Brusa NLG664-U0 Manual

TECHNICAL 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
[phone]
www.brusa.biz inf[email protected]

Technical information
and start-up
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LEGAL NOTICE
Publisher
BRUSA Elektronik AG
Neudorf 14
CH–9466 Sennwald
T [phone] - 00
F [phone] - 99
www.brusa.biz
[e-mail]
Date of issue
07.10.2016
Copyright
© 2016
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 to make
constructional changes. Any 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 Tschumper / Beat Graf
REVISIONS
Revision Date Name Change
01
---
HS
Translation of rev01 german - no changes
02
01.02.2013
HS
Chapter 6.1, 7.1.4.2, 7.1.4.7 and 7.3.1 corrected
03
07.02.2013
HS
Chapter 7.1.5 - Pin 6+8 WakeUp - functions changed
04
25.03.2013
HS
Chapter 6.3 corrected, minor corrections
05
14.10.2013
MT
Chapter 3.3.3 / 6.6 / 9.1 tightness note LV cabel
06
18.11.2013
MT
Chapter. 1.1 VDE
07
17.12.2013
MT
200 V - 450 V
08
12.02.2015
bg
General Revision
09
09.11.2015
bg
Chapter 5.1 Vehicle integration / EMC
10
21.11.2016
bg
Upgrade 50/60Hz, 1-ph/7kW, max. 50mA WakeUp current
11 28.11.2016 ag Chapter 11 Warranty new; Chapter 12 Instructions regarding
disposal new

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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 designation is as follows:

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TABLE OF CONTENTS
1 Foreword.................................................................................................................................. 7
1.1 General characteristics...................................................................................................................7
1.2 Labelling information, traceability and documentation of devices and components.......................... 8
2 List of abbreviations................................................................................................................ 8
3 Safety and warning instructions ............................................................................................ 9
3.1 Symbols and their meaning............................................................................................................9
3.2 Safety instructions and danger levels ...........................................................................................10
3.3 Generally applicable safety measures..........................................................................................11
3.4 Safety installations / power limitations.......................................................................................... 14
3.4.1 Control Pilot acc. to SAEJ1772 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 acc. to LV123....................................................................................................16
3.4.7 Proximity Detection acc. to IEC 61851 ..................................................................................17
3.4.8 Active discharge....................................................................................................................17
3.5 Requirements on the start-up personnel.......................................................................................18
4 General................................................................................................................................... 19
4.1 Content and scope of this manual ................................................................................................19
4.2 Scope of the documentation.........................................................................................................19
4.3 Scope of delivery..........................................................................................................................19
4.4 Optional scope of delivery ............................................................................................................20
4.5 Applicable standards....................................................................................................................20
4.6 Contact information of the manufacturer.......................................................................................20
5 Use and limitations of the product....................................................................................... 21
5.1 Proper use....................................................................................................................................21
5.2 Improper Use / Limitations of the product.....................................................................................21

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6 About this device................................................................................................................... 23
6.1 Technical data..............................................................................................................................23
6.2 Warnings on the device................................................................................................................25
6.3 Technical properties.....................................................................................................................26
6.4 Basic function...............................................................................................................................26
6.4.1 Voltage-dependent control of 1-phase and 3-phase charging................................................ 27
6.4.2 PFC compensation................................................................................................................27
6.4.3 PRC compensation ...............................................................................................................27
6.5 Overview of the main structural components................................................................................ 28
6.6 Dimensions and installation information .......................................................................................29
6.6.1 Fixing points..........................................................................................................................30
6.6.2 Dimensions ...........................................................................................................................31
6.6.3 Installation position................................................................................................................31
6.7 Vehicle installation basic principle................................................................................................32
6.8 Block diagram ..............................................................................................................................33
6.9 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, device side)........................................................... 38
7.1.4 Pin assignment LV plug vehicle 12-pole (Code A, device side).............................................. 39
7.1.5 Pin assignment LV plug charging socket 12-pole (Code B, device side)................................ 44
7.2 Cooling water connections ...........................................................................................................48
7.3 Wakeup mechanism.....................................................................................................................49
7.3.1 WakeUp via CAN ..................................................................................................................49
7.3.2 WakeUp via Proximity...........................................................................................................50
7.3.3 WakeUp via Pin HW-WakeUp...............................................................................................50
7.3.4 WakeUp via Control Pilot CP................................................................................................. 50
7.3.5 WakeUp via AC (mains voltage)............................................................................................50
7.4 Power limitations / Limiting controller............................................................................................51
7.4.1 Input current limitation Indem................................................................................................51
7.4.2 Input power limitation Pndem................................................................................................52
7.4.3 Mains voltage dependent limitation .......................................................................................52

