Scania PTO EL User manual

Scania Truck Bodybuilder 22:10-834 Issue 2 2021-11-11
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General information on battery electric vehicles
Work on electric power take-off (PTO EL)
General information on battery electric ve-
hicles
This document contains information on vehicles powered by battery electricity and
the electric power take-off that these vehicles are fitted with. The electric power take-
off is currently available on battery electric vehicles (BEV) and plug-in hybrid elec-
tric vehicles (PHEV).
Battery electric vehicles are powered by an electric motor and battery power as the
energy source. The energy is stored in lithium batteries. Battery electric vehicles do
not have a combustion engine, whereas for example plug-in hybrid electric vehicles
can be powered by both an electric motor and a combustion engine.
Battery electric vehicles have 2 electrical systems, one of which has VCA, 24 V
(voltage class A) and the other VCB, 650 V (voltage class B):
Battery electric vehicles should be considered low-voltage systems >60 V and
<1,500 V (DC). This means that everyone who manufactures, distributes or installs
electrical equipment must ensure that the work and equipment satisfy the relevant
safety requirements for each market.
Follow the safety precautions under the headings Safety precautions and standards
and Chassis modifications on electric vehicles. This also applies if only mechanical
work is carried out or if work is only carried out in the 24 V system and no work is
carried out on the VCB system.
When working in the workshop, the battery electric vehicle must be positioned so
that it can be driven out in the event of a fire or other risk without obstruction.
More information on safety regulations can be found in the following document:
Electrical system DC (direct current) AC (alternating current)
VCA 0-60 V 0-30 V
VCB 60-1,500 V 30-1,000 V

General information on battery electric vehicles
Work on electric power take-off (PTO EL)
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•Work on battery electric vehicles
•Working with hybrid vehicles

General information on battery electric vehicles
Work on electric power take-off (PTO EL)
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Safety precautions and standards
IMPORTANT!
• Save the results of the insulation measurements and display on request
• Save test results and test reports that verify that electrical systems and compo-
nents connected to the electric power take-off comply with the requirements.
The following standards must be followed for bodywork VCB components and their
installation:
• ISO6469-3
• UN standard 10 (R10) and standard 100 (R100)
• Only CE labelled components may be used
The vehicle is delivered certified in accordance with UN standard 10 and standard
100 with factory-fitted CE marked components. It is the responsibility of the body-
builder to ensure that the vehicle is certified after the bodywork has been completed.
More information can be found under the heading "Electrical requirements for sys-
tems and components connected to the electric power take-off". It must be possible
to present test results and test reports on request.

General information on battery electric vehicles
Work on electric power take-off (PTO EL)
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Chassis modifications on electric vehicles
WARNING!
Modification of the VCB system is prohibited. The VCB components or their cable
harnesses, which are orange coloured, must not be moved or changed in any way af-
ter the vehicle has been delivered. All work in the vicinity of VCB components and
their cable harnesses must be carried out with caution.
Taking current from or connecting units to the propulsion batteries is prohibited, ex-
cept via the electric power take-off.
More information on work on VCB systems can be found in the following document:
•Work on battery electric vehicles
•Working with hybrid vehicles

Position of electric power take-off and its components
Work on electric power take-off (PTO EL)
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Position of electric power take-off and its
components
Scania's battery electric vehicles may be factory-fitted with the Electric power take-
off (PTO-EL) (variant code 8932A) option, which makes it possible to connect the
bodywork to the VCB system. The connection is made via a terminal box (1) that
provides access to the direct current supply from the vehicle's VCB batteries.
On battery electric vehicles, the fuse box (2) and the terminal box for connecting to
bodywork are located at the rear edge under the cab; see illustration detail (A).
On plug-in hybrid electric vehicles, the fuse box and the terminal box are positioned
inside the frame behind the third crossmember; see illustration detail (B).
Pos Designation Description
1 Terminal box R126 Contactor unit for electric power take-off
2 Fuse box P14 Fusebox for electric power take-off
3 BMU control unit Control unit for the rechargeable energy stor-
age system (fitted to the underside of the frame)
4 BCI control unit Bodywork communication interface. Factory-
fitted in the cab on vehicles fitted with the Bod-
ywork communication interface (BCI) (variant
code 5837A) option.
A
B
1
2
1
2
3
4
442 503

Position of electric power take-off and its components
Work on electric power take-off (PTO EL)
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Terminal box R126 for electric power take-off
Pos Designation Description
1 Voltage supply Incoming voltage supply from the vehicle's
VCB system
2 Bodybuilder connection,
positive voltage supply
Connection point for electric power take-off,
positive voltage supply
3 Bodybuilder connection,
negative voltage supply
Connection point for electric power take-off,
negative voltage supply
2
3
1
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Electric power take-off description and function
Work on electric power take-off (PTO EL)
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Electric power take-off description and
function
Performance
The above table applies to the factory-fitted 100 A fuse. If a fuse with a lower rated
current is fitted, the maximum output is based on the selected fuse.
More information can be found under the heading Fuse size.
Magnitude Nominal Min. Max.
Current (A) 90 0 100
Voltage (V DC) 650 500 750
Output (kW) 50 0 60

