BCL25-700-8

BCL25-700-8 22/25 kW Battery Charger The BCL25-700-8 is a 22 kW liquid cooled on-board battery charger that converts 3-phase AC voltage to DC voltage in hybrid or full electric vehicles. Key Features & Benefits • Input power up to 22/25 kW @ 400/480 VAC • Typical efficiency 94% • AC input range: Three phases: 330 - 528 VAC (L-L) Single phase: 190 – 264 VAC (L-N) • DC output 240 - 800 VDC • Bi-directional operation: AC-DC charge mode DC-AC export mode • Parallelable up to 4 units in charge mode • Over-temperature, output over-voltage and over-current protections • Operating temperature -40°C to 60°C at full load • SAE J1939 compliant CAN bus communication interface • SAE J1772 & EN 61851 compliant • Active HVDC interlock monitoring • IEC 61851-21-1 compliant immunity requirements • SAE J1455 compliant environmental standards • IP67, IP6K9K protection • J1939 compliant CAN Control and Monitoring Applications • Hybrid and Electric Vehicles • Medium through heavy duty, on and off highway vehicles belfuse.com/power-solutions BCL25-700-8 2 1. MODEL SELECTION MODEL DESCRIPTION BCL25-700-8 Converter System 2. INVERTER CHARGER SUBSYSTEM 2.1 AC SIDE CHARGE MODE INPUT PARAMETER Input Voltage 3-phase Input Voltage 1-phase Input Current DESCRIPTION / CONDITION MIN Nominal Operating Range Absolute Operating Range Nominal Operating Range Absolute Operating Range NOM 330 Frequency 47 @ 528 VAC, 63 Hz; 3-phase @ 264 VAC, 63 Hz; 1-phase Power Factor VAC_IN = 400 VAC, 3-phase, PIN > 11kW Input Inrush Current Pre-charge Mechanism Efficiency VAC_IN = 400 VAC, 3-phase, PIN > 11kW 264 32 AAC 230 190 50 / 60 UNIT VAC VAC VAC VAC 528 Charge Mode: Leakage Current MAX 400/440 63 Hz 3.5 5 mA mA 0.99 94 % 2.2 AC SIDE EXPORT MODE OUTPUT PARAMETER DESCRIPTION / CONDITION Output Voltage 3 phase Output Current Export Mode: @ 400 VAC @ 480 VAC Output Power MIN Mode: 50 Hz Mode: 60 Hz Frequency CAN selectable 50 or 60 Hz Efficiency @ VHV = 350 VDC (Nom), PIN > 11kW Load Step 1 3 AAC to 15 AAC and back Load Step 2 15 AAC to 30 AAC and back Load 0 – 32 AAC Voltage deviation Export Mode: Turn-On Delay Turn-Off Delay Load Step Response Voltage Total Harmonic Distortion Turn-On/Off Delay NOM MAX 3x400 3x480 3x32 49.9 59.9 - 10% 50 60 93 0 UNIT VAC 20.5 23.5 50.1 60.1 ARMS kVA kVA Hz % + 10% VAC 3 5 0.1 % MAX UNIT 800 VDC 60 66 6 60 ADC AAC s 2.3 HV DC SIDE CHARGE/EXPORT MODE PARAMETER DESCRIPTION / CONDITION Output Type DC current source with 100/120 Hz sine wave ripple component Output Voltage Not regulated; depends on battery voltage Output Current Output Current Ripple NOM 250 Average output charging current adjustable via CAN Including AC ripple component (AC + DC) 100/120 Hz 3 phase 100/120 Hz 1 phase Input Capacitance Inrush Current MIN μF 50 Use external pre-charge resistor 50Ohm Apk-pk 20 A tech.support@psbel.com belfuse.com/power-solutions BCL25-700-8 3 2.4 PROTECTIONS PARAMETER AC Over-Current Protection AC Over-Voltage Protection AC Under-Voltage Protection DESCRIPTION / CONDITION MIN NOM Phase - L1, L2, L3 Export Mode: 10 s Current limit 3 phase @ 528 VRMS 1 phase @ 264 VRMS 3 phase @ 330 VRMS, 1 phase @ 