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A BRUSA NLG5xx
series battery charger as well as upcoming high power NLG644 charger is universal
multi-chemistry charging device converting mains AC power into DC power suitable for
charging any type of traction battery. Designed to be installed either onboard of battery
electric or plug-in hybrid electric vehicles, or to build stationary J1772 compliant
charging stations. So far there is no battery in existence the BRUSA chargers cannot
handle - their unmatched flexibility, efficiency, safety, compliance with automotive
standards and open software allowing users to define charging algorithm make NLG5xx the
charger of choice not only for OEMs but also any serious end users. This is because
despite high initial cost users gain by prolonging life of far more costly modern EV
batteries. There are several NLG5 series base models - two standard and two custom models distinguished by different output voltage ranges as shown below in the selection matrix. Each model comes with three cooling options - vertical air blow (top cooled), horizontal air blow (side cooled) and water cooled. Also lower cost NLG503-lite charger is available, which is half of the output power of the standard NLG5xx but otherwise is identical in its functionality. Two main target application for NLG503-lite include plug-in hybrid electric vehiclesand any vehicle meant to be charged from mains limited to 120VAC which prevents taking full advantage of standard NLG5xx power capabilities. Since 120VAC mains protected with 20A circuit breaker have maximum power limitation of 2.4kW that can be possibly drawn before circuit breaker trips, NLG503-lite makes more sense for such use. The upcoming 22kW NLG644 will be prodused in EU and USA versions. It meant to be installed on-board of an EV and will be expecially useful for large capacity batteries in trucks, buses, delivery, fleets and similar vehicles, providing level 1 or rapid level 2 charge. Granted, NLG644 can be the heart of a fully compliant J1772 charging station. Max output power depends on the mains feed and output (battery) voltage. Initially EU version will be relased followed by US version. Preliminary data sheet can be downloaded here. All featured models are based on resonant switching topology, power factor corrected and fully isolated, meaning there is no galvanic connection between AC mains, traction battery and charger enclosure. Rated AC input voltage for NLG5xx is 220VAC single phase, while acceptable AC input voltage range is 90 VAC...240 VAC single phase. Please refer to the AC mains connection User's manual amendment for proper configuration on the input side. For NLG644 there is also 3 phase 344...440VAC input available. The NLG5xx charger is guaranteed to deliver full power into a battery with specified minimum voltage with AC input at least 170VAC. At lower input voltages (120VAC...170VAC the charger still maintains full functionality, however output power is proportionally reduced. For the end user this means that with occasional 120VAC input form opportunity or emergency charging, the process will take longer, but the charger will work just fine. The rate of the power reduction with lower than rated AC mains input is described on the page 16 of the NLG5 User's Manual. The absolute minimum mains input voltage required for proper operation of NLG5xx is about 90VAC. Because as with any charger the output current is limited at some point, the max output power depends on the output voltage and is guaranteed within specified output voltage range. However, the charger will supply max output current (for given AC mains voltage) and will successfully charge a lower voltage battery than specified output range. Even the NLG514-xx, the highest output voltage model (360...720VDC nominal output) in theory can charge a single 12V battery, rather working as constant current power supply. However because of 1% accuracy of the full scale, such use is not encouraged and the hardware may refuse to regulate such low output voltages. 3 offered options for NLG5xx are shown here - top air cooled ( photo 1, photo 2 ), side air cooled (photo 1, photo 2) and water cooled (photo 1, photo 2). The overview of NLG644 is shown here. All base NLG51x models have guaranteed 3.3 kW nominal charging power and overall cover output voltage range from 130 VDC to 720 VDC (broken into 4 output voltage ranges, see selector guide). The NLG503-lite has 1.6kW output power at nominal 220VAC input. Only one output voltage range 200...520 VDC is available for NLG503-lite; other parameters are the same as for NLG51x-xx series. The NLG51x-xx chargers are stackable, i.e. one or more booster modules can be connected to the base model, respectively increasing total output current and so the output power. Same result can be achieved paralleling charger's inputs and outputs, this is allowed. The total output capability in this case is only limited by the capacity of the AC mains supply. There are three modes of charger operation - autonomous, booster and driven via CAN interface. In autonomous programmable mode the charger operates without external intervention and completes charging on its own. User definable charging profile is stored in the charger's memory and can easily be modified. Charging profiles are stored as files in a host PC and can be downloaded to or uploaded from the charger via RS232 serial interface. The library of charging profiles for the most common battery chemistries, as well as host PC software, comes on included CD-ROM, and free updates are available from MMC and BRUSA web site as newer batteries are appearing on the market. The mode of operation (autonomous, CAN or booster) as well as any changes in charging profile can be easily set by user via ChargeStar software available from library page. Physical charger is the same and suffix -SA, -SB or -SC in the model only denotes how the charger comes preconfigured from the factory. User can change -SA mode to -SC mode and back with a few clicks of a mouse. Chargers provide temperature compensation based on input from up to three temp sensors, optionally expandable to 48 sensors. There are means to track amp-hours for precise delivery of predetermined amount of Amp-hours. LED status display allows monitoring charger activity. Also there are digital inputs meant to interface with external hardware allowing advancing to the next charging stage in the chargign profile based on the status of these inputs, as well as digital outputs capable of driving external circuits (relays, optocouplers, etc). There are means to limit input power to prevent tripping of the circuit breakers and other innovative features - see User's manual. For NLG5xx a selection of high quality accessory cables is offered, and the set of desired cables is normally specified at the time of placing order. Standard set consists of one mains cable with charger side plug and loose ends, one output battery cable with charger side plug, and 23 pin control interface mating connector. Additional cables can be purchased separately. Each charger also comes with unpopulated mating connector with crimp terminals, DB9 PC interface connector and set of 4 NTC thermistors. Please review Safety bracket attachment User's manual amendment if you plan to install the charger. Chargers are manufactured by one of the best and the most reputable EV components company - BRUSA, in Switzerland. 2 years warranty. The chargers are CE certified and fully qualify and ready for UL approval if an OEM customer requests it, subject to BRUSA's decision and approval, Please contact MMC for this matter. Reliability and capability to handle any voltage and any battery chemistry as well as extreme flexibility and configurability sets these chargers apart from competition. They are very safe investment: flash upgradable, ready for practically any existing today or future battery - BRUSA NLG5 or NLG6 series charger will likely be the last charger you will ever need. Information for Solectria Force EV owners: BRUSA has developed special adapter for NLG511-SA or -TA charger, allowing directly replacment of old NLG4 charger in these vehicles. The cable with round connector from Solectria's interface box currently plugged into NLG4 has to be unplugged, connector cut off (notice pin numbers!), adapter PCB inserted inline and wired according to the schematic, and round connector replaced with 23 pin Ampseal connector that plugs into new NLG511 (this connector comes with new charger). Adapter consists of a small PCB with circuitry inverting some signals and shifting voltage levels making NLG5 electrically look like NLG4 for the rest of the vehicle. The PCB can reside either outside or inside the interface box. More than 10 years old NLG4 design is outdated and no longer produced nor supported by BRUSA or MMC. Thefefore adapter cable also has been discontinued, however it is easy to make it - welcome to download page 1 and page 2 of schemtic and description of the interface. |