Electric power take-off description and function
Work on electric power take-off (PTO EL)
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General function
• Activation can only be carried out when the 15 voltage1 is active. The power take-
off can be activated if the 15 voltage is switched off.
• Activation can only be carried out once every 30 seconds
• The power take-off can be used when the propulsion batteries are being charged
• If the power take-off is used when the propulsion batteries are being charged and
charging is interrupted, the power take-off may still be active. It is possible for the
bodybuilder to build in logic that allows the power take-off to remain active after
charging has been interrupted.
• The power take-off is not deactivated due to low battery level. It is possible to set
the power take-off activation and deactivation conditions via a logic that uses the
SOC (State Of Charge) of the propulsion batteries.
• If the bodywork is connected to the grid, the power take-off must be deactivated
automatically.
• Charging the propulsion batteries via the bodywork is prohibited if the electric
power take-off is activated.
• If the bodywork's VCB components are water-cooled, they can be connected to
the vehicle's cooling circuit. The connection requires approval from Scania.
• The power take-off is controlled via the BCI control unit. More information can
be found under the heading General information about activating and deactivat-
ing PTO EL.
1. Voltage activated when the starter lock is in drive mode.

Using PTO EL
Work on electric power take-off (PTO EL)
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Using PTO EL
IMPORTANT!
• The electrical power take-off must be unloaded when activation or deactivation is
requested. The contactors will be damaged if they open and cut high currents.
• The bodywork's VCB system must be de-energised when activating the power
take-off. This may lead to interrupted activation and fault code generation.
The bodywork's electric power consumption is also monitored by protective software
with the following limit values and consequences if the limits are exceeded:
• Electric power consumption above 100 A for more than 2 seconds results in a re-
quest from the vehicle to reduce the load on PTO EL; if this does not occur, de-
activation will take place within 8 seconds
• Electric power consumption above 150 A for longer than 30 milliseconds results
in an emergency shutdown of PTO EL

Using PTO EL
Work on electric power take-off (PTO EL)
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General information about activation/deactivation
of PTO EL
The bodywork must have functionality to handle a deactivation request for the elec-
trical power take-off from the vehicle. This includes ramping down the load and ac-
tive discharging of the VCB circuit.
The number of activations/deactivations of the electrical power take-off must be
minimised as this affects the service life of the contactors.
It is recommended that the power take-off is activated at the start of the working shift
and left activated until the work shift is over even if the bodywork is not active during
certain periods.
When PTO EL is activated, this is displayed via an indicator lamp in the instrument
cluster (ICL).
The following flow charts show different sequences for activating/deactivating PTO
EL; all sequences are controlled via BMU:
• Activation
• Deactivation
• Deactivation initiated by the chassis
• Emergency deactivation
As standard, vehicles are delivered without a switch for activating the power take-
off. However, it is possible to install a switch that controls the activation via BCI
functionality.

Using PTO EL
Work on electric power take-off (PTO EL)
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Activating PTO EL
1. Prerequisites
• Bodywork VCB system deactivated (1a)
• No energy consumption from the bodywork's VCB system (1b)
• PTO EL status "Ready" (1c)
• Bodywork VCB system ready for activation (1d)
2. Request to activate PTO EL via BICT or CAN from Bodywork (2)
3. Activation sequence initiated
• Pre-charging VCB system (3a)
• Result pre-charging (3b)
• Diagnostics, all parameters OK (3c)
(Includes contactor function and detection of breaks/short circuits; see
section Electrical requirements for systems and components con-
nected to electric power take-off for requirements)
4. PTO EL activation
• PTO EL is activated by closing the contactors (4a)
• Bodywork VCB system activated (4b)
• PTO EL status "Active" (4c)
ABC
1a
1b
1c
1d
2
3a
3b
3c
4a
4b
4c
444 289
Flow chart for activating PTO EL.
A: Bodywork, B: Terminal box R126, C: BMU/BCI
Colour designation
Black: Bodywork VCB
Green: CAN or BICT signals
Purple: The vehicle's internal signals
Blue: Internal process

