BRUSA Elektronik AG
Neudorf 14
CH–9466 Sennwald
+41 81 758 19 00
info@brusa.biz
www.brusa.biz
PDU254
TECHNICAL DATA
AND START-UP
Translation of the original German operating instructions
Technical data
and start-up
PDU254
2
LEGAL NOTICE
Publisher
BRUSA Elektronik AG
Neudorf 14
CH–9466 Sennwald
T +41 8175 809–00
F +41 8175 809–99
www.brusa.biz
office@brusa.biz
Date of issue
19. January 2013
Copyright
© 2012
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. All technical information, drawings and
photos used in this document are protected by copyright and any infringement 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 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
30.04.2013
H. Schmidt
Chap 3.3, 3.5, 7.4, 7.4.2 small corrections
Chap 6.7.3 and 6.7.4 added
02
06.08.2013
M. Tschumper
Chap 8.1 new, 8 small corrections
03
27.01.2014
M. Tschumper
Chap 3.5 Principle of operation Interlock
04
18.02.2014
M. Tschumper
Chap 6.5.1 added signal pin in diagram
05
20.02.2014
M. Tschumper
Chap 8 grafic 7.12..14.15
06
12.02.2015
R. Roth
Chap 4.2 adjust the scope of delivery
Chap 8 adjust table with information about the screw
07
04.06.2015
F. Müller
Chap 8.1 add information about cable and terminal insert
08
28.11.2016
A. Girod
Chap 9 updated
09
26.06.2017
M. Cvorak
Chap 6.1 DEL: discharge resistor;
Chap 7.4.2; 7.4.4 DEL: reverence to active discharge
3
Technical data
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PDU254
VALIDITY
This manual is only valid for the devices listed in the following table:
PDU254-A01
PDU254-A02
The decoding of the device designation is as follows:
Technical data
and start-up
PDU254
4
TABLE OF CONTENTS
1 Foreword .............................................................................................................................. 6
2 List of abbreviations ........................................................................................................... 6
3 Safety and warning instructions ........................................................................................ 7
3.1 Symbols and their meaning ........................................................................................................ 7
3.2 Safety instructions and danger levels ......................................................................................... 8
3.3 Generally applicable safety measures ........................................................................................ 9
3.3.1 Safety instructions for handling and operation ..................................................................... 9
3.3.2 Safety instructions for electrical systems ........................................................................... 10
3.4 Safety installations ................................................................................................................... 11
3.4.1 Interlock switch .................................................................................................................. 11
3.4.2 Shorting link ...................................................................................................................... 12
3.5 Safety concept for vehicle installation ....................................................................................... 13
3.5.1 Principle of operation Interlock .......................................................................................... 13
3.6 Requirements regarding the start-up personnel ........................................................................ 14
4 General ............................................................................................................................... 14
4.1 Content and scope of this manual ............................................................................................ 14
4.2 Scope of the entire documentation ........................................................................................... 14
4.3 Scope of delivery ...................................................................................................................... 15
4.4 Optional delivery contents ........................................................................................................ 17
4.5 Applicable standards ................................................................................................ ................ 17
4.6 Contact information of the manufacturer ................................................................................... 17
5 Use and limits of the product ........................................................................................... 18
5.1 Proper use................................................................................................................................ 18
5.2 Improper use ............................................................................................................................ 18
6 About this device............................................................................................................... 19
6.1 Technical data .......................................................................................................................... 19
6.2 Technical properties ................................................................................................................. 20
6.3 Warnings on the PDU ............................................................................................................... 20
6.4 Overview of the main structural components ............................................................................ 21
6.5 Basic function PDU254 ............................................................................................................ 22
6.5.1 Block diagram PDU254 ..................................................................................................... 22
5
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PDU254
6.6 Basic principle of vehicle installation ........................................................................................ 23
6.7 Dimensions and installation information ................................ ................................................... 24
6.7.1 Fixing points ...................................................................................................................... 24
6.7.2 Housing dimensions .......................................................................................................... 25
6.7.3 Interface dimensions ......................................................................................................... 25
6.7.4 Fully assembled view ........................................................................................................ 26
6.8 Type plate ................................................................................................................................ 26
7 Connections ....................................................................................................................... 27
7.1 Input side ................................................................................................................................. 27
7.2 Output side ................................................................................................ ............................... 28
7.3 Earth GND................................................................................................................................ 29
7.4 Pin assignment of control connector (device side) .................................................................... 30
7.4.3 Pin 4 DO0 ......................................................................................................................... 32
7.4.4 Pin 5 DO1 ......................................................................................................................... 32
7.4.5 Pin 7 DO3, pin 16 DI0 ....................................................................................................... 33
7.4.6 Pin 19 IL1, pin 20 IL2 ........................................................................................................ 33
8 Installation / initial start-up ............................................................................................... 34
8.1 Connecting the HV lines ........................................................................................................... 41
9 Warranty ............................................................................................................................. 44
10 Instructions for disposal ............................................................................................... 44
11 Index ................................................................................................................................ 45
Technical data
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PDU254
6
1 Foreword
Dear customer!
