pdu254 - brusa.biz · symbol meaning symbol meaning general prohibition warning! ... this safety...

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

Technical data and start-up

PDU254 2

LEGAL NOTICE

Publisher BRUSA Elektronik AG

Neudorf 14 CH–9466 Sennwald T +41 8175 809–00 F +41 8175 809–99 www.brusa.biz [email protected]

Date of issue 19. January 2013

Copyright © 2012

The content of this document may not be passed on to third parties without the written authorisation of the company BRUSA Elektronik AG - not even in extracts. All technical information, drawings and photos used in this document are protected by copyright and any infringement constitutes a punishable offence!

Updates In light of the further technical development of our products, we reserve the right to make constructional changes. Any changes will be disclosed 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

01 30.04.2013 H. Schmidt Chap 3.3, 3.5, 7.4, 7.4.2 small corrections Chap 6.7.3 and 6.7.4 added

02 06.08.2013 M. Tschumper Chap 8.1 new, 8 small corrections

03 27.01.2014 M. Tschumper Chap 3.5 Principle of operation Interlock

04 18.02.2014 M. Tschumper Chap 6.5.1 added signal pin in diagram

05 20.02.2014 M. Tschumper Chap 8 grafic 7.12..14.15

06 12.02.2015 R. Roth Chap 4.2 adjust the scope of delivery

Chap 8 adjust table with information about the screw

07 04.06.2015 F. Müller Chap 8.1 add information about cable and terminal insert

08 28.11.2016 A. Girod Chap 9 updated

09 26.06.2017 M. Cvorak Chap 6.1 DEL: discharge resistor;

Chap 7.4.2; 7.4.4 DEL: reverence to active discharge

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:


PDU254 4

TABLE OF CONTENTS

1 Foreword .............................................................................................................................. 6

2 List of abbreviations ........................................................................................................... 6

3 Safety and warning instructions ........................................................................................ 7

3.1 Symbols and their meaning ........................................................................................................ 7

3.2 Safety instructions and danger levels ......................................................................................... 8

3.3 Generally applicable safety measures ........................................................................................ 9

3.3.1 Safety instructions for handling and operation ..................................................................... 9

3.3.2 Safety instructions for electrical systems ........................................................................... 10

3.4 Safety installations ................................................................................................................... 11

3.4.1 Interlock switch .................................................................................................................. 11

3.4.2 Shorting link ...................................................................................................................... 12

3.5 Safety 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 the entire documentation ........................................................................................... 14

4.3 Scope of delivery ...................................................................................................................... 15

4.4 Optional delivery contents ........................................................................................................ 17

4.5 Applicable standards ................................................................................................................ 17

4.6 Contact information of the manufacturer ................................................................................... 17

5 Use and limits of the product ........................................................................................... 18

5.1 Proper use................................................................................................................................ 18

5.2 Improper use ............................................................................................................................ 18

6 About this device............................................................................................................... 19

6.1 Technical data .......................................................................................................................... 19

6.2 Technical properties ................................................................................................................. 20

6.3 Warnings on the PDU ............................................................................................................... 20

6.4 Overview of the main structural components ............................................................................ 21

6.5 Basic function PDU254 ............................................................................................................ 22

6.5.1 Block diagram PDU254 ..................................................................................................... 22

5


6.6 Basic principle of vehicle installation ........................................................................................ 23

6.7 Dimensions and installation information ................................................................................... 24

6.7.1 Fixing points ...................................................................................................................... 24

6.7.2 Housing dimensions .......................................................................................................... 25

6.7.3 Interface dimensions ......................................................................................................... 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

7.4.4 Pin 5 DO1 ......................................................................................................................... 32

7.4.5 Pin 7 DO3, pin 16 DI0 ....................................................................................................... 33

7.4.6 Pin 19 IL1, pin 20 IL2 ........................................................................................................ 33

8 Installation / initial start-up ............................................................................................... 34

8.1 Connecting the HV lines ........................................................................................................... 41

9 Warranty ............................................................................................................................. 44

10 Instructions for disposal ............................................................................................... 44

11 Index ................................................................................................................................ 45


PDU254 6

1 Foreword

Dear customer!

With the BRUSA PDU254, you have obtained a very capable and versatile product. As this is a power electronics

product, specialist knowledge is required for dealing with it as well as operating it!

