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
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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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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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6.14.7 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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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!

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3.3.3 Safety Instructions for Handling and Operation
INSTRUCTION
Damage to the HV Battery:
Before the start of the first charging process ensure that the charging profile of the device is
compatible with your HV battery!
You must make sure that the voltage ranges of the device and the HV battery are identical!
Only use compatible and high-quality cabling! For this we recommend our specially configured
original BRUSA mains and charging cables.
INSTRUCTION
Damage to the Charger:
Check while connecting the device that the mains voltage is within the permitted range (see
chapter 6.1 Technical Data)!
A high cooling 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 heat sources!
Although if the device has high IP protection, you should avoid placing it in direct contact with
water (rain, spurting water) if 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 device!
Prevent any penetration of fluids into the device (e.g. during assembly work)! The penetration of
fluids will lead to a short circuit and subsequent damage to the device!
Under no circumstances should you operate the device if liquid is leaking in anywhere, contact
BRUSA Elektronik AG immediately!

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3.3.4 Safety Instructions for Electrical Systems
DANGER
High voltage!
Danger to life!
Under no circumstances should you touch the HV wires or HV connections without ensuring that
there is no voltage beforehand!
The device may only be connected by a qualified electrician!
Under no circumstances should you bypass or avoid security installations! Any malfunctions
resulting from this could have life-threatening consequences!
Never connect the device to a socket without a protective ground wire connection!
A residual current device (RCD) must be used in the mains supply line!
You must disconnect the mains connection immediately after charging has finished!
CAUTION
Overheating of the cables!
Fire hazard!
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 authorisation! The opening of the
device (housing sealed-up) leads directly to the forfeit of any guarantee and warranty rights!
INFORMATION
Adhere strictly to the following 5 safety rules when working on an HV grid:
Disconnect system from power.
Switch off the ignition.
Remove service / maintenance plug and/or turn off main battery switch.
Remove fuse.
Ensure that the system does not reconnect.
Keep ignition key safe to prevent unauthorised access.
Keep service / maintenance plug safe to prevent unauthorised access and/or
use lockable cover cap to ensure that the main battery switch does not reconnect.
Check that it is not live with a suitable voltage tester (note voltage range!).
Ground and short-circuit the system.
Cover or seal off adjacent live parts.

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3.4 Safety Installations / Power Limitations
3.4.1 Control Pilot (CP)
The control pilot is a safety installation which also increases the reliability of the charging process of an electric
vehicle. It is absolutely necessary if the supply-side charging current exceeds 16 A. The CP signal is fed to the
charger from the charging station via an additional contact in the mains plug and thereby transmits the maximum
permitted current carrying capacity of the mains socket. Here, currents of 6 A - 32 A can be transmitted. The CP
signal generator can also be integrated into an adapter cable for normal household sockets. In this case, this signal
generator transmits a suitable current limitation so that the household socket is not overloaded.
The CP interface enables the bi-directional exchange of information between the charging station and the electric
vehicle and it is standardised worldwide.
3.4.2 Overload Protection (Derating)
INSTRUCTION
Continuous operation at the temperature limit will inevitably lead to a higher level of wear o
f the
components!
This security installation is the charger's self-protection. If the charger reaches a defined temperature threshold,
this means a decrease in power (derating) to protect the charger from damage through overheating. The power will
subsequently be reduced in proportion to the temperature increase until the temperature falls back within the target
range.
Air-cooled chargers start to reduce the maximum power as soon as the ambient temperature is at +40°C. Water-
cooled chargers can charge on full power up to a cooling water temperature of +60°C.
3.5 Requirements of 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 dispose of
professional training,
knowledge and experience in the field of electronics / electric mobility,
as well as knowledge of relevant requirements and dangers
which they can display in practice. Furthermore, they must be able to assess the work assigned to them
independently, detect possible dangers and establish necessary protection measures.

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4 General
4.1 Content and scope of this manual
The present documentation gives an overview of all required working steps regarding the installation and operation
of the charger and the necessary safety measures.
It contains technical data, application information and a basic description of the charger and its functions.
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 the warranty requirements of
BRUSA Elektronik AG.
4.2 Scope of the Entire Documentation
INFORMATION
In order to successfully commission the charger, you need this manual and the software manual, and
possibly further software. BRUSA will be happy to provide this so-called (documentation-
) “customer
package” by download links.
4.3 Scope of Delivery
NAME
PIECES
ILLUSTRATION
1.
NLG513 charger (water-cooled)
or
1
NLG513 charger (air-cooled)
2.
M18 x 1.5 cooling water connection piece
*
2
3.
Protective cap for cooling water connection piece
*
2
4.
Software - ChargeStar on enclosed CD-ROM
1
---
* Only with the NLG513 charger (water-cooled)

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4.4 Optional Scope of Delivery
INFORMATION
These accessories can be obtained optionally from BRUSA Elektronik AG.
MEANING
TYPE
ILLUSTRATION
1.
23-pole control plug set, includes:
1 piece AMPSEAL 770680-1 control plug for wire diameter of 0.5 mm2
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.
Mains cable (modular plug - input) 3 m
11316
3.
Mains cable (modular plug - input) 10 m
11663
4.
Battery cable (modular plug - output) 2 m
11665
5.
Set of cooling water connection pieces - long (2 pieces incl. seals)
2 pieces M18 x 1.5 110 mm
2 pieces rubber sealing ring Ø 16 mm
11857