With the BRUSA PDU254, you have obtained a very capable and versatile product. As this is a power electronics
product, specialist knowledge is required for dealing with it as well as operating it!
Read this manual – in particular the chapter Safety and warning instructions– carefully before installing the battery
or carrying out any other work on it!
2 List of abbreviations
Throughout this manual, some specific technical abbreviations are used. The following table provides an overview
of these abbreviations and their meaning:
ABBR.
MEANING
ABBR.
MEANING
AUX
Auxiliary
IL
Interlock
BSC
On-board converter
NLG
Netzladegerät (mains charger)
DMC
Digital Motor Controller (inverter)
PDU
Power Distribution Unit
EMC
ElectroMagnetic Compatibility
PTC
Resistor with Positive Temperature
Coeffizient
HF
High Frequency
RXT
Range Extender
HV
High Voltage
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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, some specific technical symbols are used. The following table provides an overview of
these symbols and their meaning:
PROHIBITION SYMBOLS
SYMBOL
MEANING
SYMBOL
MEANING
General prohibition
Warning! High voltage!
Do not touch!
Do not switch!
WARNING SYMBOLS
SYMBOL
MEANING
SYMBOL
MEANING
General hazard warning
Warning! Danger caused by suspended
loads!
Warning! Explosive environment!
Warning! Danger caused by batteries!
Warning! Hot surface!
Warning! High voltage!
Warning! High pressure / fluid ejection!
Warning! Fire hazard!
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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PDU254
8
3.2 Safety instructions and danger levels
DANGER
This instruction warns against serious, irreversible risks of personal injury with possibly fatal
consequences!
Avoid these risks by observing these instructions!
WARNING
This instruction warns against serious but reversible risks of injury!
Avoid these risks by observing these instructions!
CAUTION
This instruction warns against a minor risk of injury!
Avoid these risks by observing these instructions!
INSTRUCTION
This instruction warns against possible damage to property if the following instructions and work
procedures are not observed.
INFORMATION
This type of instruction discloses important information for the reader.
9
Technical data
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PDU254
3.3 Generally applicable safety measures
The following safety measures have been developed based on the knowledge of the manufacturer. They are
incomplete as 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 handling and operation
WARNING
Overheating!
Fire hazard!
The plus and minus poles must not be bypassed using a metallic object! This will lead to a short-
circuit and fast overheating of the device and the cables!
Do not carry out any unauthorised work on the PDU! This may cause the safety installations to
be disabled and could lead to fires as a consequence!
The device must by no means be subjected to rough mechanical impacts! This could destroy the
circuit boards and lead to short-circuits and fires as a consequence!
Do not store any highly flammable substances or combustible fluids in the direct surroundings of
the device! Sparks forming at the device connections can set these on fire and lead to
explosions!
WARNING
Hot surfaces!
Burn hazard!
The device produces high levels of waste heat when in operation. Carelessly touching the device
can cause burns to the skin! Therefore, the device is to be handled with care and caution at all
times! Avoid operating the device close to heat sources or in direct sunlight!
INSTRUCTION
Even though the PDU has a high IP protection class, direct contact with water (rain, splashing
water) during operation is to be avoided as far as 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 PDU!
Before connecting the cabling, make sure that the battery cables have been properly connected!
Reverse polarity can lead to the destruction of not only the battery but of other devices as well!
Check if the used system voltage is within the admissible range before connecting the cabling!
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PDU254
10
3.3.2 Safety instructions for electrical systems
DANGER
High voltage!