Read this manual – in particular the chapter Safety and warning instructions– carefully before 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 these abbreviations and their meaning:

ABBR. MEANING ABBR. MEANING

AUX Auxiliary IL Interlock

BSC On-board converter NLG Netzladegerät (mains charger)

DMC Digital Motor Controller (inverter) PDU Power Distribution Unit

EMC ElectroMagnetic Compatibility PTC Resistor with Positive Temperature Coeffizient

HF High Frequency RXT Range Extender

HV High Voltage

7


3 Safety and warning instructions

In this chapter, you will find safety instructions applying to this device. These instructions refer to the assembly,

start-up and the running operation in the vehicle. Always read and observe these instructions in order to protect

people's safety and lives and to avoid damage to the device!

3.1 Symbols and their meaning

Throughout this manual, some specific technical symbols are used. The following table provides an overview of

these symbols and their meaning:

PROHIBITION SYMBOLS

SYMBOL MEANING SYMBOL MEANING

General prohibition

Warning! High voltage!

Do not touch!

Do not switch!

WARNING SYMBOLS


General hazard warning

Warning! Danger caused by suspended loads!

Warning! Explosive environment!

Warning! Danger caused by batteries!

Warning! Hot surface!

Warning! High voltage!

Warning! High pressure / fluid ejection!

Warning! Fire hazard!

MANDATORY SIGNS


Disconnect device from voltage

Disconnect device from mains

Wear protective glasses

Wear protective gloves

INFORMATION SIGNS


Important information on avoiding possible damage to property

Important information


PDU254 8

3.2 Safety instructions and danger levels

DANGER

This instruction warns against serious, irreversible risks of personal injury with possibly fatal consequences!

Avoid these risks by observing these instructions!

WARNING

This instruction warns against serious but reversible risks of injury!


CAUTION

This instruction warns against a minor risk of injury!


INSTRUCTION

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

INFORMATION

This type of instruction discloses important information for the reader.

9


3.3 Generally applicable safety measures

The following safety measures have been developed based on the knowledge of the manufacturer. They are

incomplete as they can be supplemented by local and/or country-specific safety instructions and guidelines for

accident prevention!

The system integrator and/or distributor of the device must therefore supplement the present general safety

instructions by country-specific and local guidelines.

3.3.1 Safety instructions for handling and operation

WARNING

Overheating!

Fire hazard!

The plus and minus poles must not be bypassed using a metallic object! This will lead to a short-circuit and fast overheating of the device and the cables!

Do not carry out any unauthorised work on the PDU! This may cause the safety installations to be disabled and could lead to fires as a consequence!

The device must by no means be subjected to rough mechanical impacts! This could destroy the circuit boards and lead to short-circuits 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 fire and lead to explosions!

WARNING

Hot surfaces!

Burn hazard!

The device produces high levels of waste heat when in operation. Carelessly touching the device can cause burns to the skin! Therefore, the device is to be handled with care and caution at all times! Avoid operating the device close to heat sources or in direct sunlight!

INSTRUCTION

Even though the PDU has a high IP protection class, direct contact with water (rain, splashing water) during operation is to be avoided as far as possible!

Under no circumstances should you put a low-resistance connection between the HV contacts, the housing contacts and the LV contacts! This will lead to malfunctions and furthermore to the destruction of the PDU!

Before connecting the cabling, make sure that the battery cables have been properly connected! Reverse polarity can lead to the destruction of not only the battery but of other devices as well!

Check if the used system voltage is within the admissible range before connecting the cabling!


PDU254 10

3.3.2 Safety instructions for electrical systems

DANGER

High voltage!

Danger to life!

Do not touch the HV wires or connections without ensuring the absence of voltage beforehand!

The PDU may only be connected by a qualified electrician!

Safety installations must not be by-passed or avoided! Any resulting malfunctions could have life threatening consequences!

Before carrying out any work on the PDU, make sure that the coupled motor has come to a complete standstill! Even when the HV supply is switched 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 off the ignition. Remove service / maintenance plug and/or turn off main battery switch. Remove fuse (external fuse box).

Ensure that the system does not reconnect. Keep ignition key safe to prevent unauthorised access. Keep the service / maintenance plug safe to prevent unauthorised access and/or use lockable cover cap to ensure that the main battery switch does not reconnect.