Using PTO EL
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Deactivation of PTO EL
1. Prerequisites
• Bodywork VCB system activated (1a)
• PTO EL status "Active" (1b)
2. Request for deactivation of PTO EL via BICT or CAN from Body-
work (should only happen when necessary to minimise contactor
wear)
(2)
3. Deactivation sequence initiated
• PTO EL status "Deactivated" in the event that the vehicle initiates
deactivation
(3a)
• Maximum deactivation delay 10 seconds (3b)
• The bodywork's VCB system must be unloaded within 10 seconds.
If this does not happen, an emergency shutdown will be carried out
and the vehicle must be restarted before PTO EL can be reacti-
vated
(3c)
4. PTO EL deactivation
• PTO EL is deactivated via opening the contactors (4a)
• Bodywork VCB system deactivated (4b)
• PTO EL status "Deactivated" (4c)
5. Active discharging of the bodywork's VCB system (5)
(see the section General requirements)
ABC
1a
1b
2
3a
3b
3c
4a
4b
4c
5
444 326
Flow chart for activating PTO EL.
A: Bodywork
B: Terminal box R126
C: BMU/BCI
Colour designation
Black: Bodywork VCB
Green: CAN or BICT signals
Purple: The vehicle's internal signals
Blue: Internal process

Using PTO EL
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Deactivation of PTO EL initiated by the chassis
1. Prerequisites
• Bodywork VCB system activated (1a)
• PTO EL status "Active" (1b)
(Request for deactivation of PTO EL initiated by the chassis due to a
fault in the VCB system)
2. Deactivation sequence initiated
• PTO EL status "Deactivated" (2a)
• Maximum deactivation delay 10 seconds (2b)
• The bodywork's VCB system must be unloaded within 10 seconds.
If this does not happen, an emergency shutdown will be carried out
and the vehicle must be restarted before PTO EL can be reacti-
vated
(2c)
3. PTO EL deactivation
• PTO EL is deactivated via opening the contactors (3a)
• Bodywork VCB system deactivated (3b)
• PTO EL status "Deactivated" (3c)
4. Active discharging of the bodywork's VCB system (4)
(see the section General requirements)
ABC
1a
1b
2a
2b
2c
3a
3b
3c
4
444 700
Flow chart for activating PTO EL.
A: Bodywork
B: Terminal box R126
C: BMU/BCI
Colour designation
Black: Bodywork VCB
Green: CAN or BICT signals
Purple: The vehicle's internal signals
Blue: Internal process

Using PTO EL
Work on electric power take-off (PTO EL)
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Deactivation of PTO EL in an emergency
1. Prerequisites
• Bodywork VCB system activated (1a)
• PTO EL status "Active" (1b)
(Request for deactivation of PTO EL initiated by the chassis due to a
fault in the VCB system)
2. Deactivation sequence initiated
• PTO EL status "Deactivated" (2a)
• Maximum deactivation delay 10 seconds (2b)
• The bodywork's VCB system must be unloaded within 10 seconds.
If this does not happen, an emergency shutdown will be carried out
and the vehicle must be restarted before PTO EL can be reacti-
vated
(2c)
3. PTO EL deactivation
• PTO EL is deactivated via opening the contactors (3a)
• Bodywork VCB system deactivated (3b)
• PTO EL status "Deactivated" (3c)
4. Active discharging of the bodywork's VCB system (4)
(see the section General requirements)
ABC
1a
1b
2
3a
4a
4b
4c
5
444 701
Flow chart for activating PTO EL.
A: Bodywork
B: Terminal box R126
C: BMU/BCI
Colour designation
Black: Bodywork VCB
Green: CAN or BICT signals
Purple: The vehicle's internal signals
Blue: Internal process

Using PTO EL
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Signals for checking PTO EL
BICT: Signal name
Swedish
BICT: Signal name
English
CAN signal Signal value Description
PTO EL ready PTO EL ready PTOInformationProp::PTO_EL 0x01: Ready PTO EL is not activated but ready to be activated when
the vehicle's propulsion system is activated, provided
all other requirements are satisfied
- - 0x00: NotReady PTO EL is not active and is not ready to be activated
PTO EL deactivated PTO EL deactivating 0x03: Deactivating The deactivation sequence for PTO EL has started; this
can be initiated by the bodywork or by the chassis if a
fault is detected in the VCB system
The bodywork's VCB system must be unloaded within
10 seconds. If this does not happen, an emergency
shutdown will be carried out and the vehicle must be
restarted before PTO EL can be reactivated
PTO EL engaged PTO EL activated 0x02: Activated PTO EL is activated
PTO EL emergency
deactivated
PTO EL emergency
deactivated
0x04: Emergency
Deactivated
PTO EL has undergone an emergency deactivation and
the vehicle must be restarted before PTO EL can be re-
activated