Danger to life!
Do not touch the HV wires or connections without ensuring the absence of voltage beforehand!
The PDU may only be connected by a qualified electrician!
Safety installations must not be by-passed or avoided! Any resulting malfunctions could have life
threatening consequences!
Before carrying out any work on the PDU, make sure that the coupled motor has come to a
complete standstill! Even when the HV supply is switched off, a turning motor can still produce
voltage!
INFORMATION
When working on a HV grid, the following 5 safety rules have to be strictly adhered to:
Disconnect the system from the voltage supply.
Switch off the ignition.
Remove service / maintenance plug and/or turn off main battery switch.
Remove fuse (external fuse box).
Ensure that the system does not reconnect.
Keep ignition key safe to prevent unauthorised access.
Keep the service / maintenance plug safe to prevent unauthorised access and/or
use lockable cover cap to ensure that the main battery switch does not reconnect.
Ensure that the device is de-energised by means of a suitable voltage tester (note voltage
range!)
Earth and short-circuit the system.
Cover or seal off adjacent live parts.
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PDU254
3.4 Safety installations
3.4.1 Interlock switch
The interlock switch (1) protects the operator from injuries from the HV connections. The interlock switch (1) is
automatically activated as soon as the service cap is opened.
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PDU254
12
3.4.2 Shorting link
In order to put the PDU into a safe state for assembly work, a shorting link (1) is included in the delivery. After the
service cap has been opened, the interlock switch (2) is automatically activated. By means of the interlock switch
(2), the HV circuit is immediately disconnected from the voltage supply. In order to additionally short-circuit the
PDU, the shorting link (1) must be inserted into the contacts (3) and (4). This will put the PDU into a safe state.
13
Technical data
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PDU254
3.5 Safety concept for vehicle installation
INFORMATION
This safety concept is a recommendation of the company BRUSA Elektronik AG and is a general
requirement for the safe operation of electric vehicles!
3.5.1 Principle of operation Interlock
The interlock switch (1) is closed if the corresponding interlock condition of each devices is met (closed service
cover, plugged HV connections ...). The interlock evaluation of the PDU switches the 12V supply voltage (2) of the
HV contactors (4) in the battery if the interlock circuit is closed. The emergency stop switch (3) also interrupts the
12V supply voltage of the HV contactors (4). The second interlock (5) of the line insulation guard interrupts the
interlock circuit, if a fault in the HV- insulation is detected.
Technical data
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PDU254
14
3.6 Requirements regarding 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 possess
professional training,
knowledge and experience in the field of high voltage electronics / electric mobility,
as well as knowledge of the relevant requirements and dangers
which they can display in practice. Furthermore, they must be able to assess the work assigned to them
independently, identify possible dangers and establish necessary protection measures.
4 General
4.1 Content and scope of this manual
The present documentation provides the reader with an overview of all required operating steps in the installation
and operation of the device and the safety measures necessary for these purposes.
Furthermore, it contains technical data, usage information and a basic description of the battery and its specific
components.
The operational and safety instructions given must be adhered to in order to ensure the ongoing optimum
functioning of the device and to meet the warranty requirements of the company BRUSA Elektronik AG.
4.2 Scope of the entire documentation
INFORMATION
To start up the PDU254 successfully, you will need the entire documentation. With the provision of
the customer package, it is ensured that the required documentation is complete and up-to-date. The
updating of specific documents is carried out automatically and can be seen in the history.
The customer package includes the following indexes:
Manual:
Contains all information fundamentally necessary for the installation and operation of the device.
Tools:
---
History:
List of all updates within the customer package indicating the affected documents.
15
Technical data
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PDU254
4.3 Scope of delivery
MEANING
PIECES
ILLUSTRATION
1.
High voltage distribution unit PDU254
1
2.
Fuse FWH-300 A / 500 VDC for main connections
4
3.
Fuse FWH-100 A / 500 VDC for range extender / DC quick charger
2
4.
Fuse 20 A / 600 V
for small-scale energy users
6
5.
23-pole control connector with crimp terminals
AMPSEAL 770680-1
1
6.
SN/LP contacts
AMPSEAL 770854-1
for wire diameter: 0.5 mm2
We recommend the use of the following crimping tool:
Tyco 58440-1
25
7.