190 VRMS 528 264 320 180 HV DC Over-Current Protection CAN adjustable HV DC Over-Voltage Protection Latch type, CAN adjustable, max. OVP Duration 1 ms HV DC Under-Voltage Protection UVP Duration 1 s MAX UNIT 32 ARMS 535 275 330 190 VRMS VRMS 60 A 250 800 VDC 230 250 VDC AC input fuse internal, EVSE external circuit breaker Type C 32 Input and Output Fuse Protection HV external input fuse (800 VDC minimum): Aux_Supply_12/24 V fuse: external Automotive (Car) fuse 80 5 Over-Temperature Protection Converter shutdown at T_coolant higher than 75 A A A °C 3. MONITORING AND CONTROL SIGNALS PARAMETER IGN (Key Switch) Control Pilot Proximity Detection VBAT EVSE_WAKE_OUT CAN_BAUD_RATE DESCRIPTION / CONDITION CAN communication enable Level High = Enable (connected to +VBAT) Function and levels according to SAE J1772 Duty cycle accuracy +/-2% in range 20 – 96%. Duty cycle accuracy -2/+5% in range 10 – 20%. Function and levels according to SAE J1772 12/24 V battery voltage input. Used to supply internal aux converter. Input protected against reverse connected. Energy taken from VBAT. High side switch to wake VCU (Vehicle Control Unit) and other vehicle control modules. Output is protected by resetable PTC fuse. CAN bus speed; CAN speed settings is detected only at start up when 12/24 V voltage is applied. 500 kbit/s – signal not connected / left floating 250 kbit/s – signal grounded; connected to -VBAT 4. SAFETY, REGULATORY AND EMI SPECIFICATIONS PARAMETER DESCRIPTION / CONDITION CRITERION Radiated Emission IEC 61851-21-1:2017 According norm. Conducted Emission IEC 61851-21-1:2017 According norm. Emission of voltage changes, voltage fluctuations and flicker on AC power lines IEC 61851-21-1:2017 According norm. Harmonic Input Current IEC61000-3-2:2014 and IEC 61000-3-12:2011 According norm. Electrostatic Discharge IEC 61204-3:2014 level 3 Performance Criterion B Radiated Electromagnetic Field ISO 11452-2:2004, SAE J1113/21 Performance Criterion B, Status 2 Electrical Fast Transient (EFT) /Burst IEC 61000-4-4; Level 2 (+/-5 kHz) Performance Criterion B Surge Immunity IEC 61000-4-5; Level 3 surge (+/-1 kV DM and +/-2 kV CM) Performance Criterion C RF Conducted Immunity IEC 61000-4-6; Level 3 (10 V, 0.15…80 MHz, AM 80%, 1 kHz) Performance Criterion A BCI (Bulk Current Injection) ISO 11452-4-5, 20-200 MHz, 60 mA, 80% AM Class B CCC (Capacitive Coupling Clamp) ISO 7637-3, -60 V, +40 V, Class A Asia-Pacific Europe, Middle East North America +86 755 298 85888 +353 61 225 977 +1 408 785 5200 © 2020 Bel Power Solutions & Protection BCD.20004_1 BCL25-700-8 4 Electrical Transient Conduction Along Supply Lines ISO 7637-2:2011 Pulse number 1 Pulse number 2a Pulse number 2b Pulse number 3a Pulse number 3b C A C A A Starting profile ISO 16750-2 A Load Dump ISO 16750-2. Insulation (Factory tested) A AC Input to HV output: AC Input to chassis: HV Output to chassis: 2500 VDC* 2500 VDC* 2500 VDC* * Power transformers and safety insulation is designed to meet 4242 VDC (3000 VAC) between AC input and HV output. 