Ensure that the device is de-energised by means of a suitable voltage tester (note voltage range!)

Earth and short-circuit the system.

Cover or seal off adjacent live parts.

11


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 as the service cap is opened.


PDU254 12

3.4.2 Shorting link

In order to put the PDU into a safe state for assembly work, a shorting link (1) is included in the 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 supply. In order to additionally short-circuit the

PDU, the shorting link (1) must be inserted into the contacts (3) and (4). This will put the PDU into a safe state.

13


3.5 Safety concept for vehicle installation

INFORMATION

This safety concept is a recommendation of the company BRUSA Elektronik AG and is a general requirement for the safe operation of electric vehicles!

3.5.1 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 ...). The interlock evaluation of the PDU switches the 12V supply voltage (2) of the

HV contactors (4) in the battery if the interlock circuit is closed. The emergency stop switch (3) also interrupts the

12V supply voltage of the HV contactors (4). The second interlock (5) of the line insulation guard interrupts the

interlock circuit, if a fault in the HV- insulation is detected.


PDU254 14

3.6 Requirements regarding the start-up personnel

All courses of action described in this manual may only be carried out by a qualified electrician! Specialist staff are

defined as electricians who possess

professional training,

knowledge and experience in the field of high voltage electronics / electric mobility,

as well as knowledge of the relevant requirements and dangers

which they can display in practice. Furthermore, they must be able to assess the work assigned to them

independently, identify possible dangers and establish necessary protection measures.

4 General

4.1 Content and scope of this manual

The present documentation provides the reader with an overview of all required operating steps in the installation

and operation of the 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 operational and safety instructions given must be adhered to in order to ensure the ongoing optimum

functioning of the device and to meet the warranty requirements of the company BRUSA Elektronik AG.

4.2 Scope of the entire documentation

INFORMATION

To start up the PDU254 successfully, you will need the entire documentation. With the provision of the customer package, it is ensured that the required documentation is complete and up-to-date. The updating of specific documents is carried out automatically and can be seen in the history.

The customer package includes the following indexes:

Manual: Contains all information fundamentally necessary for the installation and operation of the device.

Tools: ---

History: List of all updates within the customer package indicating the affected documents.

15


4.3 Scope of delivery

MEANING PIECES ILLUSTRATION

1. High voltage distribution unit PDU254 1

2. Fuse FWH-300 A / 500 VDC for main connections 4

3. Fuse FWH-100 A / 500 VDC for range extender / DC quick charger 2

4. Fuse 20 A / 600 V for small-scale energy users

6

5. 23-pole control connector with crimp terminals

AMPSEAL 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 M20 for side terminals 5

9. Shorting link 1

10. Cable lug 50 mm2 for main connection 300 A and cascading 10

11. Cable lug 50 mm2 for chassis GND (KL31) 1

12. Cable lug 25 mm

2 for range extender or DC quick charger 2

13. Cable lug 4 mm2 for small-scale energy users 6

14. Serrated lock washers for fuse 300A installation (12 for replacing the fuse)

24


PDU254 16


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 cable lug connection 6

17


4.4 Optional delivery contents


1. Special key for HV cable fitting RAAA041 ---

2. Fuse FWH-400 A / 500 VDC for main connections MSAA419

4.5 Applicable 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 product PDU254.

4.6 Contact information of the manufacturer

BRUSA Elektronik AG

Neudorf 14

9466 Sennwald

Switzerland

Phone: +41 81 758 19 - 00

Fax: +41 81 758 19 - 99

Internet: www.brusa.biz

Email: [email protected]


PDU254 18

5 Use and limits of the product

5.1 Proper use

The product PDU254 has been designed for the following uses, taking into consideration the limit values indicated

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 motors (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 boats

Test bench applications

If the device is to be used for applications in areas other than those previously defined, the buyer is obliged to

coordinate 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 research and development facilities for such purposes.

5.2 Improper use

Improper use is any use implemented under conditions which deviate from those indicated by the manufacturer in

their technical documents and data sheets. Taking into consideration the proper use indicated in chapter 5.1 , the

following limit values have been stipulated for the operation of the product PDU254. The product may not be used

outside these limit values. Operation outside these limit values can lead to life-threatening situations!