Blanking plug M25 for main connections
10
8.
Blanking plug M20 for side terminals
5
9.
Shorting link
1
10.
Cable lug 50 mm2 for main connection 300 A and cascading
10
11.
Cable lug 50 mm2 for chassis GND (KL31)
1
12.
Cable lug 25 mm2 for range extender or DC quick charger
2
13.
Cable lug 4 mm2 for small-scale energy users
6
14.
Serrated lock washers for fuse 300A installation (12 for replacing the
fuse)
24
Technical data
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PDU254
16
MEANING
PIECES
ILLUSTRATION
15.
Washers for fuse 300A installation
16
16.
Screw M8x22 for fuse 300A installation
12
17.
Serrated lock washers for cable lug connection
6
18.
Screw M4x8 for cable lug connection
6
17
Technical data
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PDU254
4.4 Optional delivery contents
MEANING
PIECES
ILLUSTRATION
1.
Special key for HV cable fitting
RAAA041
---
2.
Fuse FWH-400 A / 500 VDC for main connections
MSAA419
4.5 Applicable standards
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 PDU254.
4.6 Contact information of the manufacturer
BRUSA Elektronik AG
Neudorf 14
9466 Sennwald
Switzerland
Phone:
+41 81 758 19 - 00
Fax:
+41 81 758 19 - 99
Internet:
www.brusa.biz
Email:
support@brusa.biz
Technical data
and start-up
PDU254
18
5 Use and limits of the product
5.1 Proper use
The product PDU254 has been designed for the following uses, taking into consideration the limit values indicated
in chapter 5.2 :
Installation in a drive train for hybrid vehicles
Installation in a drive train for electric vehicles
Installation in a drive train for fuel cell vehicles
Use in high-performance motors (motor-racing sector)
Installation in a drive train for electric motorbikes
Installation in a drive train for utility vehicles (electric and hybrid)
Installation in a drive train for electric boats
Test bench applications
If the device is to be used for applications in areas other than those previously defined, the buyer is obliged to
coordinate these applications with the manufacturer and to obtain a written approval for these uses.
INFORMATION
This equipment is a custom built evaluation kit destined for professionals to be used solely at
research and development facilities for such purposes.
5.2 Improper use
Improper use is any use implemented under conditions which deviate from those indicated by the manufacturer in
their technical documents and data sheets. Taking into consideration the proper use indicated in chapter 5.1 , the
following limit values have been stipulated for the operation of the product PDU254. The product may not be used
outside these limit values. Operation outside these limit values can lead to life-threatening situations!
PDU254-A01
UNIT
Max. HV input voltage (operating voltage)
500
V
Min. ambient temperature
- 40
°C
Max. ambient temperature
+ 85
°C
Permissible peak current for a max. duration of 10 s
400
A
Max. permissible voltage drop via interlock loop
30
V
19
Technical data
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PDU254
6 About this device
6.1 Technical data
BASIC ELECTRICAL DATA
PDU254
UNIT
Operating voltage
200...500
V
Peak inrush current, contactors
3.7
A
Voltage for control signals (Pin = high)
7 to 15
V
Interlock current
10
mA
Max. permissible voltage drop via interlock loop
30
V
Recommended cable diameter for main connection 300 A and cascading
50
mm2
Recommended cable diameter for range extender or air conditioning compressor
25
mm2
Recommended cable diameter for small-scale energy users (up to max. 24 A)
4
mm2
POWER DATA AT + 25 °C
VALUE
UNIT
Peak current: BATT 1/2 connection DMC 1/2 connection
300
A
Peak current: BATT 1/2 connection RXT connection
100
A
Peak current: BATT 1/2 connection NLG / BSC / AUX connection
20
A
BASIC MECHANICAL DATA
VALUE
UNIT
Material
AlMgSi1
---
Length
300
mm
Width
178
mm
Height
78
mm
Housing volume
4.16
l
Total weight
3.9
kg
Weight of fuse 300 A
200
g
Weight of fuse 100 A
90
g
Weight of fuse 20 A
10
g
IP protection
IP68
---
Water-tight pressure compensation membrane
---
---
THERMAL
VALUE
UNIT
Min. ambient temperature
- 40
°C
Max. ambient temperature
+ 85
°C
Technical data
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PDU254
20
6.2 Technical properties
Parallel connection of two PDUs possible (cascading)
Compact and light-weight construction
Meets standard requirements (EMC, mains harmonics etc.)
