Brusa EVB1-400-40-HP Instruction manual

BRUSA Elektronik AG
Neudorf 14
CH-9466 Sennwald
[phone]
[email protected]
www.brusa.biz
EVB1-400-40-HP
EVB1-350-40-HP
TECHNICAL DATA
AND START-UP
Translation of the original German operating instructions

Technical data
and start-up
EVB1-350/400-40-HP
2
LEGAL NOTICE
Publisher
BRUSA Elektronik AG
Neudorf 14
CH-9466 Sennwald
T [phone]
F [phone]
www.brusa.biz
[email protected]
Date of issue
13 Juni 2013
Copyright
© 2013
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 structural
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
24.10.2014
R. Roth
Preparation of Document based on standard Battery
Manual
chap. 4.3.1 adjust diagram to HP
chap. 4.3.2 adjust diagram to HP
chap. 6.4 adjust diagram to HP
chap. 6.5 adjust diagram to HP
chap. 6.6.3 adjust diagram to HP
chap. 3.4.1 adjust diagram to HP
chap. 3.3.3 add a comment about responsibility
02
28.05.2015
R. Roth
chap. 3.4.1 adjust diagram
03
29.12.2015
R. Roth
chap. 3.4.1 adjust and add diagram
chap. 3.4.2 adjust diagram
chap. 6.6.2 adjust diagram

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VALIDITY
This manual is valid only for the following devices:
EVB1-400-40-A02-HP
EVB1-350-40-A03-HP
Decoding of the device designation is as follows:

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TABLE OF CONTENTS
1Foreword..............................................................................................................................8
2List of abbreviations ...........................................................................................................8
3Safety 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
3.3.1 Safety instructions for cooling water systems....................................................................11
3.3.2 Safety instructions for handling and operation...................................................................11
3.3.3 Instructions for Storage and Transportation.......................................................................13
3.3.4 Safety instructions for electrical systems...........................................................................14
3.4 Safety installations / power limitations......................................................................................15
3.4.1 Temperature Monitoring (Derating) ...................................................................................15
3.4.2 Current Monitoring (Derating)............................................................................................17
3.4.3 Monitoring of Cell Voltages................................................................................................19
3.4.4 Main Fuse of the Battery ...................................................................................................20
3.4.5 Contactors in the BMS ......................................................................................................21
3.4.6 Emergency Stop Switch ....................................................................................................21
3.5 Requirements of the Start-up Personnel...................................................................................21
4General...............................................................................................................................22
4.1 Content and Scope of this Manual............................................................................................22
4.2 Scope of the Entire Documentation..........................................................................................22
4.3 Delivery Contents.....................................................................................................................23
4.4 Optional Delivery Contents.......................................................................................................24
4.5 EU Guidelines..........................................................................................................................24
4.6 Contact Information of the Manufacturer ..................................................................................24
5Use and Limits of the Product..........................................................................................25
5.1 Proper Use...............................................................................................................................25
5.2 Improper Use ...........................................................................................................................26
6About This Device .............................................................................................................27
6.1 Technical Data.........................................................................................................................27
6.2 Technical Properties.................................................................................................................28

