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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Technical data
and start-up
EVB1-350/400-40-HP
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:

Technical data
and start-up
EVB1-350/400-40-HP
4
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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Technical data
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EVB1-350/400-40-HP
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

Technical data
and start-up
EVB1-350/400-40-HP
6
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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Technical data
and start-up
EVB1-350/400-40-HP
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

Technical data
and start-up
EVB1-350/400-40-HP
8
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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Technical data
and start-up
EVB1-350/400-40-HP
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

Technical data
and start-up
EVB1-350/400-40-HP
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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.