Active HVIL (HV interlock)
Connection of 2 HV batteries possible
2 connections with 300 A, fuse-protected for inverter (e.g. DMC5)
1 connection with 100 A, fuse-protected for range extender (RXT) or DC quick charger
3 connections for additional peripheral devices (e.g. charger, air conditioning compressor, on-board converter
etc.)
6.3 Warnings on the PDU
Warning signs are installed on the PDU to warn the operator of possible dangers. Should one of these warning
signs be missing or become illegible due to wear and tear, it is to be renewed immediately! In order to obtain an
original label, please contact the BRUSA support at the manufacturer's address provided in chapter 4.6 .
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Technical data
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PDU254
6.4 Overview of the main structural components
1. Service cap
2. Connections, input side
see chapter 7.1 Input side
3. Pressure compensation membrane
4. Control connector
Chap. 7.4 Pin assignment of control connector
(device side)
5. Earth GND
Chap. 7.3 Earth GND
6. Housing
7. Fuse 100 A
8. Interlock switch
see chapter 3.4.1 Interlock switch
9. Fuse 20 A
10. Type plate
see chapter 6.8 Type plate
11. Connections, output side (fuse protection 20 A)
see chapter 7.2 Output side
12. Connections, output side (fuse protection 100 A)
see chapter 7.2 Output side
13. Connections, output side (fuse protection 300 A)
see chapter 7.2 Output side
14. Fuse 300 A
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PDU254
22
6.5 Basic function PDU254
The PDU254 is a HV distribution unit that combines the features required to meet all relevant requirements
(automotive sector, industrial service life) in one robust, compact and light-weight device. The HV distribution unit
features two battery connections and two inverter connections with a 300 A fuse protection for each connection. A
range extender or a DC quick charger with up to 100 A can additionally be connected. The cascading connections
can be used in order to connect two PDU254 with each other. For small-scale energy users, a total of six 20 A
fuses is available (e.g. BRUSA charger NLG5, BRUSA on-board converter BSC6, air conditioning compressor
etc.).
For short-circuiting the HV circuit (e.g. for fuse replacement), an insulated shorting link provided with two
connections designated for this purpose is available. The interlock generator is connected via the 23-pole AMP
control connector. The interlock circuit is constantly monitored by means of two signals indicating the current state
of the PDU254.
6.5.1 Block diagram PDU254
23
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PDU254
6.6 Basic principle of vehicle installation
Technical data
and start-up
PDU254
24
6.7 Dimensions and installation information
For the installation of the PDU, the following points must be strictly adhered to:
Despite the IP protection provided, the PDU should be installed in a dry location, protected from splashing
water.
When bringing the device into its installation position, make sure that the connection sides are positioned as
horizontally as possible. This prevents water accumulation on the cable sealings which could result in water
leaking into the housing.
The mechanical fixings must be arranged so that the PDU is fitted firmly and in a way that is as vibration-proof
as possible.
The cable feeds should have sufficient space and must never touch components with sharp edges.
6.7.1 Fixing points
1. M6 through hole (thread depth 16 mm)
Min. screw-in depth = 10 mm
Torque = 6 Nm
Min screw tension 8.8
25
Technical data
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PDU254
6.7.2 Housing dimensions
6.7.3 Interface dimensions
Technical data
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PDU254
26
6.7.4 Fully assembled view
6.8 Type plate
1. Classification
2. Version
3. Serial number
4. Date of production (dd.mm.yy)
5. Admissible voltage range HV battery
6. Fuse protection output DMC1, DMC2 (admissible
maximum current)
see chapter 7.2 Output side
7. Fuse protection output RXT (admissible maximum
current)
see chapter 7.2 Output side
8. Fuse protection output BSC, NLG, AUX (admissible
maximum current)
see chapter 7.2 Output side
9. IP protection class
27
Technical data
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PDU254
7 Connections
7.1 Input side
You will find the required cable types and cable diameters in chapter 6.1 Technical data
1. Battery input 1+ (HV plus)
2. Battery input 1- (HV minus)
3. Battery input 2+ (HV plus)
4. Battery input 2- (HV minus)
5. Cascading output + (HV plus)
Output for the connection of a second PDU
6. Cascading output - (HV minus)
Output for the connection of a second PDU
7. Control connector
Chap. 7.4 Pin assignment of control connector
(device side)
8. Earth GND
Chap. 7.3 Earth GND
Technical data
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PDU254
28
7.2 Output side
You will find the required cable types and cable diameters in chapter 6.1 Technical data
1. Output AUX
Fuse protection 20 A
2. Output BSC
Fuse protection 20 A
3. Output NLG
Fuse protection 20 A
4. Output RXT+ (HV plus)
Fuse protection 100 A
5. Output RXT- (HV minus)
Fuse protection 100 A
6. Output DMC2+ (HV plus)
Fuse protection 300 A
7. Output DMC2- (HV minus)
Fuse protection 300 A
8. Output DMC1+ (HV plus)
Fuse protection 300 A
9. Output DMC1- (HV minus)
Fuse protection 300 A
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Technical data
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PDU254
7.3 Earth GND
INFORMATION
The grounding screw (1) must be connected with the earth of the vehicle and/or test bench.
