Brusa PDU254 Series Technical Data And Start-Up Download

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BRUSA Elektronik AG
Neudorf 14
CH

–9466 Sennwald

+41 81 758 19 00
[email protected]

www.brusa.biz

PDU254

ASM

TECHNICAL DATA

AND START-UP

Translation of the original German operating instructions

Summary of Contents for PDU254 Series

Page 1: ...BRUSA Elektronik AG Neudorf 14 CH 9466 Sennwald 41 81 758 19 00 info brusa biz www brusa biz PDU254 ASM TECHNICAL DATA AND START UP Translation of the original German operating instructions...

Page 2: ...sclosed in the relevant manuals through the replacement of the relevant pages and or a revision of the electronic data storage device Writer Author Holger Schmidt REVISIONS REVISION DATE NAME CHANGE 0...

Page 3: ...3 Technical data and start up PDU254 VALIDITY 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...

Page 4: ...y concept for vehicle installation 13 3 5 1 Principle of operation Interlock 13 3 6 Requirements regarding the start up personnel 14 4 General 14 4 1 Content and scope of this manual 14 4 2 Scope of t...

Page 5: ...ions 25 6 7 4 Fully assembled view 26 6 8 Type plate 26 7 Connections 27 7 1 Input side 27 7 2 Output side 28 7 3 Earth GND 29 7 4 Pin assignment of control connector device side 30 7 4 3 Pin 4 DO0 32...

Page 6: ...installing the battery or carrying out any other work on it 2 List of abbreviations Throughout this manual some specific technical abbreviations are used The following table provides an overview of th...

Page 7: ...symbols and their meaning PROHIBITION SYMBOLS SYMBOL MEANING SYMBOL MEANING General prohibition Warning High voltage Do not touch Do not switch WARNING SYMBOLS SYMBOL MEANING SYMBOL MEANING General h...

Page 8: ...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...

Page 9: ...ircuits and fires as a consequence Do not store any highly flammable substances or combustible fluids in the direct surroundings of the device Sparks forming at the device connections can set these on...

Page 10: ...off a turning motor can still produce voltage INFORMATION When working on a HV grid the following 5 safety rules have to be strictly adhered to Disconnect the system from the voltage supply Switch of...

Page 11: ...up PDU254 3 4 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 a...

Page 12: ...he 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 suppl...

Page 13: ...ck switch 1 is closed if the corresponding interlock condition of each devices is met closed service cover plugged HV connections The interlock evaluation of the PDU switches the 12V supply voltage 2...

Page 14: ...e device and the safety measures necessary for these purposes Furthermore it contains technical data usage information and a basic description of the battery and its specific components The operationa...

Page 15: ...770680 1 1 6 SN LP contacts AMPSEAL 770854 1 for wire diameter 0 5 mm 2 We recommend the use of the following crimping tool Tyco 58440 1 25 7 Blanking plug M25 for main connections 10 8 Blanking plug...

Page 16: ...rt up PDU254 16 MEANING PIECES ILLUSTRATION 15 Washers for fuse 300A installation 16 16 Screw M8x22 for fuse 300A installation 12 17 Serrated lock washers for cable lug connection 6 18 Screw M4x8 for...

Page 17: ...plicable standards 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 prod...

Page 18: ...te these applications with the manufacturer and to obtain a written approval for these uses INFORMATION This equipment is a custom built evaluation kit destined for professionals to be used solely at...

Page 19: ...pressor 25 mm2 Recommended cable diameter for small scale energy users up to max 24 A 4 mm2 POWER DATA AT 25 C VALUE UNIT Peak current BATT 1 2 connection DMC 1 2 connection 300 A Peak current BATT 1...

Page 20: ...nection with 100 A fuse protected for range extender RXT or DC quick charger 3 connections for additional peripheral devices e g charger air conditioning compressor on board converter etc 6 3 Warnings...

Page 21: ...ntrol connector device side 5 Earth GND Chap 7 3 Earth GND 6 Housing 7 Fuse 100 A 8 Interlock switch see chapter 3 4 1 Interlock switch 9 Fuse 20 A 10 Type plate see chapter 6 8 Type plate 11 Connecti...

Page 22: ...00 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 ch...

Page 23: ...23 Technical data and start up PDU254 6 6 Basic principle of vehicle installation...

Page 24: ...tion make sure that the connection sides are positioned as horizontally as possible This prevents water accumulation on the cable sealings which could result in water leaking into the housing The mech...

Page 25: ...25 Technical data and start up PDU254 6 7 2 Housing dimensions 6 7 3 Interface dimensions...

Page 26: ...tion dd mm yy 5 Admissible voltage range HV battery 6 Fuse protection output DMC1 DMC2 admissible maximum current see chapter 7 2 Output side 7 Fuse protection output RXT admissible maximum current se...

Page 27: ...a 1 Battery input 1 HV plus 2 Battery input 1 HV minus 3 Battery input 2 HV plus 4 Battery input 2 HV minus 5 Cascading output HV plus Output for the connection of a second PDU 6 Cascading output HV m...

Page 28: ...Fuse protection 20 A 2 Output BSC Fuse protection 20 A 3 Output NLG Fuse protection 20 A 4 Output RXT HV plus Fuse protection 100 A 5 Output RXT HV minus Fuse protection 100 A 6 Output DMC2 HV plus F...

Page 29: ...ench 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...

Page 30: ...e side 1 GND Earth minus wiring system terminal 31 2 3 EN Enable power ON terminal 15 4 DO0 Digital output 1 5 DO1 Digital output 2 6 7 DO3 Digital output 4 8 9 10 11 12 13 14 15 16 DI0 Digital input...

Page 31: ...3 EN Internal wiring 100 F Pin 3 EN Internal Supply PTC 1 5A 36V AUX safe The control unit of the PDU is only supplied via this connection The device is generally ready for operation as soon as a volt...

Page 32: ...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 7 4 4 Pin 5 DO1 Internal w...

Page 33: ...result the main contactors are immediately opened 7 4 6 Pin 19 IL1 pin 20 IL2 Internal wiring 10nF Pin 19 INL1 Pin 20 INL2 K 48V INL Generator Deckel Schalter Pin 19 INL1 is the output signal of the i...

Page 34: ...ised Before carrying out any work on the PDU follow strictly the safety instructions chap 3 3 2 Safety instructions for electrical systems and the 5 safety rules for working on a HV grid INFORMATION T...

Page 35: ...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 Establish the earth connection between the PDU...

Page 36: ...FORMATION 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...

Page 37: ...e 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 11 Pla...

Page 38: ...crew M8 x 22 Torque of screws M8 x 22 12 Nm If you use just one side of the fuse for example with two DMC5 and one Battery it s necessary to use a washer instead of the cable lug 1 Washer 2 Fuse 3 Was...

Page 39: ...s 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 Check the interaction of the a...

Page 40: ...U254 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 Cl...

Page 41: ...r the type see chapter 4 3 Scope of delivery To assemble the cable lugs using the appropriate crimping tool is absolutely necessary INSTRUCTION You must absolutely make sure that the individual strand...

Page 42: ...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 electric...

Page 43: ...ck the secure positioning of the cable lug manually 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...

Page 44: ...ecycling 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 ord...

Page 45: ...Dimensions of housing 19 25 Dimensions of interfaces 25 Disposal 45 E Earth connection GND 29 F Fully assembled view 26 I Important installation instructions 9 Installation instructions 24 Interlock...

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