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4.5 EU Guidelines
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 NLG5 charger .
4.6 Contact Information of the Manufacturer
BRUSA Elektronik AG
Neudorf 14
9466 Sennwald
Switzerland
Phone:
[phone] - 00
Fax:
[phone] - 99
Internet:
www.brusa.biz
E-mail:
[e-mail]

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5 Use and Limits of the Product
5.1 Proper Use
The BRUSA NLG5 charger has been designed for the following uses. In the case of planned operations in other
areas, please contact the company BRUSA Elektronik AG beforehand at the manufacturer address as given in
chapter 4.6.
Universal charger for charging of various batteries e.g.
NiCd batteries
Pb batteries
Li-Ion batteries
The user must ensure at all times during a charging process that the specific operational limits of the
connected battery are never exceeded.
The charger may only be operated within the limits given in chapter 5.2.
INFORMATION
This equipment is a custom built evaluation unit destined for professionals 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 requirements stated in the technical
documents and datasheets of the manufacturer is viewed as improper use.
The following limit values are set for the operation of the NLG5 charger . Operation outside these defined limits can
lead to life-threatening situations and is therefore forbidden!
Max. AC input voltage 265 VAC
DC output voltage range 0 - 520 VDC
Battery voltage range 200 – 520 VDC
Min. ambient temperature - 25°C
Max. ambient temperature + 70°C
Min. coolant temperature - 25°C
Max. coolant temperature + 70°C
Maximum pressure cooling water system 1.0 bar
INFORMATION
The functioning of the charger can only be
guaranteed if the given voltage range is observed!
Batteries with differing loads will lead to malfunctioning of the charger!

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6 About This Device
6.1 Technical Data
AC INPUT NLG5
AIR-COOLED
NLG5
WATER-COOLED
UNIT
Min. input voltage 100 100 V
Max. input voltage 264 264 V
Min. input frequency 48 48 Hz
Max. input frequency 62 62 Hz
Max. input currenteff 16 16 A
Max. input power (at input current eff = 16 A) 3.680 3.680 W
Power factor > 0.99 > 0.99 ---
Efficiency (P = Pa1max) 93 93 %
X capacity 11.6 11.6 µF
Y capacity L1 PE 44 44 nF
Y capacity N PE 46.2 46.2 nF
DC OUTPUT NLG5
AIR-COOLED
NLG5
WATER-COOLED
UNIT
Charging capacity 3.300 3.300 W
Voltage range 200 – 520 200 – 520 V
Charging voltage accuracy ± 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 µF
Y capacity B+(B-) PE 16.5 16.5 nF
THERMAL / COOLING SYSTEM NLG5
AIR-COOLED
NLG5
WATER-COOLED
UNIT
Amount of coolant in device --- ~ 0.3 L
External diameter of cooling water connection pieces --- 15.2 mm
Minimum coolant temperature at inlet --- - 25 °C
Maximum coolant temperature at inlet --- + 70 °C
Coolant pressure drop @ 5l/min, Tcoolant = 25°C
(with a water to glycol mixture ratio of 50 / 50) --- 50 mbar
Maximum cooling system pressure --- 1.0 bar
Cooling water flowing rate --- 4 to 6 l/min
Ambient temperature range for storage - 40 to + 85 - 40 to + 85 °C
Ambient temperature range in operation - 25 to + 70 - 25 to + 70 °C
Device temperature range without reduced power (derating) - 20 to + 40 - 20 to + 60 °C

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BASIC MECHANICAL DATA NLG5
AIR-COOLED
NLG5
WATER-COOLED
UNIT
Weight 6.3 6.2
*
kg
IP protection IP54 IP65 ---
Height 88 88 mm
Width 334 267 mm
Length (without modular plug) 250 250 mm
*
without coolant
SAFETY AND PROTECTION FUNCTIONS NLG5
AIR-COOLED
NLG5
WATER-COOLED
UNIT
Insulation testing (AC input / DC output) 2 2 kV
Power inlet over-voltage protection 264 264 V
Short-circuit protection yes yes ---
Open output protection yes yes ---
Internal over-temperature protection yes yes ---
Temperature sensor 1 (PT1000 @ 25°C) 1097 1097 Ω
Temperature sensor 2 and 3 (NTC @ 25°C) 33 33 kΩ
Min. insulation resistance (initial) 2 2 > GΩ
WIRING SYSTEM INTERFACE AUX NLG5
AIR-COOLED
NLG5
WATER-COOLED
UNIT
Wiring system voltage 14 14 V
Max. wiring system voltage 30 30 V
Max. wiring system current 0.5 0.5 A
Wiring system close-circuit current (without terminal 15)
@ Uaux = 12 V 230 230 uA
Wiring system no-load power (with terminal 15) 6 6 W
CAN INTERFACE NLG5
AIR-COOLED
NLG5
WATER-COOLED
UNIT
CAN 2.0 b (11-bit identifier) --- --- ---
CAN baud rate (125 / 250 / 500 / 1000) 500 (default) 500 (default) Kbit/s
Max. CAN input voltage (ESD protection) +/- 24 +/- 24 V
CAN input capacity 64 64 pF
Rdiff CANH - CANL 21 21 kΩ

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6.2 Warnings on the Device
Warning signs are 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 original
label, please contact BRUSA support at the manufacturer address given in chapter 4.6 !