We generally recommend to guide the earth cables of all drive components to one earth point
altogether. This minimises the risk of potential differences which may cause malfunctions of
individual drive components!
The cable diameter of the earth cable must correspond to the dimensions of the HV wiring.
Torque of grounding screw (1) M8 x 10 = 10 Nm
Technical data
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PDU254
30
7.4 Pin assignment of control connector (device side)
1.
GND
Earth (minus wiring system,
terminal 31)
2.
---
---
3.
EN
Enable (power ON, terminal 15)
4.
DO0
Digital output 1
5.
DO1
Digital output 2
6.
---
---
7.
DO3
Digital output 4
8.
---
---
9.
---
---
10.
---
---
11.
---
---
12.
---
---
13.
---
---
14.
---
---
15.
---
---
16.
DI0
Digital input 1
17.
---
---
18.
---
---
19.
INL1
Interlock signal source
20.
INL2
Interlock signal feedback
21.
---
---
22.
---
---
23.
---
---
31
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PDU254
7.4.1 Pin 1 GND
Internal wiring
1MΩ
9,4μF
Pin 1 GND
housing
Earth connection to control unit.
7.4.2 Pin 3 EN
Internal wiring
100μF
Pin 3
EN
Internal
Supply
PTC
1,5A
36V
AUX safe
The control unit of the PDU is only supplied via this connection.
The device is generally ready for operation as soon as a voltage of 12 V is applied to this pin.
VOLTAGE AT PIN 3 EN
INTERLOCK CIRCUIT
CURRENT CONSUMPTION AT PIN
3 EN
12 V
open
16 mA
12 V
closed
100 mA
Technical data
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PDU254
32
7.4.3 Pin 4 DO0
Internal wiring
10k
10nF
Pin 4
DO0
This output indicates the state of the interlock generator.
This pin becomes active (= low) as soon as LV is applied and the interlock circuit is closed.
As soon as the interlock circuit is opened, this pin becomes inactive (= high). Now, the LV supply voltage is
applied to this pin.
7.4.4 Pin 5 DO1
Internal wiring
10k
10nF
Pin 5
DO1
The device is ready for operation when:
The interlock circuit is closed, Pin 4 DO0 active (low)
The supply voltage of the main contactors (LV) is applied to pin 16 DI0.
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PDU254
7.4.5 Pin 7 DO3, pin 16 DI0
Internal wiring
10nF
Pin 16
DI0
Pin 7
DO3
K
On the one hand, pin 16 DI0 is used to supply the main contactors of the HV bus and, on the other hand, to
supply the internal logic of the active intermediate circuit discharge.
As soon as LV is applied to the device (pin 3 EN) and the interlock circuit is closed, the relay (K) is energised
and pin 16 DI0 is connected to pin 7 DO3. As a result, the main contactors actuated by pin 7 DO3 are closed.
As soon as the interlock circuit is opened, the relay (K) is de-energised again. As a result, the main contactors
are immediately opened.