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6.3 Warning Instructions on the Battery..........................................................................................29
6.4 Basic Principle for Vehicle Installation......................................................................................30
6.5 Safety measures for vehicle installation....................................................................................31
6.5.1 Principle of operation Interlock ..........................................................................................31
6.6 Basic Function Batterie EVB1-400/350-40-HP .........................................................................32
6.6.1 EVB1-400/350-40-HP Block Circuit Diagram.....................................................................33
6.6.2 Pre-charging Voltage.........................................................................................................34
6.6.3 Temperature Measurement / Temperature Monitoring ......................................................35
6.6.4 Balancing..........................................................................................................................36
6.6.5 Auto-reset of the Ah Meter ................................................................................................37
6.7 Overview of the Main Structural Components...........................................................................38
6.8 Dimensions and Installation Information...................................................................................39
6.8.1 Fixing Points......................................................................................................................39
6.8.2 Dimensions .......................................................................................................................40
6.8.3 Installation Position ...........................................................................................................40
6.9 Regulation and Control System................................................................................................41
6.9.1 Control via Terminal 15 (without CAN Bus) .......................................................................41
6.9.2 Control via Terminal 15 with Driving via CAN....................................................................42
7Connections.......................................................................................................................43
7.1 Circuit Connections..................................................................................................................43
7.2 Ground (GND)..........................................................................................................................44
7.3 Pin Assignment of Control Plug (Device-side)..........................................................................45
7.3.1 Pin 1 GND.........................................................................................................................46
7.3.2 Pin 2 AUX .........................................................................................................................46
7.3.3 Pin 3 EN............................................................................................................................47
7.3.4 Pin 4 PWML / PWM-out ....................................................................................................47
7.3.5 Pin 5 PWMP / PWM-out....................................................................................................48
7.3.6 Pin 9 CAN1L, Pin 10 CAN1H ............................................................................................48
7.3.7 Pin 8 APG, Pin 14 CANG, Pin 15 RS232G........................................................................49
7.3.8 Pin 11 RS232T, Pin 12 RS232R........................................................................................49
7.3.9 Pin 13 PRO.......................................................................................................................50
7.3.10 Pin 16 RFK1, Pin 17 RFK2, Pin 18 RFKC.........................................................................51
7.3.11 Pin 19 INT1, Pin 20 INT2...................................................................................................52

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7.3.12 Pin 21 NAUS.....................................................................................................................53
8Profiles and Diagrams.......................................................................................................54
8.1 Charging / Discharging of Battery.............................................................................................54
8.1.1 Charging (120 A) EVB1-400-40-HP...................................................................................54
8.1.2 Discharging (80A) EVB1-400-40-HP.................................................................................54
8.1.3 Discharging (320 A peak) EVB1-400-40-HP......................................................................55
8.1.4 Discharging (600 A peak) EVB1-400-40-HP......................................................................55
8.1.5 Charging (120 A) EVB1-350-40-HP...................................................................................56
8.2 Discharging (200 A) EVB1-350-40-HP .....................................................................................56
8.2.1 Discharging (80 A) EVB1-350-40-HP................................................................................56
8.2.2 Discharging (320 A peak) EVB1-350-40-HP......................................................................57
8.2.3 Discharging (600 A peak) EVB1-350-40-HP......................................................................57
8.3 Temperature / Cooling System.................................................................................................58
8.3.1 Cooling Behaviour at Cooling Water Inlet Temperature +5°C............................................58
8.3.2 Cooling Behaviour at Cooling Water Inlet Temperature +15°C..........................................58
8.3.3 Cooling Behaviour at Cooling Water Inlet Temperature +25°C..........................................59
8.3.4 Cooling Behaviour without Active Cooling (Cooling Circuit Deactivated) ...........................59
9Installation / Initial Start-up ..............................................................................................60
9.1 Unpacking the Battery..............................................................................................................67
9.2 Building HV Supply...................................................................................................................69
9.3 Ventilating the Cooling System.................................................................................................72
9.4 Installing the CAN Dongle ........................................................................................................72
10 Operation........................................................................................................................73
10.1 Reading CAN Parameters........................................................................................................73
10.1.1 Debug Messages –Data Logging with PARAM.................................................................73
10.1.2 Analysing Battery Data......................................................................................................74
10.2 Live View of the Battery Data ...................................................................................................75
10.3 Changing the CAN Parameters with PARAM ...........................................................................76
10.3.1 Configurable Parameters...................................................................................................80
10.4 Charging with the NLG513 Charger .........................................................................................82
10.4.1 Charging via the CAN........................................................................................................82
10.4.2 Course of a Charging Process ..........................................................................................83
10.5 Charging with the NLG664 Charger .........................................................................................84

