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59

Technical data

and start-up

NLG5 charger

8.2.2

Programming New Charging Profiles

INSTRUCTION

The programming of a charging profile should only be carried out by experienced specialist
personnel! Incorrectly defined parameters will lead to the malfunctioning of the charger and the
connected HV battery! So in case of any questions or confusion, contact BRUSA Support at the
manufacturer address given in chapter

!

INFORMATION

With ChargeStar you have the possibility of configuring existing charging profiles to fit in with your
own requirements or even programming new charging profiles.

PROCEDURE STEP

ILLUSTRATION / OTHER INFORMATION

1.

If you have not yet done so, start the

ChargeStar

software.

2.

In the

Profiles

menu, press

New

(1).

To configure an existing charging profile, load
the charging profile in question from the
database. For this see chapter

8.2.1 Loading

Charging Profiles from the Database

3.

Enter the required values in the field

(1).

See chapter

8.2.7.1 General Parameters

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Summary of Contents for NLG513

Page 1: ...BRUSA Elektronik AG Neudorf 14 CH 9466 Sennwald 41 81 758 19 00 info brusa biz www brusa biz NLG513 TECHNICAL DATA AND START UP Translation of the original German operating instructions NLG513...

Page 2: ...punishable offence Updates In light of the further technical development of our products we reserve the right for technical changes Any changes will be disclosed in the relevant manuals through the re...

Page 3: ...l data and start up NLG5 charger VALIDITY This manual is valid only for the following devices NLG513 U1 01A water cooled version NLG513 U1 02A air cooled version Decoding of the device designation is...

Page 4: ...ual 14 4 2 Scope of the Entire Documentation 14 4 3 Scope of Delivery 14 4 4 Optional Scope of Delivery 15 4 5 EU Guidelines 16 4 6 Contact Information of the Manufacturer 16 5 Use and Limits of the P...

Page 5: ...17 IL2 34 6 8 4 11 Pin 18 DI3 Pin 19 DI4 35 6 8 4 12 Pin 20 TS1 35 6 8 4 13 Pin 21 TS2 Pin 22 TS3 36 6 8 4 14 Pin 23 PI 36 6 9 Dimensions and Installation Information 37 6 9 1 Fixing Points 37 6 9 2...

Page 6: ...ar 57 8 2 1 Loading Charging Profiles from the Database 57 8 2 2 Programming New Charging Profiles 59 8 2 3 Retrieving Current Charging Profile from the Charger 62 8 2 4 Retrieving the Battery Propert...

Page 7: ...r carry out any 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...

Page 8: ...meaning in the following table PROHIBITION SYMBOLS SYMBOL MEANING SYMBOL MEANING General prohibition Warning high voltage Touching forbidden Switching on forbidden WARNING SYMBOLS SYMBOL MEANING SYMB...

Page 9: ...ion 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 dange...

Page 10: ...lines 3 3 1 Safety instructions for cooling water systems WARNING Spurting cooling fluid Skin burning hazard Check the tightness of the cooling water system particularly the pipes screw joints and pre...

Page 11: ...ng water temperature or ambient temperature reduces the life span So take ongoing care to ensure sufficient cooling of the device Do not place the device in direct sunlight and in close proximity to h...

Page 12: ...azard If using a cable reel this can catch fire through heat accumulation You must completely unroll the cable rolls INSTRUCTION Under no circumstances should the device be opened without authorisatio...

Page 13: ...tinuous operation at the temperature limit will inevitably lead to a higher level of wear of the components This security installation is the charger s self protection If the charger reaches a defined...

Page 14: ...ing optimum functioning of the charger This is also a precondition to meet the warranty requirements of BRUSA Elektronik AG 4 2 Scope of the Entire Documentation INFORMATION In order to successfully c...

Page 15: ...wire diameter of 0 5 mm 2 23 pieces AMPSEAL 770854 1 crimp terminals 4 pieces NTC 1 piece 9 pole SUB D We recommend the use of the following crimping tool for the assembly Tyco 58440 1 MPAA208 2 Main...

Page 16: ...on of the EC guidelines national laws and harmonised standards EN valid at the time of production relevant to the product NLG5 charger 4 6 Contact Information of the Manufacturer BRUSA Elektronik AG N...

Page 17: ...to be used solely at research and development facilities for such purposes 5 2 Improper Use Limits of the Product The carrying out of applications which do not conform to the conditions and requireme...

Page 18: ...1 1 Max charging current 12 5 12 5 A Charging current accuracy 2 2 Charging current ripple amplitude 100 fr 2 fn 100 Hz 12 5 12 5 A X capacity 7 9 7 9 F Y capacity B B PE 16 5 16 5 nF THERMAL COOLING...

Page 19: ...re protection yes yes Temperature sensor 1 PT1000 25 C 1097 1097 Temperature sensor 2 and 3 NTC 25 C 33 33 k Min insulation resistance initial 2 2 G WIRING SYSTEM INTERFACE AUX NLG5 AIR COOLED NLG5 WA...

