Brusa NLG5
Connecting a Brusa NLG5 charger

You MUST provide a way for the BMS to shut down the charger, DIRECTLY!

Just because you have a BMS on board, don't think that your pack is protected.
Until you allow the BMS to shut down the charger, your pack IS NOT PROTECTED!

You MUST make sure that:

  • When the BMS says "stop charging" the chargers does stop charging
  • When the BMS says "restart charging" the chargers does restart charging.
  • The BMS is powered whenever the vehicle is plugged in the wall (whether or not the charger is on at the time)

DO NOT SKIP THIS, or YOU WILL KILL YOUR BATTERY!

The BMS must be powered whenever the vehicle is plugged in the wall to protect the pack during charging, and to perform balancing even if the charger is off at the moment.

If there is any current in or out of the pack, yet the BMS is off, your pack IS NOT PROTECTED!

Near the end of charge, the BMS will turn the charger on and off, continuously, for a while.
You MUST allow the BMS to do that; otherwise, the BMS will not be able to balance the pack.

Just follow the instruction below, exactly, and you'll be fine.

You MUST use a fuse ("Charger fuse"), between the pack and the Lithiumate Lite master's "Charger current sensor" input, as close as possible to the battery.

The fuse must rated for DC operation, rated for the full pack voltage, and rated for the charger current (30 A maximum, else you may blow up the Lithiumate Lite's charger sensor input).

This charger allows both control options: AC power and DC control.

With this option, the BMS master controls the Brusa NLG5 charger through a contactor to switch the charger's AC power on and off.

Schematic diagram
AC power switching
NOTE: pin-out of 4-wire AC connector is for rev C Master. For rev F Master use pins 3 and 4 instead.

A note about AC relays

You need a relay (or contactor) whose contacts are rated for BOTH the line voltage (i.e.: 125 Vac or 250 Vac), and for the current (i.e.: 15 A, or whatever the maximum input current of the charger is).
Just because a relay is rated for 30 A, it does not mean that it can switch the AC power.
AN AUTOMOTIVE, "CUBE" RELAY WILL NOT WORK!

With this option, the BMS master controls the Brusa NLG5 charger through an input that disables or enables the charger.

No isolation relay is required.

Schematic diagram
Control input
NOTE: pin-out of 4-wire AC connector is for rev C Master. For rev F Master use pins 3 and 4 instead.

 

DISCLAIMER
By reading this page you acknowledge that you understand that this application note is just a suggestion, and that you will not hold Elithion responsible for its accuracy or appropriateness in you application, and that Elithion is not responsible for the fact that other manufacturers change their products in a way that may make these suggestions no longer applicable.
 
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Page published on: Jul 19 2013.      Installation manual