Installation Guide

EV Power Chargers 3kW HE

Traction Battery Charger Modules ~ IP67

Electric Vehicle Power Chargers Range
.

350015.033
 1 Installation EV Power Chargers 3kW HE, IP67

Information in this document is subject to change without notice and does not represent a commitment
on the part of Eltek Valere.

No part of this document may be reproduced or transmitted in any form or by any means — electronic
or mechanical, including photocopying and recording — for any purpose without the explicit written
permission of Eltek Valere.

Copyright ©: Eltek Valere, 2010

NS-EN ISO 14001 Certified NS-EN ISO 9001 Certified

Certificate No: Certificate No:

11276-2007-AE-NOR-NA 4072-2007-AQ-NOR-NA

Safety Precautions

 The equipment represents an energy hazard and failure to observe this could
cause terminal injury and invalidate our warranty
 There are hazardous voltages inside the power charger. As they incorporate
large charged capacitors, it is dangerous to open the modules even if the mains
supply is disconnected.
 Products into which our components are incorporated have to comply with a
number of requirements. Installation is to be in accordance with the
recommendations herein
 Please read the manual carefully before using the equipment

This booklet describes following modules:

Part no. Description

241121.110 EV Power Charger 110/3000 HE IP67 G2
241121.120 EV Power Charger 220/3000 HE IP67 G2
241121.130 EV Power Charger 360/3000 HE IP67 G2

350015.033 Issue 1.1, 2010 Nov

Published 2010-11-04

Mafe

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 1 Installation EV Power Chargers 3kW HE, IP67

Table of Contents

1. Installation EV Power Chargers 3kW HE, IP67 4

Safety Precautions .......................................................................................................... 4
Mechanical Installation ....................................................................................................... 4
1. Prepare the Cold-Plate ............................................................................................... 5
2. Position and Fasten the Battery Charger .................................................................... 6
Electrical Installation .......................................................................................................... 7
CAN Bus Communication .................................................................................................. 8
Firmware Upgrade of the Battery Charger ................................................................................8

2. Technical Specifications 9
Specifications EV Power Chargers 3kW HE, IP67.......................................................... 9
Ordering Information ....................................................................................................... 9
Reference Documents .................................................................................................. 10

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 1 Installation EV Power Chargers 3kW HE, IP67

1. Installation EV Power Chargers 3kW HE, IP67

Safety Precautions
Get acquainted with the satety precautions on page 2, before installing or handling the
equipment.

! CAUTION: The battery chargers may be warm, but do not hand-carry them by the Terminal wires.
Device
Hazard

CAUTION: Double Pole / Neutral Fusing. There is a Mains fuse in each line.

Mechanical Installation
The EV Power Chargers 3kW HE, IP67 are designed in a very compact box measuring
61x356x167 mm, and can be mounted in installation sites requiring IP67 rating.
The charger’s mechanical design implements
Charger’s top
EV Power Charger, 3kW HE IP67 thermal coupling, by mounting all internal major
heat generating components against a solid
aluminum outer wall.
The EV Power Chargers 3kW HE, IP67 must be
fastened with this solid aluminum outer wall
Fastening holes against a cold-plate, which is either water cooled or
has sufficient heat transfer capacity to comply with
Aluminum outer wall, bottom
(thermal coupling) the environmental specification of the installation
site.
Figure 1 Aluminum outer wall, bottom, in EV Power Chargers 3kW HE, IP67

WARNING: The cold-plate must have a heat transfer capacity of minimum 220W, keeping the charger at a lower
temperature than 60ºC (output power derating level).

Fastenings holes
Diam. 63 mm (8x)

DC Output
Terminal Wires

CAN Bus
wires Charger’s top
AC Input
Terminal Wires

Figure 2 Mounting screws and dimensions for the EV Power Chargers 3kW HE, IP67

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 1 Installation EV Power Chargers 3kW HE, IP67

1. Prepare the Cold-Plate

The EV Power Chargers 3kW HE, IP67 must be mounted on a cold-plate, which is either
water cooled or has sufficient heat transfer capacity to comply with the environmental
specification of the installation site.
Prepare the cold-plate for mounting the charger, as follows:

1 Thermal Interface Material

M5 threaded hole
depth 8 mm Cold-plate
x8

Figure 3 Cold-plate preparations:

drilling holes, cutting threads and applying thermal interface material

Cold-Plate Preparation Procedure — Steps Action OK

1. Clean the surface and apply a • Thoroughly clean the cold-plate’s holes and the
thermal interface material surface using rubbing alcohol (isopropyl alcohol)
or pure acetone
• Apply a thin Thermal Interface Material (TIM) to
the surface
Warnings:
— The TIM should be a thermally conductive foil, for
instance HALA TFO-X300-SI or similar, with 3 W/mK
heat conductivity or better

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 1 Installation EV Power Chargers 3kW HE, IP67

2. Position and Fasten the Battery Charger

After preparing the cold-plate and the EV Power Charger 3kW HE, IP67 for installation,
fasten the charger to the cold-plate with the 8 screws(D), as follows:

x8 3
D (x8)

cw
Fastenings screws
M5 (x8)
Torque: 4 Nm

Hole diam. 6.30 (x8) EV Power Charger

(through-holes) 3kW HE IP67

Charger’s top

M5 threaded hole
depth 8 mm
2
(x 8)

Cold-plate

Thermal Interface
Material

Figure 4 Fastening the EV Power Chargers 3kW HE, IP67 to the cold-plate

Charger Fastening Procedure — Steps Action Power is OFF! OK

1. Clean the charger’s • Thoroughly clean the charger’s surface

surface underneath underneath (aluminum outer wall) using rubbing
alcohol (isopropyl alcohol) or pure acetone
2. Position the charger on • Carefully position the charger’s bottom
the cold-plate (aluminum outer wall) against the cold-plate, so
that the 8 screws (D) meet with the threaded
holes on the cold-plate
3. Fasten the screws (D) • Using the screwdriver, fasten the 8 M5 screws in
the cold-plate’s threaded holes (torque 4 Nm)

NOTICE: The car manufacturer must carefully consider the need for additional spring washers or glue to secure the
screws, in order to maintain a good contact between charger and cold plate/heat sink over time. Although long term vibration
tests, performed on complete drive train inside a vehicle, have indicated that there should be no need for this, this may depend
on the actual application.

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 1 Installation EV Power Chargers 3kW HE, IP67

Electrical Installation
All connections to the EV Power Charger 3kW HE IP67 are implemented by connecting
the AC input and DC output wires to the car’s respective sockets. Also, connecting the
CAN bus terminal wires to the car’s controller.
NOTICE:
The car manufacturer must select suitable connectors, and assemble them at the end of the AC, DC and CAN bus terminal
wires. The AC wires have no wire braid or screen (unshielded wires).

Connect the charger to the car, as follows:

CAN Bus output

Terminal Wires
DC Load CAN-H (white)
CAN-L (green)
CAN-Ref (brown)

1 EV Power Charger
3kW HE IP67
DC Output
Terminal Wires
+ (brown or red) Cold-plate
– (blue or black)

CAN cable

3
To the car’s controller
Thermal Interface
Material

AC Input
Terminal Wires
L (brown)
N (blue)
PE (yellow/green)

2
AC Mains External AC Fuses
Recommended Rating
(OFF)
16A-C (Europe)
20A-C (USA)

Figure 5 Connecting the EV Power Charger 3kW HE, IP67

Charger Connection Procedure — Steps Action Power is OFF! OK

1. Mount suitable • Mount 3 suitable connectors to the end of the

connectors to the terminal respective terminal wires for DC Output, AC Input
wires and CAN bus output
2. Connect the DC Output • Plug the mounted DC Output connector into the
terminal wires car’s correct “load” socket.
(the “load” is the car’s onboard DC high-voltage
battery bank)
3. Connect the AC Input • Plug the mounted AC Input connector into the
terminal wires car’s correct “AC” socket
(the “AC” socket will normally get current from a
standard single phase AC outlet, 16A wall
socket, external to the car)
4. Connect the CAN Bus • Plug the mounted CAN bus connector to the
terminal wires to the car’s car’s controller CAN bus socket
controller

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 1 Installation EV Power Chargers 3kW HE, IP67

CAN Bus Communication

The EV Power Chargers 3kW HE IP67 utilize the CAN 1 bus  a digital interface
architecture that supports a dedicated communication channel between the car’s
controller, the battery charger and other CAN devices or nodes connected to the bus.
The EV Power Chargers 3kW HE IP67 support CAN 2.0A/2.0B at the speed of 125, 250
and 500kbits/s, and implements CAN Bus signals: “CAN-L”, “CAN-H” and “CAN-Ref”.