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10.6 Carrying Out Firmware Updates...............................................................................................85
11 CAN Matrix......................................................................................................................89
11.1 CAN Signals / Messages..........................................................................................................89
11.2 CAN Signals / Errorand Warning Messages.............................................................................91
12 Warranty..........................................................................................................................96
13 Instructions for Disposal...............................................................................................96
14 Index................................................................................................................................97

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1 Foreword
Dear customer!
With the BRUSA Batterie EVB1-400/350-40 you have obtained a very capable and versatile product. As this is a
high performance electronic product, 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 battery
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
Li-Ion
Lithium Ionen Battery
CAN
Controller Area Network
MDF
Measurement Data Format
CCU
Cell Contol Unit
Ni-Cd
Nickel-Cadmium Battery
DoD
Depth of Discharge (Discharging state)
Ni-MH
Nickel-Metal Hydride Battery
EVB
Electric Vehicle Battery
PTC
Positive Temperature Coefficient
(Thermistor)
HV
High Voltage
PDU
Power Distribution Unit (HV Distributor)
IP
Ingress Protection
SoC
State of Charge

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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, some specific technical abbreviations 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
Suspended load hazard 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
Wear protective glasses
Wear protective gloves
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!
INSTRUCTION
The cooling water must always be actively cooled to ensure the optimum operating temperature.
To achieve the optimum performance, the temperature at the cooling water inlet should not
exceed +20°C. At temperatures higher than this, the cooling water to battery Delta-T does not
reach high enough a level to have a cooling effect!
Furthermore, we recommend the use of a climate compressor for the active cooling of the
battery. At ambient temperatures of > 30°C, the maximum temperature of the battery (+45°C)
can be reached very quickly through operation and recuperation or charging. When the
maximum temperature is reached, charging and/or recuperation is no longer possible!
Even when the optimum operating temperature is deceeded, the capacity of the battery
diminishes continually.
3.3.2 Safety instructions for handling and operation
DANGER
Explosion Danger!
Danger to life!
Under no circumstances should you carry out unauthorised work on the battery! This can lead to
the deactivation of security installations and can then lead to fire or an explosion!
Under no circumstances should you link the positive and negative poles with a metal object!
Never heat or burn a cell packet! This leads to the release of toxic fumes and to explosions!
The installation of the battery must take place in an EMI secure environment!

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WARNING
Overheating!
Fire hazard!
Always end the charging process after the given charging time is up even if the battery has not
charged to 100%! A significant extension of the charging time can lead to overheating and then
to the setting alight of the battery!
Do not use the battery or even the single cell packets for other purposes! This can lead to the
emission of smoke and to fire!
In the case of a defective battery or defective cell packets harmful fumes can occur! So, in
general, make sure that both the charging process as well as any other work on the battery are
carried out in a secure environment with sufficient fresh air supply!
In the case of any recognisable mechanical damage to the battery housing, odour coming from it
or the emission of smoke you must stop operating the battery immediately! In this case, the
battery must not be used again until it has undergone a professional inspection by the
manufacturer!
Always avoid anything which will have serious mechanical implications for the battery! This can
lead to the cell structures being destroyed and this can then lead to short-circuiting or fire!
INSTRUCTION
A high cooling water temperature reduces the life span! So take ongoing care to ensure sufficient
cooling of the device!
Even if the battery has high IP protection, direct contact with water (rain, splashing water) should
be avoided as far as possible while in operation!
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 then to the
destruction of the battery!
Before connecting the wiring, ensure that the battery poles are correctly connected! Reverse
polarity can lead to the destruction of both the battery and other devices!
During any charging outside of the vehicle, ensure that the battery is on an even, non-conductive
surface!
Never charge the cell packets at a voltage higher than 4.2 V and never discharge them at a
voltage lower than 2.7 V per cell! This can lead to damage to the cell packets!
Do not connect the battery to other batteries e.g. dry batteries, Ni-Cd or Ni-MH batteries! These
could have different capacities or voltages and lead to faults in the system!