7.4.6 Pin 19 IL1, pin 20 IL2
Internal wiring
10nF
Pin 19
INL1
Pin 20
INL2
K
-48V INL-
Generator
Deckel-
Schalter
Pin 19 INL1 is the output signal of the interlock generator. The signal current amounts to 10 mA and flows
from the earth GND through the relay coil of the main contactor supply to all other devices in the interlock
circuit (to the corresponding feedback pin INL2). From the last device in the interlock circuit, the signal is lead
back to the PDU to pin 20 IL2. In the PDU, the signal is lead back to the interlock generator via the lidoperated switch.
The interlock generator (-48V) allows a maximum voltage drop of 30 V between INL1 and INL2, which means
via all other devices in the interlock circuit as well.
lid-operated switch
Technical data
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PDU254
34
8 Installation / initial start-up
DANGER
High voltage!
Danger to life!
If the battery is switched on, high voltage is applied to the HV connections which also includes HV
cables that have already been connected! Therefore, do not connect any HV cables before making
absolutely sure that the device is de-energised!
Before carrying out any work on the PDU, follow strictly the safety instructions, chap.3.3.2 Safety
instructions for electrical systems and the 5 safety rules for working on a HV grid.
INFORMATION
The following procedure is described for the connection battery input 1+ (HV plus).
The following torques apply to all fixing screws of the cable lugs:
Torque of screws M8 x 22 = 12 Nm
Torque of screws M4 x 8 = 2.5 Nm
WARNING
It is not allowed to tighten the screws without washers and without serrated lock-
washers, otherwise the PDU will be damaged!
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Technical data
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PDU254
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
1.
Make sure that all of the HV cables to be connected
are de-energised.
2.
Connect the cables to the control connector.
See chapter 7.4 Pin assignment of control
connector (device side)
---
3.
Connect the HV supply and the ground wiring.
See chapter 8.1 Connecting the HV lines
---
4.
Establish the earth connection between the PDU
and the vehicle.
See chapter 7.3 Earth GND
The cable length should be kept as short as
possible.
---
5.
Unscrew the screws for the service cap (1).
6.
Remove the service cap (1).
The interlock switch (2) is activated.
Technical data
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PDU254
36
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
7.
Unscrew the cable fitting union nut (1) on both
sides.
For this, we recommend the special key for HV
cable fitting type: RAAA041
See chapter 4.4 Optional delivery contents
8.
Unscrew the screws (1).
Remove the serrated lock washers (2) and the
washers (3).
9.
Remove the fuse (1).
37
Technical data
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PDU254
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
10.
Guide the prepared HV cables through the housing
openings on both sides.
For building the HV lines cabels
See chapter 8.1 Connecting the HV lines
Place the cable lug (1) on the connector pin on both
sides.
11.
Place the fuse (1) on the cable lugs (2).
In any event, the fuse (1) must be placed above
the cable lugs (2)!
Technical data
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PDU254
38
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
12.
Bring the washers (3) and then the serrated lockwashers (4) in position and tighten the screws (5).
The order must always be observed as shown!
(1) = Cable lug
(2) = Fuse
(3) = Washer
(4) = Serrated lock-washer
(5) = Screw M8 x 22
Torque of screws M8 x 22 = 12 Nm
If you use just one side of the fuse (for example
with two DMC5 and one Battery) it’s necessary
to use a washer instead of the cable lug
(1) = Washer
(2) = Fuse
(3) = Washer
(4) = Serrated lock-washer
(5) = Screw M8 x 22
The PDU can be damaged, if you don’t use
the additional washer!
13.
Tighten the cable fitting in the housing on both sides.
For this, we recommend the special key for HV
cable fitting type: RAAA041
See chapter 4.4 Optional delivery contents
---
39
Technical data
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PDU254
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
14.
For install output side connections with fuse
protection 20 A, connect the cables with lugs,
serrated lock-washer and tighten the screws (1).
Torque of screws M4 x 8 = 2.5 Nm
15.
Assemble the service cover.
Make sure that the service cap is correctly fitted.
Check the interaction of the actuation surface on
the service cap (1) and the interlock switch (2).
16.
Tighten the screws for the service cap (1).
Torque of screws M6 x 20 = 7.0 Nm
(with serrated lock-washer)
Technical data
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PDU254
40
INFORMATION
The cable connection has been established. Repeat the procedure for all required cable
connections. Unused cable entries and exits must be closed using the supplied blanking plugs!
Close the service cap afterwards.