The EV Power Chargers 3kW HE IP67 are by default designed to be OFF, when connected
to AC mains. To turn the chargers ON, they have to receive via the CAN bus a message
containing voltage, current limit and power limit settings.
For prototype testing, Eltek Valere can provide a dedicated computer program for
integration with the car electronics and the battery management system. Please, refer to
the description of Eltek Valere’s CAN bus communication protocol, see chapter “Reference
Documents” on page 10.

Firmware Upgrade of the Battery Charger

Please, contact your Eltek Valere Local Office if you need to upgrade the chargers’
firmware, or if you need support with software integration.

1
Control Area Network. Serial protocol utilised for communication between CAN devices

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 2 Technical Specifications

2. Technical Specifications
Specifications EV Power Chargers 3kW HE, IP67
AC Input Other Specifications
Voltage 85-275 VAC (Nominal 230VAC) Efficiency 96% at 50% load, 95% at 100% load
Frequency 45-65 Hz Isolation o 1.5 KVAC – input to earth
o 1.5 KVAC – output to earth
Current 14 Arms maximum
o 3.0 KVAC – input to output
Power Factor >0,99 at 50% load or more Alarms/error o Internal communication failure
messages: o Control system communication
Input Protection o Varistors for transient protection timeout
o Mains fuse in both lines o High mains shutdown
o Low mains shutdown
o High temperature shutdown
o Low temperature shutdown
o Charger failure
DC Output o DC voltage high (overvoltage
shutdown)
Voltage See table below
o DC voltage low
for adjustable voltage range **
Current See table below Warnings: o Rectifier in power derate mode
Measurements: Available on CAN bus:
o AC voltage, current and frequency
Charge control: Controlled over CAN bus
o DC voltage and current
o Enable/Disable (On/Off)
o Rectifier temperature (two
o Constant voltage
measurements)
o Current limit
o Power limit Operating temp -40 to 60°C
o Available power (mains dependent) Storage temp -40 to +85°C (-40 to +185°F)
Dynamic ±5% for 10-90% or 90-10% load variation, Cooling Cold plate
voltage regulation time < 100ms
regulation Reliability o MTBF > 162 000 hours, with 60°C
cold plate temperature
Ripple and Noise < 250 mVrms
Humidity o Operating: 5% to 95% RH non-
condensing
Output o Output fuse o Storage: 0% to 99% RH non-
Protection o Overvoltage shutdown condensing
o Short circuit proof
Dimensions o 60x355x167mm (IP67)
o High temperature protection
o Under-voltage shutdown:
50V for *.010 & *.110 chargers, 110VDC Weight o 4.3 kg (IP67)
100V for *.020 & *.120 chargers, 220VDC
170V for *.030 & *.130 chargers, 360VDC

Applicable Standards
Electrical safety IEC 61851-1
UL 2202
Compliant to IEC/UL 60950
EMC EN 61000-6-1 (immunity, light industry)
EN 61000-6-2 (immunity, industry)
EN 61000-6-3 (emission, light industry)
EN 61000-6-4 (emission, industry)
Mains Harmonics EN 61000-3-2
Environment
WDS 00.00EA-D11
Specifications are subject to change without notice 241121.nnn.DS3 – v3(b)

Ordering Information
Part no. Description Output Power Output Voltage Range Output Current
241121.110 EV Power Charger 110/3000 HE IP67 G2 3000W 70 – 122Vdc 25A
241121.120 EV Power Charger 220/3000 HE IP67 G2 3000W 150 – 250Vdc 16A
241121.130 EV Power Charger 360/3000 HE IP67 G2 3000W 250 – 420Vdc 10A
** Please, refer to technical specifications for further details

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 2 Technical Specifications

Reference Documents

Doc no. Description

2090185 Technical specification EV PC 360/3000 HE IP67
2090187 Technical specification EV PC 220/3000 HE IP67
2090189 Technical specification EV PC 110/3000 HE IP67
2086930 EV Power Charger CAN protocol description

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Installation Guide EV Power Chargers 3kW HE, IP67 350015.033, 1v1-2010-11 11

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Headquarters:
Eltek Valere
Gråterudv. 8, Pb 2340 Strømsø, 3003 Drammen, Norway
Phone: +47 32 20 32 00 Fax: +47 32 20 32 10