Bel Power Unveils 60 amp, 800 VDC Liquid-Cooled Inverter/Battery Charger for EVs and Hybrids

The BCL25-700-8 is a 22/25 kW onboard inverter/battery charger. In charge mode, it is parallelable up to 4 units, offering efficiency levels as high as 94%.

 

The BCL25-700-8 Battery Charger. Image courtesy of Bel Power Solutions

 

The BCL25-700-8 can receive charging power directly from an EVSE (electric vehicle supply equipment) charging station. It can also utilize public grid power, three-phase at 330 to 528 V_AC or single-phase at 190 to 264 V_AC. Output power is 60 amps, at voltages ranging from 240 to 800 V_DC.

Alternatively, the unit can be employed in the other direction, to export stored power from a high voltage (HV) battery. Possible outputs are 22 kW at 400 Vac/50Hz or 25 kW at 480 Vac/60Hz.

 

Liquid Cooling

The unit can deliver 800 volts at 60 amps to an HV battery. Even at 94% efficiency, there is a lot of heat generated. Thus, liquid cooling, through an external liquid-cooled heat exchanger, is essential. 

The coolant itself is a 50/50 mixture of ethylene glycol and distilled water. The maximum inlet coolant temperature is +75℃, at which time the converter will shut down. The device will operate with 50% derating at temperatures above +60℃. The maximum ambient temperature is +80℃. At +20℃, coolant flow must be at least 10 liters per minute.

 

Protections

AC Over-Voltage Protections

• 3 phase @ 528 V_RMS: minimum and maximum are 528 and 535 V_AC, respectively
• 1 phase @ 264 V_RMS: minimum and maximum are 264 and 275 V_AC, respectively

 

AC Under-Voltage Protections

• 3 phase @ 330 V_RMS: minimum and maximum are 320 and 330 V_AC, respectively
• 1 phase @ 190 V_RMS: minimum and maximum are 180 and 190 V_AC, respectively

 

Connectors

AC Side Power Connector

• Inverter Charger side: TE CONNECTIVITY PN: HVA630-5P: 0-2141619-1
• Mating connector: TE CONNECTIVITY PN: HVA630-5P: 114-94114-1

 

AC side power connectors. Image courtesy of datasheet

 

DC Side HV Power Connector

• Inverter Charger side: AMPHENOL PN: HVSLS600022A1H6
• Mating connector: AMPHENOL PN: HVSLS600062A125

 

DC side power connector.  Image courtesy of datasheet

 

Signal Connector

• Inverter Charger side: TE CONNECTIVITY PN: DRC23-40PAN012
• Mating connector:  TE CONNECTIVITY PN: DRC26-40S

 

Standards Adhered To

Electric mobility is an embryonic industry. As such, the standards are adrift in a sea of shifting sands, which is why they deserve the designers' most careful attention. The complete list of standards can be found on the datasheet. Representative standards include:

• IEC 61851-21-1 EMC requirements
• e-Mark certification (ECE R10.6) for EU approval
• SAE J1455 compliant for environmental consideration
• IP67 and IP6K9K protection standards
• SAE J1939 for the CAN bus control and monitoring
• IEC 62196 for ESVE Type 1 and Type 2 connection
• IEC 61851-1 Mode 2 and Mode 3 for EVSE communications

 

Physical Considerations

• The device can operate over a -40 to +60℃ temperature range at full load
• Dimensions are 705 x 106 x 359 mm
• Weight is 19 kg