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Technical information

and start-up

Fast Charger

NLG6xx

3.2

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!

CAUTION

This instruction warns about a minor risk of injury!

Avoid this risk by adhering to these instructions!

INSTRUCTION

This instruction warns against possible damages to property if the following instructions and work
procedures are not observed.

INFORMATION

This type of instruction makes important information known to the reader.

WARNING

This instruction warns about the risk of severe but reversible injury!

Avoid this risk by adhering to these instructions!

Содержание NLG664-U0

Страница 1: ...INFORMATION AND START UP Translation of the original German operating instructions On board Fast Charger NLG664 U0 BRUSA Elektronik AG Neudorf 14 CH 9466 Sennwald 41 81 758 19 00 www brusa biz info b...

Страница 2: ...changes will be made known in the relevant manuals through the replacement of the relevant pages and or a revision of the electronic data storage device Originator author Holger Schmidt Manuel Tschump...

Страница 3: ...ion and start up Fast Charger NLG6xx 3 VALIDITY 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 designat...

Страница 4: ...AEJ1772 and or IEC61851 14 3 4 2 Mains overvoltage protection 14 3 4 3 Mains protection input current 14 3 4 4 Overcurrent protection 14 3 4 5 Overtemperature protection derating 15 3 4 6 HV Interlock...

Страница 5: ...Type plate 34 7 Connections 35 7 1 Electrical 35 7 1 1 Earthing Grounding Screw equipotential bonding 36 7 1 2 Pin assignment DC plug Code A device side 37 7 1 3 Pin assignment AC mains plug Code A de...

Страница 6: ...7 4 8 Output voltage limitation Uadem 52 8 Efficiency 53 8 1 1 Level of efficiency 1 phase charging 53 8 1 2 Level of efficiency 3 phase charging 53 9 Installation Start up 54 9 1 Installation and co...

Страница 7: ...ual properties as you read through thismanual Manufactured and tested according to European automotive standards This VDE certified charger complies with all applicable European legal requirements EMC...

Страница 8: ...ecific technical abbreviations are used The following table provides an overview of these abbreviations and their meaning Abk Bezeichnung Abk Bezeichnung BMS Battery anagementSystem LV Low Voltage BTL...

Страница 9: ...ols are used The following table provides an overview of these abbreviations and their meaning Symbol Meaning Symbol Meaning General prohibition Warning High voltage Do not touch Do not switch Symbol...

Страница 10: ...CAUTION This instruction warns about a minor risk of injury Avoid this risk by adhering to these instructions INSTRUCTION This instruction warns against possible damages to property if the following...

Страница 11: ...ess of the cooling water system particularly the pipes screw jointsand pressure tanks Repair any identifiable leaks immediately Ensure at all times that the maximum permissible pressure in the cooling...

Страница 12: ...ed sufficiently Do not install the device in direct sunlight and in direct proximity to heat sources Even though the device has a high IP protection class direct contact with water rain splashing wate...

Страница 13: ...te due to heat accumulation 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...

Страница 14: ...ated in the charger to provide permanent protection against overloading Mains overvoltage is detected by the quick sensor system and leads to immediate shut down of the charger Highly energetic overvo...

Страница 15: ...from damage due to overheating The power is reduced according to the temperature increase in order to keep the temperature within the target range The charging process is not interrupted though but c...

Страница 16: ...ich 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...

Страница 17: ...Detection the charger can detect Whether a charging cable is connected to the vehicle Which cable type is connected Which amperage is possible with the charging cable range of 6 63 A The NLG6 charger...

Страница 18: ...ecialist staff are defined as electricians who have had specific professional training have knowledge and experience in the field of electronics electricmobility as well as knowledge of relevant provi...

Страница 19: ...The operational and safety instructions provided are to be adhered to in order to ensure personal safety as well the ongoing optimum functioning of the charger This is also a precondition to meet warr...

Страница 20: ...rds The NLG6 charger is designed according to IEC61851 mains side and LV123 HV DC side The NLG6 charger is exclusively approved for Europe The NLG6 charger is CE compliant EMC radiation must be evalua...

Страница 21: ...ufacturer are regarded as improper use The following limit values are defined for the operation of the Fast Charger NLG6xx Operation outside of these defined limit values may lead to the device becomi...

Страница 22: ...Technical information and start up Fast Charger NLG6xx 22...

Страница 23: ...ncy 45 65 Hz Max Input power 22 kW Power factor 0 99 Power Factor Correction PFC Yes Mains protection all phases 40 A Lightning protection overvoltage protection IEC61000 4 5 Class 2 X capacity 4 7 F...

Страница 24: ...coolant mixture ratio of 50 50 100 mbar Max cooling circuit pressure 3 0 bar Ambient temperature range for storage 40 to 105 C Ambient temperature range operation 2 40 to 85 C Basic mechanical data N...

Страница 25: ...arging until CAN communication 1 s Sample point 81 BTL cycles 16 SJW 3 6 2 Warnings on the device Warning signs are installed on the device to warn the operator of possible dangers Should one of these...

Страница 26: ...battery current ripple Evaluation of external PT1000 sensors Vehicle WakeUp output to wake up the vehicle when the charging plug is plugged in 6 4 Basic function The NLG6 transforms 1 or 3 phase alte...

Страница 27: ...y voltage reaches 316 V hysteresis dependent switchover threshold If the battery voltage is 310 V when switching on the charger 3 phase charging is automatically activated 6 4 2 PFC compensation To op...

Страница 28: ...standards Mode 3 Alternating current AC charging from a dedicated EV charging appliance either provided by means of a socket usually type 1 or type 2 or a fixed mode 3 charging cable connected to the...

Страница 29: ...s of the battery charger can only be guaranteed if all signal wires to the signal connectors are assembled and connected to a tight unit on both sides If this is not the case for a cable or wire it mu...