PDU254-A01 UNIT

Max. HV input voltage (operating voltage) 500 V

Min. ambient temperature - 40 °C

Max. ambient temperature + 85 °C

Permissible peak current for a max. duration of 10 s 400 A

Max. permissible voltage drop via interlock loop 30 V

19


6 About this device

6.1 Technical data

BASIC ELECTRICAL DATA PDU254 UNIT

Operating voltage 200...500 V

Peak inrush current, contactors 3.7 A

Voltage for control signals (Pin = high) 7 to 15 V

Interlock current 10 mA

Max. permissible voltage drop via interlock loop 30 V

Recommended cable diameter for main connection 300 A and cascading 50 mm2

Recommended cable diameter for range extender or air conditioning compressor 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 1/2 connection RXT connection 100 A

Peak current: BATT 1/2 connection NLG / BSC / AUX connection 20 A

BASIC MECHANICAL DATA VALUE UNIT

Material AlMgSi1 ---

Length 300 mm

Width 178 mm

Height 78 mm

Housing volume 4.16 l

Total weight 3.9 kg

Weight of fuse 300 A 200 g



IP protection IP68 ---

Water-tight pressure compensation membrane --- ---

THERMAL VALUE UNIT

Min. ambient temperature - 40 °C

Max. ambient temperature + 85 °C


PDU254 20

6.2 Technical properties

Parallel connection of two PDUs possible (cascading)

Compact and light-weight construction

Meets standard requirements (EMC, mains harmonics etc.)

Active HVIL (HV interlock)

Connection of 2 HV batteries possible

2 connections with 300 A, fuse-protected for inverter (e.g. DMC5)

1 connection 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 on the PDU

Warning signs are installed on the PDU to warn the operator of possible dangers. Should one of these warning

signs be missing or become illegible due to wear and tear, it is to be renewed immediately! In order to obtain an

original label, please contact the BRUSA support at the manufacturer's address provided in chapter 4.6 .

21


6.4 Overview of the main structural components

1. Service cap 2. Connections, input side see chapter 7.1 Input side

3. Pressure compensation membrane 4. Control connector Chap. 7.4 Pin assignment of control 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. Connections, output side (fuse protection 20 A) see chapter 7.2 Output side



14. Fuse 300 A


PDU254 22

6.5 Basic function PDU254

The PDU254 is a HV distribution unit that combines the features required to meet all relevant requirements

(automotive sector, industrial service life) in one robust, compact and light-weight device. The HV distribution unit

features two battery connections and two inverter connections with a 300 A fuse protection for each connection. A

range extender or a DC quick charger with up to 100 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 charger NLG5, BRUSA on-board converter BSC6, air conditioning compressor

etc.).

For short-circuiting the HV circuit (e.g. for fuse replacement), an insulated shorting link provided with two

connections designated for this purpose is available. The interlock generator is connected via the 23-pole AMP

control connector. The interlock circuit is constantly monitored by means of two signals indicating the current state

of the PDU254.

6.5.1 Block diagram PDU254

23


6.6 Basic principle of vehicle installation


PDU254 24

6.7 Dimensions and installation information

For the installation of the PDU, the following points must be strictly adhered to:

Despite the IP protection provided, the PDU should be installed in a dry location, protected from splashing water.

When bringing the device into its installation position, 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 mechanical fixings must be arranged so that the PDU is fitted firmly and in a way that is as vibration-proof as possible.

The cable feeds should have sufficient space and must never touch components with sharp edges.

6.7.1 Fixing points

1. M6 through hole (thread depth 16 mm)

Min. screw-in depth = 10 mm Torque = 6 Nm Min screw tension 8.8

25


6.7.2 Housing dimensions

6.7.3 Interface dimensions


PDU254 26

6.7.4 Fully assembled view

6.8 Type plate

1. Classification 2. Version

3. Serial number 4. Date of production (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) see chapter 7.2 Output side

8. Fuse protection output BSC, NLG, AUX (admissible maximum current) see chapter 7.2 Output side

9. IP protection class

27


7 Connections

7.1 Input side

You will find the required cable types and cable diameters in chapter 6.1 Technical data

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 minus) Output for the connection of a second PDU

7. Control connector Chap. 7.4 Pin assignment of control connector (device side)

8. Earth GND Chap. 7.3 Earth GND


PDU254 28

7.2 Output side

You will find the required cable types and cable diameters in chapter 6.1 Technical data

1. Output AUX

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) Fuse protection 300 A

7. Output DMC2- (HV minus) Fuse protection 300 A

8. Output DMC1+ (HV plus) Fuse protection 300 A

9. Output DMC1- (HV minus) Fuse protection 300 A

29


7.3 Earth GND

INFORMATION

The grounding screw (1) must be connected with the earth of the vehicle and/or test bench.

