Brusa NLG513 Instruction manual

BRUSA Elektronik AG
Neudorf 14
CH-9466 Sennwald
[phone]
[e-mail]
www.brusa.biz
NLG513
TECHNICAL DATA
AND START-
UP
Translation of the original German operating instructions
NLG513

Technical data
and start-up
NLG5 charger
2
L
EGAL NOTICE
Publisher
BRUSA
Elektronik AG
Neudorf 14
CH
-9466 Sennwald
T [phone]
- 00
Fax: [phone]
- 99
www.brusa.biz
[e-mail]
Date of issue
09.01.2012
Copyright
©
2011
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. Any technical information, drawings
and photos used are copyrighted and failure to respect this
constitutes a 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 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
30.01.2012
Holger Schmidt
Kap. 7.3 (Kühlsystem entlüften) entfernt, Kap. 7.3. (Spannung vorladen)
neu. Inhalt Kap. 7 optimiert, kleinere textliche Korrekturen
02
10.03.2014
M.Tschumper
PON switched positive
03
19.07.2016
B.Graf
Kap. 5.1 „…R&D use only…“ text added
04
28.11.2016
A. Girod
Kap. 9. Warranty new; Kap. 10 Instructions regarding disposal new

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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 as follows:

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TABLE OF CONTENTS
1Foreword..............................................................................................................................7
2List of Abbreviations...........................................................................................................7
3Safety and Warning Instructions........................................................................................8
3.1 Symbols and their meaning........................................................................................................8
3.2 Safety instructions and danger levels.........................................................................................9
3.3 Generally applicable safety measures......................................................................................10
3.4 Safety Installations / Power Limitations ....................................................................................13
3.4.1 Control Pilot (CP) ..............................................................................................................13
3.4.2 Overload Protection (Derating)..........................................................................................13
3.5 Requirements of the Start-up Personnel...................................................................................13
4General...............................................................................................................................14
4.1 Content and scope of this manual............................................................................................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
5Use and Limits of the Product..........................................................................................17
5.1 Proper Use...............................................................................................................................17
5.2 Improper Use / Limits of the Product ........................................................................................17
6About This Device.............................................................................................................18
6.1 Technical Data.........................................................................................................................18
6.2 Warnings on the Device ...........................................................................................................20
6.3 Technical Properties.................................................................................................................21
6.4 Basic function of the NLG5 charger..........................................................................................21
6.5 Overview of the Main Structural Components (Water-cooled NLG5)........................................22
6.6 Overview of the Main Structural Components (Air-cooled NLG5).............................................23
6.7 Mechanical Connections ..........................................................................................................24
6.7.1 Cooling System.................................................................................................................24
6.8 Electrical Connections..............................................................................................................25
6.8.1 Grounding Screw ..............................................................................................................26

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NLG5 charger
6.8.2 Pin Assignment Modular Plug Input (Device-side).............................................................27
6.8.3 Pin Assignment Modular Plug Output (Device-side)..........................................................27
6.8.4 Pin Assignment Control Plug (Device-side).......................................................................28
6.8.4.1 Pin 1 GND.......................................................................................................................................29
6.8.4.2 Pin 2 AUX .......................................................................................................................................29
6.8.4.3 Pin 3 PON.......................................................................................................................................30
6.8.4.4 Pin 4 FLT ........................................................................................................................................30
6.8.4.5 Pin 5 DO2, Pin 6 DO3, Pin 7 DO4..................................................................................................31
6.8.4.6 Pin 8 PG1, Pin 14 PG2, Pin 15 PG3...............................................................................................31
6.8.4.7 Pin 9 CNL, Pin 10 CNH...................................................................................................................32
6.8.4.8 Pin 11 TXD, Pin 12 RXD.................................................................................................................33
6.8.4.9 Pin 13 PRO.....................................................................................................................................33
6.8.4.10 Pin 16 IL1, Pin 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 Dimensions (Water-cooled NLG5).....................................................................................38
6.9.3 Dimensions (Air-cooled NLG 5).........................................................................................38
6.10 Basic Principle for Installation into the Vehicle..........................................................................39
6.11 Block Circuit Diagram NLG5.....................................................................................................40
6.12 Regulation and Control System................................................................................................41
6.13 Modes of Operation..................................................................................................................42
6.13.1 Mode A (Automatic)...........................................................................................................42
6.13.2 Mode C (CAN controlled) ..................................................................................................43
6.14 Power Limitations.....................................................................................................................44
6.14.1 Min. Input Resistance........................................................................................................44
6.14.2 Max. Mains Power.............................................................................................................45
6.14.3 Max. Mains Current...........................................................................................................45
6.14.4 Max. Output Current..........................................................................................................45
6.14.5 Temperature Derating.......................................................................................................45
6.14.6 Control Pilot.......................................................................................................................45