Page 20: ...e 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 must be renewed immediately To get an origin...

Page 21: ...various charging power requirements can be met from motorcycles cars delivery vehicles and buses to lorries The maximum input current on 230 V 240 V mains is 16 A and is thereby within the loading ca...

Page 22: ...ew of the Main Structural Components Water cooled NLG5 1 Cooling water inlet 15 2 mm 2 Cooling water outlet 15 2 mm 3 HV battery socket plug output 4 Mains socket plug input 5 Type plate 6 Earth conne...

Page 23: ...harger 6 6 Overview of the Main Structural Components Air cooled NLG5 1 HV battery socket plug output 2 Mains socket plug input 3 Type plate 4 Earth connection 5 Control plug 6 Pressure equalisation m...

Page 24: ...air pockets are available in the cooling system The vent can also be done by pressure or vacuum filling Please note the maximum allowable system pressure Air pockets in the cooling system can lead to...

Page 25: ...ns in terms of position and pin assignment 1 23 pole control plug See chapter 6 8 4 Pin Assignment Control Plug Device side 2 Modular plug output See chapter 6 8 3 Pin Assignment Modular Plug Output D...

Page 26: ...h connection is connected correctly A loose ground circuit can lead to sparking and subsequent fires INFORMATION The grounding screw 1 must be connected with the ground of the vehicle The cable diamet...

Page 27: ...nput 2 Pin2 Reserve 3 Pin3 L1 Input mains supply phase 4 Pin4 CP Control pilot CP 5 Pin5 Reserve 6 8 3 Pin Assignment Modular Plug Output Device side 0 Pin0 PE Protective grounding 1 Pin1 B Negative b...

Page 28: ...NL CAN low 10 CNH CAN high 11 TXD RS232 transmit 9 pole D Sub pin 2 12 RXD RS232 receive 9 pole D Sub pin 3 13 PRO Enable firmware download 14 PG2 Ground signal 2 9 pole D Sub pin 5 15 PG3 Ground sign...

Page 29: ...V Direct earth connection of the charger s control electronics 6 8 4 2 Pin 2 AUX INFORMATION As soon as the power cord is connected it supplies input output 14 V max 0 5 A It then provides external si...

Page 30: ...r cord is connected the internal control unit can be activated via this pin e g for programming a charging profile For this pin 2 must be AUX high 12 V voltage is applied To activate the automatic cha...

Page 31: ...V 200 5V These pins switch to ground GND and are short circuit proof I 400 mA 6 8 4 6 Pin 8 PG1 Pin 14 PG2 Pin 15 PG3 INFORMATION The additional earth connections are intended to simplify the external...

Page 32: ...ace has the following features possibilities CAN 2 0 B 500 kHz default parameters can be set 125 250 500 1000 kBit s Both pins are electrically isolated from the ground GND avoiding faults through pot...

Page 33: ...CAN parameters can be adapted See chapter 8 2 ChargeStar The firmware for the microprocessor can be downloaded via this interface provided by BRUSA Pin 13 PRO must be high for this The running operati...

Page 34: ...ensure a passive HV DC side interlock functionality two interlock contacts are provided The interlock circuit does not have to be wired up for the charger to function In order to ensure safety we rec...

Page 35: ...48V 5V Analog Multi plexer Pin 20 TS1 5V 5 6k 5V At pin 20 TS1 the charging socket temperature can be monitored through a PT1000 resistor The NLG5 carries out the monitoring of the charging socket te...

Page 36: ...nected temperature sensors must be configured in the included ChargeStar software A temperature sensor which is not connected but configured leads to an error report and thereby shuts the charger down...

Page 37: ...must be installed so that a constant fresh air supply is guaranteed This has a direct influence on the power of the device derating The mechanical fixings must be arranged so that the device is fitted...

Page 38: ...Technical data and start up NLG5 charger 38 6 9 2 Dimensions Water cooled NLG5 6 9 3 Dimensions Air cooled NLG 5...

Page 39: ...39 Technical data and start up NLG5 charger 6 10 Basic Principle for Installation into the Vehicle...

Page 40: ...Technical data and start up NLG5 charger 40 6 11 Block Circuit Diagram NLG5...

Page 41: ...2 Regulation and Control System The following graph gives an overview of the way the different derating and shut down installations of the charger work and how they are related Green Signal Yellow Con...

Page 42: ...2 is determined using the current level I2 and the voltage level U2 Transition to the next charging stage occurs automatically if specific criteria are met e g falling below a defined charging curren...

Page 43: ...ontrolled by an external BMS via the CAN During this the charger receives all the parameters from the BMS and adapts the charging voltage and charging current to the inputs instructions In this mode t...

Page 44: ...er limitations This way depending on the mode of operation mode A or C the charging power which should be supplied by the module is produced The power limiters Power Indicator and Control Pilot are ad...

Page 45: ...0 V x 16 A 3680 W from the mains socket In Switzerland the maximum mains power is 2990 W 230 V x 13 A 2990 W from the mains socket 6 14 3 Max Mains Current The charger limits the largest permitted mai...