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 drive components!

The cable diameter of the earth cable must correspond to the dimensions of the HV wiring.

Torque of grounding screw (1) M8 x 10 = 10 Nm


PDU254 30

7.4 Pin assignment of control connector (device 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 1

17. --- --- 18. --- ---

19. INL1 Interlock signal source 20. INL2 Interlock signal feedback

21. --- --- 22. --- ---

23. --- ---

31


7.4.1 Pin 1 GND

Internal wiring

1M

Ω

9,4

μF

Pin 1 GND

housing

Earth connection to control unit.

7.4.2 Pin 3 EN

Internal wiring

100μF

Pin 3

EN

InternalSupply

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 voltage of 12 V is applied to this pin.

VOLTAGE AT PIN 3 EN INTERLOCK CIRCUIT CURRENT CONSUMPTION AT PIN 3 EN

12 V open 16 mA

12 V closed 100 mA


PDU254 32

7.4.3 Pin 4 DO0

Internal wiring

10k

10n

F

Pin 4 DO0

This output indicates the state of the interlock generator.

This pin becomes active (= low) as soon as 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 wiring

10k

10n

F

Pin 5 DO1

The device is ready for operation when:

The interlock circuit is closed, Pin 4 DO0 active (low)

The supply voltage of the main contactors (LV) is applied to pin 16 DI0.

33


7.4.5 Pin 7 DO3, pin 16 DI0

Internal wiring

10n

F

Pin 16 DI0

Pin 7 DO3

K

On the one hand, pin 16 DI0 is used to supply the main contactors of the HV bus and, on the other hand, to supply the internal logic of the active intermediate circuit discharge.

As soon as LV is applied to the device (pin 3 EN) and the interlock circuit is closed, the relay (K) is energised and pin 16 DI0 is connected to pin 7 DO3. As a result, the main contactors actuated by pin 7 DO3 are closed.

As soon as the interlock circuit is opened, the relay (K) is de-energised again. As a result, the main contactors are immediately opened.

7.4.6 Pin 19 IL1, pin 20 IL2

Internal wiring

10n

F

Pin 19 INL1

Pin 20 INL2

K

-48V INL-

Generator

Deckel-Schalter

Pin 19 INL1 is the output signal of the interlock generator. The signal current amounts to 10 mA and flows from the earth GND through the relay coil of the main contactor supply to all other devices in the interlock circuit (to the corresponding feedback pin INL2). From the last device in the interlock circuit, the signal is lead back to the PDU to pin 20 IL2. In the PDU, the signal is lead back to the interlock generator via the lid-operated switch.

The interlock generator (-48V) allows a maximum voltage drop of 30 V between INL1 and INL2, which means via all other devices in the interlock circuit as well.

lid-operated switch


PDU254 34

8 Installation / initial start-up

DANGER

High voltage!

Danger to life!

If the battery is switched on, high voltage is applied to the HV connections which also includes HV cables that have already been connected! Therefore, do not connect any HV cables before making absolutely sure that the device is de-energised!

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

The following procedure is described for the connection battery input 1+ (HV plus).

The following torques apply to all fixing screws of the cable lugs:

Torque of screws M8 x 22 = 12 Nm

Torque of screws M4 x 8 = 2.5 Nm

WARNING

It is not allowed to tighten the screws without washers and without serrated lock-

washers, otherwise the PDU will be damaged!

35


PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION

1. Make sure that all of the HV cables to be connected are de-energised.

2. Connect the cables to the control connector.

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 and the vehicle.

See chapter 7.3 Earth GND The cable length should be kept as short as possible.

---

5. Unscrew the screws for the service cap (1).

6. Remove the service cap (1).

The interlock switch (2) is activated.


PDU254 36


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 (1).

Remove the serrated lock washers (2) and the washers (3).