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6
6.14.7 Power Indicator.................................................................................................................46
7Installation / Start-up.........................................................................................................47
7.1 Installing and Connecting the Charger......................................................................................47
7.2 Configuring the Charger / Assigning Charging Profiles.............................................................50
7.3 Pre-charging Voltage................................................................................................................53
8Handling and Operation....................................................................................................54
8.1 HyperTerminal..........................................................................................................................54
8.1.1 Retrieving / Monitoring Operating Data from the Charger..................................................54
8.2 ChargeStar...............................................................................................................................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 Properties of the Charging Profile...................................................63
8.2.5 Retrieving Device Information from the Charger................................................................64
8.2.6 Changing the CAN Parameters (Options)..........................................................................65
8.2.7 Charging Profile Parameters.............................................................................................67
8.2.7.1 General Parameters........................................................................................................................67
8.2.7.2 Shut-Down Parameters...................................................................................................................68
8.2.7.3 Parameters for Charging Profiles ...................................................................................................69
9Warranty and Guarantee...................................................................................................70
10 Instructions regarding disposal....................................................................................70
11 Index................................................................................................................................71

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1 Foreword
Dear customer!
With the BRUSA NLG5 charger you have obtained a very capable and versatile product. As this is a power
electronics product with dangerous voltages and currents, specialist knowledge is required for dealing with it as
well as operating it!
Read this manual - particularly the chapter Safety and Warning Instructions - carefully before you install the NLG5
charger or 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:
ABBR.
MEANING
ABBR.
NAME
BMS
Battery Management System
HV
High Voltage
CAN
Controller Area Network
IP
Ingress Protection
CEE
Commission for Electrical Equipment
NLG
Netzladegerät (Mains Charger)
CP
Control Pilot
NTC
Negative Temperature Coefficient
EMI
Electromagnetic Interference
PI
Power Indicator
EMC
Electromagnetic Compatibility
PTC
Positive Temperature Coefficient
RCD
Residual Current Device
VP
Vehicle Pilot
GND
Ground

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8
3 Safety and Warning Instructions
In this chapter you will find safety instructions which apply to this device. These refer to assembly, start-up and
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, several symbols are used. You will find an overview as well as their 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
SYMBOL
MEANING
General hazard warning
Electromagnetic field warning
Potentially explosive warning
Battery hazard warning
Hot surface warning
High electrical voltage warning
High pressure warning / fluid spurting out
Fire hazard warning
MANDATORY SIGNS
SYMBOL
MEANING
SYMBOL
MEANING
Disconnect device from voltage
Disconnect device from mains
INFORMATION SIGNS
SYMBOL
MEANING
SYMBOL
MEANING
Important information on avoiding possible
damage to property
Important information

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3.2 Safety instructions and danger levels
DANGER
This instruction warns against serious, irreversible risks of injury and in some cases death!
Avoid these dangers by observing these instructions!
WARNING
This instruction 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 dangers by observing 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 discloses important information for the reader.

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3.3 Generally applicable safety measures
The following safety measures have been developed based on the knowledge of the manufacturer. They are not
complete, 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 cooling water systems
WARNING
Spurting cooling fluid!
Skin burning hazard!
Check the tightness of the cooling water system, particularly the pipes, screw joints and pressure
tanks.
Resolve recognisable leakages immediately!
3.3.2 Safety instructions for mechanical systems
DANGER
Potential explosion area!
Danger to life!
Do not store any highly flammable materials or combustible fluids in the direct surroundings of the
device!
Sparks at the device connections can set these on fire and lead to explosions!
CAUTION
Hot surfaces!
Burn hazard!
The device produces high temperatures when in operation!
So always handle the device with care and caution!