5. ENVIRONMENTAL SPECIFICATIONS PARAMETER Altitude Operating Temperature DESCRIPTION / CONDITION MIN SAE J1455, Non-Operating:18.6 kPa absolute pressure Operating: T_coolant @ full load T_coolant @50% power derating T_ambient @ full load Storage Temperature Humidity SAE J1455 Thermal Shock SAE J1455, Tamb = -40°C to +85°C (no coolant cycling) Vibration SAE J1455 Protection IP67 and IP6K9K , when all matting connectors are installed NOM MAX UNIT m m -40 +60 -40 12200 4000 +60 +75 +80 -40 +85 °C 95 % °C 6. COOLING SPECIFICATIONS PARAMETER DESCRIPTION / CONDITION Cooling Type Liquid cooling Maximum Inlet Coolant Temperature Maximum Ambient Temperature +75°C (50% derating above +60°C) +80°C Coolant Medium / Mixture 50/50 Ethylene Glycol l/ Distilled Water Coolant Flow min. 10 LPM @ coolant temperature +20°C Max. Coolant Pressure 29 psi (2 bar) Max. Pressure Drop 0.8 psi (0.05 bar) @ coolant temperature +20°C, @10LPM Inlet/Outlet Coolant Connection M18x1.5 DIN 9974-1 Material of Fittings Aluminum alloy 7. CONNECTORS PARAMETER AC Side Connector HV Power Connector Signal Connector DESCRIPTION / CONDITION Inverter Charger side Mating connector Inverter Charger side Mating connector Inverter Charger side Mating connector MANUFACTURER TE CONNECTIVITY AMPHENOL TE CONECTIVITY MPN PN: HVA630-5P : 0-2141619-1 PN: HVA630-5P :114-94114-1 PN: HVSLS600022A1H6 PN: HVSLS600062A116 PN: DRC23-40PAN012 PN: DRC26-40SA tech.support@psbel.com belfuse.com/power-solutions BCL25-700-8 5 8. AC SIDE POWER CONNECTOR Charger side: MFG: TE CONNECTIVITY; PN: HVA630-5P : 0-2141619-1 Mating connector: MFG: TE CONNECTIVITY; PN: HVA630-5P :114-94114-1 Use copper conductors only with an insulation rating of 120 °C, 6 mm2, OD 16.3 mm. Follow connector MFG instructions for correct connector assembly. We highly propose to use screened connecting cables (e.g. Coroplast, FHLR2GCB2G 5x6.0mm2 T180). AC input connector, Charger side Note: HVIL pins shall be shorted on mating part. Pin number Description 3 phases connect 1 phase connect EU 1 phase connect US 1. PE PE PE PE 2. Phase L3 Phase L3 3. Phase L2 Phase L2 4. Phase L1 Phase L1 5. Neutral Phase L2 (120V) AC input connector, Cable side Phase L1 (230V) Phase L1 (120V) Neutral Neutral 9. DC SIDE POWER CONNECTOR Charger side: MFG: Amphenol; PN: HVSLS600022A1H6 Mating connector: MFG: Amphenol; PN: HVSLS600062A116 Use copper conductors only with an insulation rating of 120 °C, 16 mm2, OD 11.0 mm. Follow connector MFG instructions for correct connector assembly. Note: HVIL pins shall be shorted on mating part. Pin number Description 1. HV DC negative 2. HV DC positive DC output connector, Charger side DC output connector, Cable side Asia-Pacific Europe, Middle East North America +86 755 298 85888 +353 61 225 977 +1 408 785 5200 © 2020 Bel Power Solutions & Protection BCD.20004_1 BCL25-700-8 6 10. SIGNAL CONNECTOR SIGNAL Charger side: MFG: TE Connectivity; PN: DRC23-40PAN012 Mating connector: MFG: TE Connectivity; PN: DRC26-40SA , max. 2 Amps per pin (wire AWG 20) Pin PN: 1062-20-0144 We propose to use screened connecting cables. Signal connector, Charger side Signal connector, Cable side Pin 1 2 3 Name PROXIMITY SGND EVSE_WAKE_OUT 4 5 6 7 8 9 HVIL_IN HVIL_OUT +VBAT LOCK_LOOP_A LOCK_LOOP_B LOCK_ACTUATOR_A 