Страница 30: ...Technical information and start up Fast Charger NLG6xx 30 6 6 1 Fixing points 1 Device mounting M8 x 20 screw Torque 25 Nm 2 Holes for attachment of fir tree clips...

Страница 31: ...izontally 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...

Страница 32: ...Technical information and start up Fast Charger NLG6xx 32 6 7 Vehicle installation basic principle...

Страница 33: ...Technical information and start up Fast Charger NLG6xx 33 6 8 Block diagram...

Страница 34: ...fied by the customer 4 Space for customer specific labels 5 3D bar code 6 2D bar code 7 IP protection class not connected 8 IP protection class fully connected 9 Max DC side charging capacity 10 Max A...

Страница 35: ...rew Torque 12 5 Nm refer to chapter 7 1 1 Grounding Screw equipotential bonding 2 DC plug code A refer to chapter 7 1 2 Pin assignment DC plug Code A device side 3 Mains plug refer to chapter 7 1 3 Pi...

Страница 36: ...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 The grounding cable m...

Страница 37: ...tion and start up Fast Charger NLG6xx 37 7 1 2 Pin assignment DC plug Code A device side 1 HV Batt HV battery plus 2 HV Batt HV battery minus 3 DC_HVIL_in HV interlock loop input 4 DC_HVIL_out HV inte...

Страница 38: ...Fast Charger NLG6xx 38 7 1 3 Pin assignment AC mains plug Code A device side 1 PE Protective earth conductor 2 L3 Phase 3 3 L2 Phase 2 4 L1 Phase 1 5 N Neutral conductor 6 AC_HVIL_out HV interlock out...

Страница 39: ...EV CAN low 9 HVIL_in HV interlock loop input 10 HW_WakeUp Hardware wake up input 11 Debug_CAN_H CAN high Debug 12 Debug_CAN_L CAN low Debug 7 1 4 1 Pin 1 Kl30 INSTRUCTION At this pin supply voltage m...

Страница 40: ...Internal wiring CAN 2 0B 500 kBaud In the charger there is no termination present CAN terminating resistor The CAN IDs can be changed by PARAM tool if required 7 1 4 3 Pin 3 Kl30C Internal wiring In c...

Страница 41: ...Technical information and start up Fast Charger NLG6xx 41 5 V conforms to no Crash...

Страница 42: ...ot properly locked the charger and battery should immediately be switched off by the external interlock system so dangerous situations can be avoided 7 1 4 5 Pin 7 Kl31 This pin is directly connected...

Страница 43: ...e data of this CAN bus can also be logged by the customer This may be helpful in case of an in depth system diagnosis The Debug CAN bus must not be connected to the vehicle CAN bus as this may lead to...

Страница 44: ...1 Plug locking 6 RELAY_L2 7 TEMP_Con Input PT1000 temperature sensor 8 RELAY_U2 Vehicle WakeUp output 9 LED_Red Output LED red 10 RELAY_U1 Plug unlocking 11 CTL_PIL Control Pilot 12 Kl31_out Earth out...

Страница 45: ...Technical information and start up Fast Charger NLG6xx 45...

Страница 46: ...tor see chapter 3 4 7 Proximity Detection The maximum current of the charging cable is defined by the proximity resistor according to the following table Amperage Resistance Max 63 A 100 R Max 32 A 22...

Страница 47: ...argerreturns to Sleep mode and the output is set to open INSTRUCTION The Pin RELAY_U2 is not suitable to supply 12V units The highest acceptable continuous current is max 50mA short peaks e g switch o...

Страница 48: ...e 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 1 Cooling...

Страница 49: ...ral 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 b...

Страница 50: ...ge controlled event Now the charger tries to establish a connection via CAN to the higher level control system e g VCU 7 3 4 WakeUp via Control Pilot CP Control Pilot CP is a standardized safety signa...

Страница 51: ...amage 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 dera...

Страница 52: ...7 4 4 Proximity Detection The Proximity Detection system is safety relevant Further information can be found in chapter 3 4 7 Proximity Detection acc to IEC 61851 7 4 5 Control Pilot The Control Pilo...

Страница 53: ...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 p...

Страница 54: ...ed appropriate training Always act carefully and avoid jerking movements INFORMATION Prior to installation visually check the packing material and particularly the device itself for damage Each device...

Страница 55: ...r plates are to be used these must be attached to the charger first Torque 20 Nm 2 Nm 6 Remove covers 1 of the cooling water connections 7 Connect the cooling water connections 1 and 2 to the charger...

Страница 56: ...onding 9 Connect the LV plugs 1 and 2 to the charger Manually check if the LV plugs 1 and 2 are fastened securely Always ensure suitable mounting of the required strain relief elements The tightness o...

Страница 57: ...the required strain relief element Ensure that the HV battery used includes a pre charging unit For more information refer to chapter 9 3 Precharge output capacitor Any connection without pre charging...

Страница 58: ...umstances carryout 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...

Страница 59: ...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 Disconnect the earth connection from the char...

Страница 60: ...nnections 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...

Страница 61: ...on of the charger they must be removed appropriately 13 Use appropriate equipment to lift the charger out of its installation location Charger weight 12 kg INFORMATION If the device is to be sent to B...

Страница 62: ...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...

Страница 63: ...he device is now established 10 Operation INFORMATION The unit is controlled via CAN please see Software Manual for moreinformation Also refer to chapter 4 2 Scope of the documentation 11 Warranty and...

Страница 64: ...14 62 H High voltage The 5 safety rules 14 I Installation notes 30 31 Interlock 17 Interlock pin assignment 37 38 39 41 L LED pin assignment 44 Level of efficiency 51 N Notes on assembly 13 Notes on...

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