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3.3.3 Instructions for Storage and Transportation
WARNING
Overheating!
Fire hazard!
Avoid storing or operating the device in close proximity to heat sources or direct sunlight! This
will lead to the overheating of the battery and can lead to the cell packets going on fire!
Never store or transport the battery in direct contact with metal objects! This can lead to short-
circuits and then to fire!
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!
INSTRUCTION
When storing the battery, the specified ambient temperature must always be adhered to. Storage
outside these temperatures can lead to damage to the cell packets! So the battery must be
stored in a secure environment which is inaccessible to children under the following conditions:
Ambient temperature during a storage time of < 365 days = -20°C to +25°C
Ambient temperature during a storage time of < 90 days = -20°C to +40°C
In general the cell voltage should not fall below 2.6 V. If this is the case, the battery cannot be
switched on again! In this case, a return to service can be carried out only by BRUSA experts!
In general make sure that the SoC level is at around 50% before prolonged shut-down or storage
of the battery! In the case of a complete discharge of the battery, we recommend switching off
the battery and recharging it as soon as possible so that the threshold of < 2.6 V is never fallen
short of!
INFORMATION
The battery is a dangerous good and is therefore subject to special, country-specific packaging
and labelling guidelines! Before sending the battery anywhere, find out about the necessary
transport measures from local logistics services. For instructions on the transporting of the
battery, note the reverse order of chapter 9.1.
The battery may only be sent in the transport box it was delivered in or alternatively in an
equivalent transport box. Should you have any questions, refer to the company BRUSA
Elektronik AG at the manufacturer address given in chapter 4.6.
For safety reasons, the battery should be charged to around 50% (SoC) for transportation. Pay
attention to the charge level during the first installation and in doing so, adhere to the power data
and parameters of your charging device.
For transports after the delivery, BRUSA Elektronik AG assume no responsibility

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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 and connections without ensuring that
there is no voltage beforehand!
The battery 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!
Before starting work with the battery, the shut-down of the coupled motor must be ensured! Even
when the HV supply is switched off, a turning motor can still produce voltage!
INFORMATION
Adhere strictly to the following 5 safety rules when working on a HV grid:
Disconnect system from power.
Switch off the ignition.
Remove service / maintenance plug and/or turn off main battery switch.
Remove the fuse (external fuse box).
Ensure that 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 protective 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 Temperature Monitoring (Derating)
This security installation is the battery's self-protection. If a cell packet achieves a defined temperature threshold,
this means a decrease in power (derating) to protect the battery from damage through overheating. The power will
subsequently be reduced until the temperature falls back to the target range. If a cell reaches the defined limit, the
current is reduced to 0 A. If the temperature rises despite derating and the defined default values of the battery are
not adhered to, the battery is immediately disconnected from the DC intermediate circuit. Further information on
temperature measurement can be found in chapter 6.6.3 Temperature Measurement / Temperature Monitoring
Charging
If the battery temperature is lower than 15°C, the derating begins till 5°C (reducing current with 10.8A/°C).
If the battery temperature is lower than 5°C, the BMS allows a maximum charging current of 12A till 0°C
Below 0°C the BMS limit the charging current to 0A
To inform you the CAN signal BMS_MODE_TP is emitted.
If the battery temperature is above 35°C, the derating begins till 45°C (reducing current with 8A/°C).
To inform you the CAN signal BMS_MODE_TP is emitted.
Above 45°C the BMS stops the charging process

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Discharging
2.5°C before the actual derating, pre-derating begins and reducing the current from 600 A to 320 A
(BATT_CurrentDischargeMax) at a rate of 128 A / °C.
To inform you the CAN signal BMS_MODE_TP is emitted.
5°C before reaching the limit of temperature, the actual derating engages at a rate of 64A/°C reducing the
current to 0 A (BATT_CurrentDischargeMax).

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3.4.2 Current Monitoring (Derating)
In the BMS the current is continually measured at 2.5 s intervals. This measurement can be communicated via
CAN (BATT_Current_Act). Alongside this, a second measurement is taken continually at 125 ms intervals, this has
a poorer resolution due to the shorter measurement time (6 A). This parallel measurement makes a very fast
reaction / shut-down possible in the case of an overload. With this, the BMS can recognise a short-circuit within just
6 ms and disconnect the battery from the DC intermediate circuit.

