Need fuse and relay for ~180A ~400V

[vile]

Hi all,

I need some advice:
I'm looking for a fuse for an electric vehicle traction battery: It should have a thermal and fast over-current tripping. The max drain from the battery is about 180A and the fuse should release at about 300A, that's the max allowed battery current (128S1P A123 20Ah prismatic LiFePo4). But I think a higher current wouldn't harm the battery because of the short time.
The max voltage in the system is 460V, nominal voltage is about 400V.

I'd also need for the same system high current relays (180A min) with a coil/control voltage of 12V or 24V.

Any website, shop or producer? Haven't found anything yet. The price is not so important, but the less the better.

(Sorry for my english)
Vile

 

[Trilska]

For the relay you might want to take a look at the kilovac ev200 relay. available from http://www.jozztek.com/shop/battery-management/28-kilovac-ev200-series-contactor.html, or a used one via ebay.

 

[vile]

Thank you, the contactor looks great, if I find the one with aux contacts I think I'll take it.

And what about fusing? What would you recommend?

 

[heathyoung]

Semiconductor fuse - Bussman FWH-200B / 300A

http://www.evworks.com.au/index.php?product=FUS-FWH-200B or http://www.evworks.com.au/index.php?product=FUS-FWH-300A

 

[liveforphysics]

Search "class T"

What you need exists. About $20-50 depending on brand etc.

 

[vile]

Thanks for the links, very helpful, but aren't there any automatic circuit breakers with electromagnetic tripping? Or aren't they needed for such kind of application?

 

[megacycle]

Yes tons of cheap, cheaper than correct fuse, solar dc breakers with auxillary items available to connect to them.
No blown fuses and closer operating specs than a fuse.
This is one i've been playing with for precharge.

 

[megacycle]

but aren't there any automatic circuit breakers with electromagnetic tripping? Or aren't they needed for such kind of application?

+1Yes they are.
For your application, could list 2 reasons for a fuse and 10 for a breaker.

 

[vile]

I also think a breaker would be better. But where could I get one that is rated with about 200A and 400+ volts?
Any producer or onlineshops?

 

[megacycle]

I also think a breaker would be better. But where could I get one that is rated with about 200A and 400+ volts?
Any producer or onlineshops?

Have you got a link to your build? Be good to see.

DC breakers are made scaleable for the solar industry to handle up to around 800V.
Two are ganged( linked) together, like this for 400V+.

I found GE 63A info here, theyre standard within the range of course, but un common in the field, so good luck.
http://www.luckinslive.com/product/381584452/GE-ENERGY-Industrial-Solutions/EP102UCC63?f=prs&m1=4234&m2=4234&pmaj=046134000000&pmin=046134058437
The data sheet is on the page
You only need a 200A if thats your nominal running, that would be hammering your A123's to saggaroony
Unlike a fuse, you can run a breaker outside of its nominal current ratings, it's within their parameters.
A 63A could run about 140-150A for several second without tripping or even more for 'C' curve or a motor start breaker.
If you want above 60kW+ from your battery.
This is breaker curve info, cant find the actual GE curves, but must fit within the standard and formula.

I've got access to plenty of 40A GE 4 pole cheap, might do the job if you run 2P battery, but not sure if can recommend doubling up on 1P battery, can check out for you.
You can actually intergrate precharge into the breaker scheme and trip the breaker remotely using a whole series of add auxillary devices.
The 4 gang comes with an auxillary switch for signalling, i'm using on my precharge scheme.

 

[megacycle]

I started a thread to introduce a breaker and precharge scheme i will do for a 132V controller, here.
http://endless-sphere.com/forums/viewtopic.php?f=14&t=48862
This is a link to a short circuit test i did tripping 1 pole of a GE 40A dc @ 118V 8Ah Zippy.
Not quite your level, but shows what little damage could result to cables and equipment, limiting current.
Hope you enjoy the gunshot, whipcracking, neighbours dog did
https://www.youtube.com/watch?v=OnOsSmbXCoQ&feature=youtube_gdata_player

 

[vile]

Thanks for your posts. Could you explain in a few sentences what the precharge setup/circuit is?

I think its better so use a fuse which is rated at 200 or 300 amps. A 40A or 63A fuse would trip when driving at full power for acceleration and max speed.

I forgot to mention the regen: Is a recuperation current of 300A@360V possible with a 280kg vehicle at up to ~110km/h? Is that a very hard break? Any website for more information?
300A is the max allowed charging current for the A123 20Ah for short times. The motor controller is able to drive and regen up to 140kW.

Vile

 

[megacycle]

http://endless-sphere.com/forums/viewtopic.php?f=14&t=49531
Might be good to have a good read of this thread geat an idea of what you need with this kind of project.

 

[megacycle]

http://endless-sphere.com/forums/viewtopic.php?f=10&t=29916
Its a bike build, but might be good to have a good read of this thread geat an idea of what you need with this kind of project.