 Check whether the termi...

Page 65: ...TION OTHER INFORMATION 24 Position the union nut 1 manually 25 Repeat procedure steps 22 24 on the second HV cable 26 Position the M8 hexagonal nuts 1 on the HV connections 2 and tighten them Torque 5...

Page 66: ...the special key 3 29 Remove the protective caps for the cooling water connection pieces 1 and connect the cooling water pumps with the hose clips See chapter 7 1 Circuit Connections 30 Start the softw...

Page 67: ...f the transportation box it can fall if the lifting device slips or if the crane is operated in the wrong way Never go underneath the battery Observe the loading limits when choosing a lifting device...

Page 68: ...ct both tension belts 1 evenly with the hoisting device 2 7 Hoist the battery 1 carefully by around 20 cm and check the secure position of both tension belts 2 8 Hoist the battery out of the transport...

Page 69: ...cable and that the cable lug is fixed properly pull test For the HV connections we recommend A shielded insulated automotive cable e g Huber Suhner Cable lug for the type see chapter 4 3 Delivery Con...

Page 70: ...2 5 Put the shielding braid 1 over the terminal insert 2 During this the shielding braid 1 may overlap the O Ring 3 by a maximum of 2 mm Fix the terminal insert 2 in position on the HV cable eg with...

Page 71: ...y 9 Assemble a shrinkage tube 1 on the cable lug 2 The assembly of a shrinkage tube 1 is absolutely necessary because otherwise contacting can result in the BMS housing INSTRUCTION During the layout o...

Page 72: ...on the battery temperature in chapter 8 3 Temperature Cooling System PROCEDURE STEP ILLUSTRATION OTHER INFORMATION 1 Check the secure fixing of the cooling water connections to the battery 2 Switch on...

Page 73: ...gistered messages Press on the green start button to start the data acquisition Select a filename and press Save The filename will be ap pended by a date string You ll see in the status area if the DA...

Page 74: ...ached A date string is added to the filename 10 1 2 Analysing Battery Data INFORMATION For the reading analysis of mdf files we recommend the software CANgraph by Vector www vector com The analysis ca...

Page 75: ...example the software PCAN Explorer or PCANView To be able to view the battery data you must import the included file BMS_CAN1 dbc into the software you are using Any battery data from CAN1 will then...

Page 76: ...STEP ILLUSTRATION OTHER INFORMATION 1 Start the software PARAM 2 Press the Login button 1 In this dialogue box you can see the software version serial number and the date of manufacture of the battery...

Page 77: ...p EVB1 350 400 40 HP PROCEDURE STEP ILLUSTRATION OTHER INFORMATION 5 Select the desired tab here tab 3 6 Change the desired parameters by typing in the column value 1 7 To accept the changed data in t...

Page 78: ...ues scroll down to the bottom line Cal Save CRC 1 and enter the value 1 in the column value 9 To accept the changed data in the BMS click the button Set 1 again 10 Click the button Get 1 to check whet...

Page 79: ...d the software PARAM INFORMATION To save the changed configuration the following steps must be carried out 12 Carry out a reset at terminal 15 switched positive 13 Carry out a reset at terminal 30 per...

Page 80: ...7 Tx CCU_CELL 0x302 ID of message 0 not sent 3 8 Tx BMS_Status 0x100 ID of message 0 not sent 3 9 Tx BATT_Act 0x110 ID of message 0 not sent 3 10 Tx BATT_Range 0x111 ID of message 0 not sent 3 11 Rx N...

Page 81: ...fan power in percent The fan power depends on the input voltage at pin 2 AUX 13 4 Step1 ext fan 50 Step 1 external fan power in percent 13 5 Step1 pump 99 Step 1 external water pump power in percent...

Page 82: ...st be parameterised in such a way as to enable communication with the battery Parameter setting is carried out via the software ChargeStar which is included in the delivery content of the NLG513 charg...

Page 83: ...akes place when the defined voltage U1 is reached Now the voltage is held constantly at U1 by reducing the charging current This stage is referred to as Main Charging Phase 2 I2 and U2 The transition...

Page 84: ...Technical data and start up EVB1 350 400 40 HP 84 10 5 Charging with the NLG664 Charger The charging with the NLG664 is described in following state diagram...

Page 85: ...ble control plug PIN 13 PRO Software FDT Flash Development ToolKit 4 00 http eu renesas com media products tools eu_download fdtv400r02 exe Current firmware as a mot file PROCEDURE STEP ILLUSTRATION O...

Page 86: ...s now in Boot Mode The querying of the standard battery settings starts After Boot Mode is ended the automatic reset of the battery is activated With this the battery is ready for operation immediatel...

Page 87: ...otection choose the Automatic setting 1 For Messaging choose the Advanced setting 2 Press the Finish button 3 12 Choose the place to save your new firmware mot file in the File selection User Data Are...

Page 88: ...ally disconnected after firmware updates have been completed INFORMATION To finish the firmware update the following steps must be carried out 14 Carry out a reset at terminal 15 switched positive 15...

Page 89: ..._Min Minimum battery voltage 24 16 Cyclic V BATT_CurrentChargeMax Maximum charging current 40 16 Cyclic A BATT_CurrentDischargeMax Maximum discharging current 56 16 Cyclic A BCM 0x200 Cyclic 500 BCM_U...

Page 90: ...ll index 0 8 Cyclic CCU_Number Cell block currently read by cell index 8 8 Cyclic CCU_V Voltage of the cell currently being depicted by the cell index 24 16 Cyclic mV CCU_T Temperature of the cell blo...

Page 91: ...every start up a CRC check of the flash is carried out CRC error 0 At new Kl_15 start up E 0x1000 4096 BMS_Err_NVSRam CRC error with the important PARAM values CRC at PARAM 0x80 0xFF 0x0000 0 At new K...

Page 92: ...ax charging current exceeded BCM_A 210 A 6 8 Average value over 2 5 s At new Kl_15 start up E 0x0010 16 BMS_Err_CurrentDischarge Max discharging current exceeded BCM_A 630 A 6 17 Average value over 2...

Page 93: ...ion TE 0x0080 128 BMS_TErr_bit8 0 At new Kl_15 start up TE 0x0040 64 BMS_TErr_ChargeI2t The Charge load duration of the battery is too long I2 t of under 120A 6 6 64000 A2s 6 7 6 9 0 At new Kl_15 star...

Page 94: ...CanRx CAN receive error counter 127 CAN receive error counter 127 0 Not set condition W 0x2000 8192 BMS_War_CanTx CAN transmit error counter 127 CAN transmit error counter 127 0 Not set condition W 0x...

Page 95: ...exceeded BATT_Current_Act 2A 11 2 BATT_CurrentChargeMax 0 Not set condition W 0x0004 4 BMS_War_OverCurrentDischar ge Recommended discharging current is exceeded BATT_Current_Act 2 A 11 2 BATT_CurrentD...

Page 96: ...sults from non observance of the general and product specific safety guidelines no liability claims can be asserted against BRUSA Elektronik AG For damage to peripheries which results in connection wi...

Page 97: ...ification 27 Customer Package 22 D Derating 15 18 Device Designation Decoding 3 E Error Code Decoding 91 EVB1 350 40 HP Charging 120 A 56 charging 200 A 56 Discharging 320 A peak 57 Discharging 600 A...

Page 98: ...Technical data and start up EVB1 350 400 40 HP 98 V Validity of the Manual 3...

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