Using PTO EL
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Other relevant signals
BICT: Signal name
Swedish
BICT: Signal name
English
CAN signal Signal value Description
Vehicle start active Propulsion state
ready
DLN9::PropulsionState 0x00: NotReady The propulsion system is activated, which is a require-
ment for activating PTO EL
0x01: Ready Replaces previous signals "the alternator is charging",
"the engine is running", etc. but without any connec-
tion to which propulsion system the vehicle has. Can
be used on all Vehicles, even those with a combustion
engine
0x02: Starting
0x03: Stopping
Propulsion battery
state of charge
Propulsion battery
state of charge
HybridInfoProp::StateOfChargeDisplay 0-100% Propulsion battery state of charge. PTO EL will not be
deactivated due to a low charge level, but it is possible
to program a battery level warning via BCI functional-
ity
Propulsion battery
state of charge low
Low state of charge
indication
HybridInfoProp::LowChargeIndication 0x00: NotActive Propulsion battery state of charge low is also displayed
in the instrument cluster
0x01: Active

Using PTO EL
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PTO EL control signals
More information on BCI and electric power take-off control can be found in the fol-
lowing document:
•BCI - Bodywork Communication Interface
•External CAN Communication Specification
BICT: Signal name
Swedish
BICT: Signal name
English
CAN Signal value Description
Activate PTO EL Activate PTO EL BodyworkPTOControl::PTO_EL_Request(Activate) 0x01 Activation can only be carried out if PTO EL status is
"PTO EL ready"
Among other things, the activation sequence checks
for a break or short circuit in the bodywork's VCB sys-
tem. It is therefore important that the bodywork's VCB
system satisfies the electrical requirements (refer to the
section on electrical requirements)
PTO EL will remain active as long as the signal is ac-
tive
Deactivate PTO EL Deactivate PTO EL BodyworkPTOControl::PTO_EL_Request(Deactivate) 0x00 Deactivation request, which means that the bodywork
must unload the VCB system within 10 seconds to
minimise contactor wear. If this does not happen, an
emergency shutdown will be carried out and the vehi-
cle must be restarted before PTO EL can be reactivated
Emergency deactivate
PTO EL
Emergency deacti-
vate PTO EL
BodyworkPTOControl::PTO_EL_Request(Emergency
Deactivate)
0x02 PTO EL will be deactivated regardless of whether
there is load on the connection. This should only be
done in an emergency due to the risk of wear/damage
to the components in PTO EL. The vehicle must be re-
started before PTO EL can be reactivated
- - BodyworkPTOControl::PTO_EL_Request(Take No
Action)
0x03 No active request

Using PTO EL
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General requirements
IMPORTANT!
• The bodywork must never generate a higher voltage than the VCB voltage in the
vehicle. It is prohibited to return power to the vehicle's VCB system.
• Position bodywork electrical equipment so that cables are as short as possible.
Short cables mean a reduced risk of EMC1interference and installation problems.
• All VCB components must comply with applicable standards regarding electrical
safety and comply with ingress protection class IP6K7 or IP6K9K depending on
the location on the vehicle. This also applies to connected connectors. Connectors
that can be disconnected without tools must also comply with IPXXB (R100)
when they are not connected.
• The vehicle's insulation status is monitored using an insulation monitoring device
(IMD). It is prohibited to have an active IMD in the bodywork when the electric
power take-off is activated. This applies if the bodywork VCB system is galvan-
ically connected to the vehicle's VCB system.
• The bodywork VCB system must be galvanically separate from bodywork earth
and the VCA system. An insulation test should be carried out in accordance with
ECE-R100, ISO 6469-1, ISO 6469-3.
• All electrical VCB connections in the bodywork must be designed to prevent un-
intentional polarity reversal
• The bodywork VCB system must have passive discharging, which means that the
voltage drops below 60 V within 5 minutes of deactivation of the power take-off
• The bodywork VCB system must have active discharging, which means that the
voltage drops below 60 V within 3 seconds of deactivation of the power take-off.
This applies when requesting from the vehicle or detecting an open circuit.
• All VCB components must have electrically conductive casing
1. The equipment's ability to function satisfactorily in its electromagnetic environment without
causing unacceptable electromagnetic interference for other equipment.

Connection to electric power take-off
Work on electric power take-off (PTO EL)
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Connection to electric power take-off
WARNING!
This work is classified as electrical work and may only be carried out by trained and
qualified personnel who are authorised to perform electrical work with approved pro-
tective equipment.
It is prohibited to carry out work on the electric power take-off before the following
actions have been taken:
• Disconnect the voltage supply from the VCB batteries using the control switch for
the VCB system; see points 1 to 3 in the following list
• Carry out a voltage measurement on the incoming voltage supply with an ap-
proved result; see point 5 in the following list

Connection to electric power take-off
Work on electric power take-off (PTO EL)
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To connect to the electric power take-off:
1. Switch off the voltage supply from the VCB network using the control switch
for the VCB system. The control switch is positioned behind the front left-
hand wheel; see illustration.
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