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The current monitoring takes place in three steps:
Step 1: Warning and Limit Reached
As soon as the limit is reached or exceeded, the warning message or CAN signal
MS_War_OverCurrentCharge or BMS_War_OverCurrentDischarge is emitted.
In addition, the CAN signal BMS_MODE_CP is emitted.
Step 2: Limit Reached, Peak Current Duration Exceeded
The maximum discharging current (600 A) can run for a duration of around 10 s. This produces a current field
output (I2t) of 784’000 A2s.
(Ipeak –Icont)2* t = I2t
(600A –320A)2* 10s = 784‘000A2s
If this value is reached, the derating mode enters immediately and reduces the discharge current gradually
down to <320 A (discharge cont.).
With a discharge current <320 A, the battery can recover. The longer the recovery period, the longer it can
then be run again with the maximum discharge current (max. 10 s).
It is recommended that the derating of the current be followed (BATT_CurrentDischargeMax).
If the current field output is reached or exceeded (I2t), the battery automatically disconnects from the DC
intermediate circuit and sends an error report or the CAN signal BMS_TErr_DischargeI2t.
Step 3: Maximum Current Exceeded
If the current exceeds a level of 630 A or falls below -130 A, the battery is immediately disconnected from the
DC intermediate circuit.
The CAN signal BMS_Err_CurrentCharge / BMS_Err_CurrentDischarge is emitted.

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3.4.3 Monitoring of Cell Voltages
In the BMS the two highest and the two lowest cell voltages are measured at intervals of 1 ms. These are relayed
with the CAN signal CCU_V. Additionally every cell is measured in series at a frequency of around 1 kHz. The
values measured are identified with an index and relayed one after another via CAN CCU_Cell. The following
factors are included in this index:
Number of cells (CCU_Number)
Current index (CCU_Index)
Associated voltage (CCU_V)
Associated Temperature (CCU_T)
The maximum and minimum voltage are averaged over a time frame of 100 ms and are relayed with the CAN
signal CCU_max (CCU_V_LOW_PEAK / CCU_V_HIGH_PEAK). For each voltage measurement, an internal
resistance of 1 mohm per cell is factored in.

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Monitoring of the cell voltages takes place in four steps:
Step 1: Warning
As soon as the cell voltage is larger than 4.10 V, the warning message or the CAN signal
BMS_War_OverCharge is emitted.
This CAN signal indicates that the maximum cell voltage will soon be reached.
Step 2: Limit Reached
If the cell voltage surpasses 4.15 V, the CAN signal BMS_MODE_OVP is emitted.
This CAN signal means that the maximum cell voltage has been reached.
Step 3: Limit Reached and Further Charging of the Cells
If another 0.5 Ah is charged after the CAN signal BMS_MODE_OVP is emitted, the battery immediately
disconnects from the DC intermediate circuit.
The error message or the CAN signal BMS_Err_OverCharge is emitted.
Step 4: Max. Cell Voltage Exceeded
If the cell voltage reaches 4.20 V, the battery will always be disconnected from the DC intermediate circuit
immediately.
The error message or the CAN signal BMS_Err_OverCharge is emitted.
If this is the case, then a general error exists in the battery. A diagnosis must be carried out by qualified
specialist personnel.
INFORMATION
The monitoring of under-voltage takes place in the four specified stages with the following CAN
signals:
BMS_War_OverDischarge
BMS_MODE_UVP
BMS_Err_OverDischarge
3.4.4 Main Fuse of the Battery
The battery has a 600 A DC semiconductor fuse. The main fuse protects the cell packets. The battery cables must
be secured separately over a PDU. As a rule the main fuse will only be tripped through a serious defect or short-
circuit in the battery. If this is the case, the battery must be sent back to be repaired! The replacement of the main
fuse may only be carried out by the company BRUSA Elektronik AG because specialist knowledge is necessary for
this!