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 LOCK_ACTUATOR_B CONTROL PILOT SGND KEY_SWITCH TEMP_EXT+ TEMP_EXT+VBAT SYNC_I/O SGND CAN_SPEED SGND SGND SGND SGND BUTTON_A BUTTON_B -VBAT ADDR_0 28 29 30 31 32 33 34 35 36 37 SGND CAN_H_INT CAN_L_INT LED_A LED_B LED_C BUTTON_LED_A BUTTON_LED_B -VBAT ADDR_1 38 39 40 SGND CAN_H_EXT CAN_L_EXT Function Function and levels according SAE J1772 Internally connected with pin 12 Wake Output goes high when Control Pilot is active (max delay 100ms) and goes low when CAN command from VCU is received or when goes into sleep mode or delayed sleep mode. Input pin for HVIL loop. (To detect if connectors are properly inserted.) Output pin for HVIL loop Internally connected with pin 16, connect both pin Plug motor interlock signal Plug motor lock A Plug motor lock B Function and levels according SAE J1772 Internally connected with pin 2 This is signal for CAN communication enable (Level HIGH=enable) External temperature sensor + External temperature sensor Internally connected with pin 6, connect both pin Signal for synchronization of the units working in parallel Setting of the CAN baud rate (float 500kB) Internally connected with pin 22 and 23 Internally connected with pin 21 and 23 Internally connected with pin 21 and 22 Internally connected with pin 36, connect both pin Inputs to set addresses of 4 parallel units. Internally pulled-up for logic level H. Connection to 12/24V_RTN = logic level L. Internally connected with pin 38 Diagnostic line Diagnostic line Internally connected with pin 26, connect both pin Inputs to set addresses of 4 parallel units. Internally pulled-up for logic level H. Connection to 12/24V_RTN = logic level L. Internally connected with pin 28 CAN communication CAN communication Reference pin PE Pin 2 Pin 5 Pin 4 Pin 26,Pin 36 Pin 8 Pin 10 Pin 9 PE Pin 6 Pin 15 Pin 14 Pin 26, Pin 36 Pin 18 Pin 20 Pin 23 Pin 23 Pin 28 Pin 21 Pin 22 Pin 23 Pin 23 Pin 23 Pin 38 Pin 40 Pin 39 tech.support@psbel.com belfuse.com/power-solutions BCL25-700-8 7 11. MECHANICAL SPECIFICATIONS PARAMETER CONDITIONS / DESCRIPTION Dimensions (W x H x D) 705 x 106 x 359 mm 27.75 x 4.17 x 14.13 inch Weight 19 Kg Enclosure Material Aluminum alloy Figure 2. Mechanical Dimensions – Front View Figure 3. Mechanical Dimensions – Top View Asia-Pacific Europe, Middle East North America +86 755 298 85888 +353 61 225 977 +1 408 785 5200 © 2020 Bel Power Solutions & Protection BCD.20004_1 BCL25-700-8 8 12. ACCESSORIES ACCESSORIES DESCRIPTION BCL25-700-CON-KIT Connector Kit (AC connector with the 6m cable, HV DC connector, Signal Connector) 13. POWER WIRING DIAGRAM For more information on these products consult: tech.support@psbel.com For communication manual (BCA.00290) consult: tech.support@psbel.com NUCLEAR AND MEDICAL APPLICATIONS - Products are not designed or intended for use as critical components in life support systems, equipment used in hazardous environments, or nuclear control systems. TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the date manufactured. Specifications are subject to change without notice. tech.support@psbel.com belfuse.com/power-solutions