MILITARY POWER DISTRIBUTION UNIT- PDU70 - NERO Industry

MILITARY POWER DISTRIBUTION UNIT- PDU70

MILITARY POWER DISTRIBUTION UNIT- PDU70

PRODUCT NERO CODE: LWS-2

The PDU-70 is a power distribution unit developed by NERO Industries engineers in the scope of electrical vehicle application. The PDU-70 is a safe, intelligent and versatile power distribution unit in a compact form with configurable multiple power inputs and outputs. The smart control unit provides easy integration for high voltage/high current system applications. As typical application fields; the PDU-70 is suitable for medium and heavy duty electric/hybrid vehicle power distribution and energy control. Some important features are as follows:
– High voltage power inputs for standard charging
– Isolated voltage reading at the high voltage inputs and outputs (up to 1000 VDC)
– High voltage safety interlock line (HVIL)
– Interlock line controlled high voltage battery relay control outputs
– Earth insulation level measurement
– Secondary passive high voltage DC bus energy sinking
– Active high voltage DC bus energy sinking (Through PTC Thermistors)
– Pre-charge circuit at all high-voltage power outputs
– Fuse protection at high voltage outputs
– Overvoltage, undervoltage, overcurrent and over-temperature protection
– Low power mode

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Product Description & Technical Document
22-04-2022

DS-201220211725421-001-EN TECHNICAL DOCUMENT

CAN COMMUNICATION

Military Power Distribution Unit (PDU-70) uses SAE J-1939 standart CAN protocol in order to communicate with the electrical control unit (ECU). 250kbit/s bit rate is chosen in order to provide reliable operation.

The cyclic status messages are transmitted by the Military Power Distribution Unit (PDU-70) in every 100 ms and the cyclic command message is expected from the ECU in every 100 ms. If the command message is not received by the Military Power Distribution Unit (PDU-70) for 400 ms, the emergency output is asserted (logic high) in order to indicate fault but the operational state of the Military Power Distribution Unit (PDU-70) stays the same in order to give the ECU to control the whole system. For the sake of the operation, the Military Power Distribution Unit (PDU-70) should be taken into low power mode as soon as possible. The details of the CAN messages can be found in log file.

RS422 COMMUNICATION

Military Power Distribution Unit (PDU-70) uses RS422 communication in order to send status messages to the diagnostic/ record device in the system. The Military Power Distribution Unit (PDU-70) does not receive any message through RS422, hence no operational change can be performed. By using RS422 communication, a secondary check to CAN communication can be provided.

TRACTION VOLTAGE POWER DISTRIBUTION UNIT FOR ELECTRIC VEHICLES TRACTION AND AUXLIARY HIGH VOLTAGE SYSTEMS INCLUDING:

– Active unit include traction voltage contactors and contactor controls with Voltage and current measurement units.
– Pre-charging circuit to balance voltage levels before and after contactors
– Service charging circuit with contactor switching
– High voltage circuit insulation resistance measurement & monitoring
– Fuse protection for high and low current component output
– Hazardous voltage interlock loop (HVIL)

Military PDUs often differ from commercial PDUs in some obvious and not so obvious ways. Obvious, is that certain battlefield applications do indeed require extraordinary tolerance of shock, vibration, and weather extremes. Not so obvious, is the need to condition incoming raw power to deliver clean, stable power to mission critical electronics. There are a lot of unique control and connectivity needs in military applications as well.

NERO has been meeting the needs for military PDUs in ships, submarines, planes, forward command bases, hardware service bays, and even as support for research and product development for over 30 years.

What to look for in a military PDU

  • Protects downstream equipment from noisy facility power using EMI filters, surge suppressors, and other techniques.
  • Saves space by integrating conditioning and conversion needs instead of housing them as external boxes.
  • Improves integration by providing the exact connectivity and controls needed for site-specific equipment.
  • Complies with general and military-specific standards for electrical power handling equipment.
  • Meets harsh environmental needs.

What to look for in a PDU supplier

  • Takes the time to understand the application, explore needs, and consider design options.
  • Optimizes the selection of application-specific components for capacity matching, packaging efficiency, and cost.
  • Designs and manufactures enclosures to meet unique needs for installation, cable routing, and other integration details.
  • Manages the entire process of standards testing and certification, when required, prior to delivery.
  • Understands military platforms and applications, and can apply specific military standards to PDU design.

Programs, Platforms, and Applications

  • Aircraft, naval surface vessels, submarines, UAV, ground vehicles, and others.
  • Development test roles, simulation, support facilities, and forward operating bases powering mobile data processing to multi-rack test and service bays.
  • CSRR, AMDR, VPM, BACN, WIN-T, and other programs.
  • Supporting communications, weapons, intelligence, and research systems.

Compliance and Standards

  • Certified AS9100 with ISO 9001.
  • TAA, ITAR, and NIST compliant.
  • General MIL-STDs 461, 810, 901, 167, and others.
  • Platform-specific MIL-STDs 1399, 704, and 1275.
  • Environment and reliability testing/certification when required.
  • UL and CE certification (others when required).

Custom, COTS, COTS-Modified

  • NERO specializes in application-specific PDUs.
    • Rackmount chassis from 0U to 24U, to rack sized.
    • Custom enclosures for non-rack applications.
    • Ac, dc, 400 Hz — up to 600 volts, 400 amps.
  • We have nearly 300 standard basic and smart PDUs.
    • 1-phase, 3-phase, 15-, 20-, and 30-amp models.
    • 1U, 2U, 3U, and vertical 0U configurations.

Conversion, Conditioning, and Control

  • Meet EMI standards using filters and shielded enclosures.
  • Mitigate voltage spikes/transients using surge suppression.
  • Integration of ac and dc sources.
  • Conversions for ac-ac, ac-dc, dc-dc, and dc-ac.
  • Local and remote power monitoring and switching.
  • Individually breakered branches.
  • EPO and interlock integration and remote panels.

Networked and Non-networked

  • Non-networked PDUs still offer some remote switching through discrete signals from remote panels.
  • Networked PDUs offer remote control and monitoring over Ethernet using HTTP/S, SSH, Telnet, and SNMP.
  • Remote switching of outlets.
  • Remote monitoring of inlet current, voltage, and power.
  • Event alerts for startup, user login, outlet state change, EPO, current and voltage setpoint excursion, and configuration changes (via SNMP, email, SMS).
  • Scripted automation through Telnet, SSH, SNMP, or RESTful API over HTTP/S.
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Technical Data Table
Power Consumption

24 VDC nominal (16-32 V)

Capability

Controls up to 16 smoke grenades

Communication Interface

CANBus

Dimensions

180x155x116 ±5 mm

Weight

1.9 ±0.3 kg

Protection Level

IP67

Operating Temperature

-32 / +49 °C

Storage Temperature

-55°C / +85°C