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7.4.4 Proximity Detection ...............................................................................................................52
7.4.5 Control Pilot...........................................................................................................................52
7.4.6 Temperature derating............................................................................................................52
7.4.7 Output current limitation Iadem ............................................................................................. 52
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 connection of charger..........................................................................................54
9.2 Removing the charger..................................................................................................................58
9.3 Precharge output capacitor ..........................................................................................................62
10 Operation ............................................................................................................................... 63
11 Warranty and Guarantee....................................................................................................... 63
12 Instructions regarding disposal........................................................................................... 63
13 Index....................................................................................................................................... 64

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1 Foreword
Dear Customer!
With the BRUSA NLG6 charger, you have purchased a versatile high-performance product. The device is a
power electronics product which uses dangerous voltages and currents, thus special expertise with respect
to handling and operation of such systems is required!
Read this manual – particularly the chapter Safety and warning instructions – carefully before you install the
Fast Charger NLG6xx or carry out any other work on it!
1.1 General characteristics
INFORMATION
Below there is a short overview of the performance and versatility of the NLG6 charger.
You will find details on the individual properties as you read through thismanual.
 Manufactured and tested according to European automotivestandards.
 This VDE-certified charger complies with all applicable European legal requirements. EMC
compliance is to be achieved in combination with the vehicle.
 Galvanic isolation between mains and battery circuit guarantees optimum protection ofpersonnel.
 Touch and leakage current values remain within required limits, without further measures.
 The charger can be used in connection with a standard type A RCD.
 The power factor cos(phi) is nearly =1, therefore the available mains power is used to themaximum.
 The charging current contains a very low ripple.
 Charging from single or three-phase outlet.
 Parallel connection of several chargers is possible, in order to achieve higher chargingpower.
 Highly efficient (typically >94%).
 Robust against dust, humidity, vibration etc.

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1.2 Labelling information, traceability and documentation of devices and components
 BRUSA Elektronik AG ensures a complete quality proof for all raw materials, manufacturing
processesand products by means of suitable labelling and traceabilitymeasures.
 Traceability shall be organised in such a way that in the event of a defect the following characteristics
can be identified at any time:
 Manufacturer
 Production batch
 Production line
 Original batch
2 List of abbreviations
Throughout this manual, certain specific technical abbreviations are used. The following table provides an
overview of these abbreviations and their meaning:
Abk. Bezeichnung Abk. Bezeichnung
BMS
Battery
Μ
anagementSystem
LV
Low Voltage
BTL
cycle
Time quanta per Bit NBT
NLG
Netzladegerät (AC charger)
CAN
Controller Area Network
PFC
Power Factor Correction
CP
Contol Pilot
PI
Power Indicator
EME
Electromagnetic Emission
PLC
PowerLine Communication
EMI
Electromagnetic Interference
PRC
Power Ripple Compensation
EVSE
Electric Vehicle Supply Equipment
PWM
Pulse-Width Modulation
GND
Ground
RTC
Real Time Clock
HV
High Voltage (hazardous voltage)
SAE
Society of Automotive Engineers
IEC
International Electrotechnical Commission
SJW
Synchronization Jump Width
LED
Light Emitting Diode
VCU
Vehicle Control Unit

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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, certain specific symbols 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
Meaning
Symbol
Meaning
General warning of a dangerous area
Warning! Electrical shock!
Warning! Explosive environment!
Warning! Danger caused by batteries!
Warning! Hot surface!
Warning! High voltage!
Warning! High pressure / fluid ejection!
Warning! Fire hazard!
Symbol Meaning Symbol Meaning
Disconnect device from power supply Disconnect device from mains
Symbol Meaning Symbol Meaning
Important information on avoiding possible
property damage
Important information

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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!