41
Technical data
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PDU254
8.1 Connecting the HV lines
The building of the HV wiring must be carried out in accordance with the following instructions. Here it is important
that no strands are damaged and that none stick out at the sides on the assembled cable. So check that the screw
connections are correct for each completed cable and that the cable lug is fixed properly (pull test).
For the HV connections we recommend:
A shielded, insulated automotive cable (e.g. Huber & Suhner).
Cable lug, for the type see chapter 4.3 Scope of delivery
To assemble the cable lugs, using the appropriate crimping tool is absolutely necessary!
INSTRUCTION
You must absolutely make sure that the individual strands of the shielding braid (Step 5) do not jut
out again under any circumstances! Once installed, this will damage the sealing lip and subsequently
cause an ingress of water into the housing! Therefore, cut all protruding strands to the admissible
length!
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
1.
Insulate 35 mm of the HV cable (1).
Ensure that you do not damage the shielding
braid underneath it!
2.
Shorten the shielding braid (1) by 20 mm.
The cable-side shielding braid (2) must be a
length of around 15 mm.
Technical data
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PDU254
42
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
3.
Lead the HV cable (1) through the union nut (2).
Lead the HV cable (1) through the terminal insert (3).
4.
Place the terminal insert (1) with the front edge flush
with the cable insulation (2).
5.
Put the shielding braid (1) over the terminal
insert (2).
During this, the shielding braid (1) may overlap the
O-Ring (3) by a maximum of 2 mm.
Fix the terminal insert (2) in position on the HV
cable, eg with electrical tape (4).
You must absolutely make sure that the
individual strands of the shielding braid (1) do
not jut out over the sealing ring (3) under any
circumstances! Once in the integrated state, this
will lead to leakages and subsequently to the
leaking of water into the housing!
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Technical data
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PDU254
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
6.
Insulate 16 mm of the HV cable (1).
7.
Assemble the cable lug (1) at the end of the cable.
No strands should stick out at the sides!
The crimping must be hexagonal. Ensure that
the crimping has no deformations at the sides
because this will make later installations in the
housing difficult!
8.
Check the secure positioning of the cable lug
manually.
---
9.
Assemble a shrinkage tube (1) on the cable lug (2).
The assembly of a shrinkage tube (1) is
absolutely necessary because otherwise
contacting can result in the housing!
INSTRUCTION
During the layout of the cable take care that
the first part of the cable is at least 5cm
straight before it will be bend to a radius.
INSTRUCTION
If you have to reassembly the cable you have to use a new terminal insert. Otherwise it can cause a
leakage.
The terminal inserts can be ordered from BRUSA Elektronik AG or directly from hummel.com.
5cm
Technical data
and start-up
PDU254
44
9 Warranty
The warranty corresponds to the regulations in our currently valid general terms and conditions see under
www.brusa.biz/en/support/terms-conditions.html.
10 Instructions for disposal
The correct disposal is a basic requirement for the re-use and recycling of used electronic devices.
With the implementation of the electric and electronic device regulation (ElektroG), since 24 March 2006, electronic
devices may no longer be disposed of along with ordinary household waste but must be separately collected and
recorded by a specialist service.
Disposal through a specialist service significantly helps to avoid dangers to people and the environment. Therefore,
in the case of disposal, we recommend contacting a recognised specialist disposal service.
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PDU254
11 Index
B
Block diagram
Installation into the vehicle .................................................. 23
PDU basic concept ................................................................ 22
C
Cable connections
Instructions and cross-sections ............................................. 19
Customer package ..................................................................... 14
D
Designation of the device
Decoding ................................................................................. 3
Dimensions of housing ........................................................ 19, 25
Dimensions of interfaces ........................................................... 25
Disposal ..................................................................................... 45
E
Earth connection GND ............................................................... 29
F
Fully assembled view ................................................................. 26
I
Important installation instructions .............................................. 9
Installation instructions ............................................................. 24
Interlock
Principle of operation............................................................ 13
L
Limit values ................................................................................ 18
M
Minimum wiring (unsafe operation!) ......................................... 30
O
Operating ranges ....................................................................... 18
P
PDU254
Specification .......................................................................... 19
S
Safety
Important instructions ............................................................ 9
Serial number ............................................................................. 26
T
The 5 safety rules ....................................................................... 10
V
Validity of the manual .................................................................. 3
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