9. Remove the fuse (1).

37



10. Guide the 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. Place the fuse (1) on the cable lugs (2).

In any event, the fuse (1) must be placed above the cable lugs (2)!


PDU254 38


12. Bring the washers (3) and then the serrated lock-washers (4) in position and tighten the screws (5).

The order must always be observed as shown! (1) = Cable lug (2) = Fuse (3) = Washer (4) = Serrated lock-washer (5) = Screw 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) = Washer (4) = Serrated lock-washer (5) = Screw M8 x 22

The PDU can be damaged, if you don’t use the additional washer!

13. Tighten the cable fitting in the housing on both sides.

For this, we recommend the special key for HV cable fitting type: RAAA041 See chapter 4.4 Optional delivery contents

---

39



14. For install output side connections with fuse protection 20 A, connect the cables with lugs, serrated lock-washer and tighten the screws (1).


15. Assemble the service cover.

Make sure that the service cap is correctly fitted.

Check the interaction of the actuation surface on the service cap (1) and the interlock switch (2).

16. Tighten the screws for the service cap (1).


(with serrated lock-washer)


PDU254 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!

Close the service cap afterwards.

41


8.1 Connecting the HV lines

The building of the HV wiring must be carried out in accordance with the following instructions. Here it is important

that no strands are damaged and that none stick out at the sides on the assembled cable. So check that the screw

connections are correct for each completed 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 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 strands of the shielding braid (Step 5) do not jut out again under any circumstances! Once installed, this will damage the sealing lip and subsequently cause an ingress of water into the housing! Therefore, cut all protruding strands to the admissible length!


1. Insulate 35 mm of the HV cable (1).

Ensure that you do not damage the shielding braid underneath it!

2. Shorten the shielding braid (1) by 20 mm.

The cable-side shielding braid (2) must be a length of around 15 mm.


PDU254 42


3. Lead the HV cable (1) through the union nut (2).

Lead the HV cable (1) through the terminal insert (3).

4. Place the terminal insert (1) with the front edge flush with the cable insulation (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 electrical tape (4).

You must absolutely make sure that the individual strands of the shielding braid (1) do not jut out over the sealing ring (3) under any circumstances! Once in the integrated state, this will lead to leakages and subsequently to the leaking of water into the housing!

43



6. Insulate 16 mm of the HV cable (1).

7. Assemble the cable lug (1) at the end of the cable.

No strands should stick out at the sides!

The crimping must be hexagonal. Ensure that the crimping has no deformations at the sides because this will make later installations in the housing difficult!

8. Check 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 in the housing!

INSTRUCTION

During the layout of the cable take care that the first part of the cable is at least 5cm straight before it will be bend to a radius.

INSTRUCTION

If you have to reassembly the cable you have to use a new terminal insert. Otherwise it can cause a leakage. The terminal inserts can be ordered from BRUSA Elektronik AG or directly from hummel.com.

5cm

http://www.hummel.com/en.html


PDU254 44

9 Warranty

The warranty corresponds to the regulations in our currently valid general terms and conditions see under

www.brusa.biz/en/support/terms-conditions.html.

10 Instructions for disposal

The correct disposal is a basic requirement for the re-use and recycling 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 ordinary household waste but must be separately collected and

recorded by a specialist service.

Disposal through a specialist service significantly helps to avoid dangers to people and the environment. Therefore,

in the case of disposal, we recommend contacting a recognised specialist disposal service.

http://www.brusa.biz/en/support/terms-conditions.html

45


11 Index

B

Block diagram

Installation into the vehicle .................................................. 23

PDU basic concept ................................................................ 22

C

Cable connections

Instructions and cross-sections ............................................. 19

Customer package ..................................................................... 14

D

Designation of the device

Decoding ................................................................................. 3

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

Principle of operation............................................................ 13

L

Limit values ................................................................................ 18

M

Minimum wiring (unsafe operation!) ......................................... 30

O

Operating ranges ....................................................................... 18

P

PDU254

Specification .......................................................................... 19

S

Safety

Important instructions ............................................................ 9

Serial number ............................................................................. 26

T

The 5 safety rules ....................................................................... 10

V

Validity of the manual .................................................................. 3

pdu254 - brusa.biz · symbol meaning symbol meaning general prohibition warning! ... this safety...

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