Page 46: ...esistance level can be seen in the following table Voltage relationship RPower indicator k IAC supply A Voltage relationship RPower indicator k IAC supply A 0 00 0 000 0 0 0 45 0 818 9 0 0 05 0 053 1...

Page 47: ...g material and the charger itself in particular for damages before installation Each charger undergoes a strict quality and function test at BRUSA before distribution However we have no control over t...

Page 48: ...d any of the electrical connections yet 10 Connect the battery cable output modular plug 1 with the charger Close the locking clip 2 INSTRUCTION Pay attention to the cable colours when connecting the...

Page 49: ...art up NLG5 charger PROCEDURE STEP ILLUSTRATION OTHER INFORMATION 12 Connect the mains cable modular plug input 1 with the charger Close the locking clip 2 13 Connect the charging cable to the chargin...

Page 50: ...S232 interface See chapter 6 8 4 8 Pin 11 TXD Pin 12 RXD 3 Switch pin 2 AUX to high or connect the device to an external 12 V supply 4 Make the connection to the charger Then check the operational dat...

Page 51: ...connections in case the connection cannot be established and repeat the procedure 10 In the Profiles menu press Send to NLG 1 The charging profile is sent to the NLG 11 In the Connection menu press Di...

Page 52: ...tion between the PC and the charger INFORMATION The charger is now configured and can be completely installed For this perform the procedure steps in chapter 7 1 Installing and Connecting the Charger...

Page 53: ...e used as a monitor The pre charging 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...

Page 54: ...llowing sequence is described using the example of the HyperTerminal software HyperTerminal is integrated in most Windows versions as standard Alternatively this programme can be obtained directly fro...

Page 55: ...roperties is opened 5 Set the limits as follows 1 19200 2 8 3 None 4 1 5 Xon Xoff Close the dialogue box by clicking the OK button 6 6 End HyperTerminal 7 Connect the serial interface COM1 of the PC w...

Page 56: ...your keypad Errors Warnings menu To retrieve current status reports e g serial number date of manufacture software version press the S button on your keypad By pressing the M button you go back to th...

Page 57: ...be used as examples These can be changed at any time There is also the possibility of creating your own charging profiles You can find details on this in chapter 8 2 2 Programming New Charging Profile...

Page 58: ...ATION 4 To transfer the charging profile to the charger press Send to NLG in the Profiles menu The charging profile is transferred to the NLG INFORMATION The charger must be restarted to adopt activat...

Page 59: ...6 INFORMATION With ChargeStar you have the possibility of configuring existing charging profiles to fit in with your own requirements or even programming new charging profiles PROCEDURE STEP ILLUSTRA...

Page 60: ...1 See chapter 8 2 7 2 Shut Down Parameters 5 Configure your charging profile in the field 1 See chapter 8 2 7 3 Parameters for Charging Profiles 6 To save the charging profile press Save file 1 in th...

Page 61: ...ATION 7 To transfer the charging profile to the charger press Send to NLG in the Profiles menu The charging profile is transferred to the NLG INFORMATION The charger must be restarted to adopt activat...

Page 62: ...N OTHER INFORMATION 1 If you have not yet done so start the ChargeStar software 2 In the Connection menu press Connect with NLG 1 The connection to the charger is being established When the connection...

Page 63: ...e charging profile can be allocated accordingly every time The battery properties always relate to the charging profile which is currently loaded in ChargeStar PROCEDURE STEP ILLUSTRATION OTHER INFORM...

Page 64: ...tar software 2 In the Connection menu press Connect with NLG 1 The connection to the charger is being established When the connection is active the report Connected with device will appear in the fiel...

Page 65: ...rienced specialist personnel PROCEDURE STEP ILLUSTRATION OTHER INFORMATION 1 If you have not yet done so start the ChargeStar software 2 In the Connection menu press Connect with NLG 1 The connection...

Page 66: ...r 66 PROCEDURE STEP ILLUSTRATION OTHER INFORMATION 4 In the dialogue box Options the different CAN parameters can now be changed Press the OK button 1 to close the dialogue box You can find details on...

Page 67: ...Specification of the battery temperature from which the gassing voltage is reduced when the temperature is rising From this battery temperature the charger keeps the gassing voltage constant 4 Active...

Page 68: ...ers function as an additional safety installation The charger is shut down for safety reasons anyway if one of these parameters is reached or surpassed 1 Battery temperature over C Charger shuts down...

Page 69: ...ld take place And this means that as a result if one or more parameters are reached during the charging process a transition into the next stage will take place automatically 1 Selection field stage 1...

Page 70: ...g of used electronic devices is the correct disposal With the implementation of the electric and electronic device regulation ElektroG since 24 March 2006 electronic devices may no longer be disposed...

Page 71: ...nections 25 Specification 19 Customer Package 14 D Derating 13 45 F Firmware 34 G Ground Connection 30 Guarantee Instruction 12 H High voltage The 5 Safety Rules 12 M Main Contactor Function 54 N NLG5...

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