INSTALLATION INSTRUCTIONS / NOTICE

BCL25-700-8
25 kW INVERTER/CHARGER

CHARGE MODE: AC INPUT 3-phase 230-277 V L-PE.; 400-480 V L-L; 3W+PE,

max.32 A; 50/60 Hz; 25 kW
1-phase 230 V L-PE.; 1W+N+PE;
max.32 A, 50/60 Hz; 8 kW
DC OUTPUT 250-800 VDC; 60 A
INVERTER MODE: DC INPUT 250-800 VDC; 60 A; 25 kW
AC OUTPUT 3-phase 230/277 V L-PE.; 400/480 V L-L; 3W+PE,
max.32 A; 50/60 Hz; 25 kW
SIGNAL BATTERY DC INPUT 10.5 – 32 V; max.3 A

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS — This manual contains important instructions for model BCL25-700-8 that should be followed during the maintenance of the unit.
These component level chargers are intended exclusively for installation within other equipment by an industrial assembly operation or by professional installers.
Component chargers are to be installed in end-use equipment according to the requirements of the safety standard used for that equipment.
SAFETY APPROVALS
EN 62368-1:2020+A11:2020, EN 61851-21-1:2017, UNECE Regulation 10.6

INSTALLATION
For details please see datasheet (BCD.01049) and mechanical drawing (BCL25-700-8.FD). Installation category II.

FUSING
The Charger must be properly fused to maintain safe operation in end use. It is essential to keep following fusing in final application.

AC INPUT: Maximum 32 A type B UL approved circuit breaker shall be provided by EVSE (Electric Vehicle Supply Equipment) charge station installation.

AC OUTPUT: Maximum 32 A type B UL approved residual current circuit breaker shall be provided during Export mode.

DC OUTPUT: 80 A External fuse shall be used to protect DC Output wiring with inrush limiter for Battery connection.

12/24 V BATTERY: 5 A Automotive (Car) external fuse shall be used to protect 12/24V circuits.

CAUTION / ATTENTION
CAUTION - To reduce the risk of electric shock, connect only to properly grounded outlets.
ATTENTION – Brancher l’appareil uniquement sur des prises correctement mises à la terre afin de prévenir tout risque d’électrocution.
CAUTION - Do not use this product if there is any damage to the unit.
ATTENTION – Ne pas utiliser le produit si celui-ci est endommagé
CAUTION – Risk of electric shock. Do not remove cover or attempt to open the enclosure. No user serviceable parts inside. Refer servicing to
qualified service personnel.
ATTENTION – Risque d’électrocution. Ne pas retirer le couvercle ni tenter d’ouvrir le boîtier. Cet appareil ne contient aucun composant
susceptible d’être réparé par l’utilisateur. Pour toute réparation, s’adresser à des spécialistes qualifiés.
CAUTION – Do not remove the top cover or attempt to open the enclosure as you will void the warranty.
ATTENTION – Ne pas retirer le couvercle supérieur ni tenter d’ouvrir le boîtier au risque d’annuler la garantie.

CAUTION – Hot Surfaces: The surface of our onboard charger can achieve higher temperatures (T > +70°C). The end customer must install
the onboard charger in such a way that a safe operation is guaranteed. This Charger is designed to be operated with lithium-ion batteries, use
of other types of batteries needs to be discussed with a BEL representative (manufacturer).
ATTENTION – Surfaces chaudes : La surface de notre chargeur embarqué peut atteindre des températures très élevées (T > +70 °C). Le
client final doit installer le chargeur embarqué de sorte à garantir un fonctionnement en toute sécurité. Ce chargeur est conçu pour fonctionner
avec des batteries lithium-ion. L’utilisation de tout autre type de batterie doit être convenue au préalable avec un représentant BEL (fabricant).

CAUTION – High voltage; Turn off the Charger before disconnecting any terminal. Discharge power terminals or wait 5 minutes before
servicing. Do not turn on Charger when any terminal is not connected.
ATTENTION – Haute tension ; éteindre le chargeur avant de déconnecter toute borne. Décharger les bornes d’alimentation ou patienter
5 minutes avant toute réparation. Ne pas mettre le chargeur en marche lorsqu’aucune borne n’est connectée.

CAUTION – READ THIS CAREFULLY BEFORE INSTALLATION! Before operating, read this document thoroughly and retain it for future
reference. Not respecting these instructions may reduce the performances and safety of the devices and cause danger for people and the
performance and safety of the unit.
ATTENTION – À LIRE ATTENTIVEMENT AVANT TOUTE INSTALLATION ! Avant toute utilisation, lire ce document attentivement et le
conserver à des fins de consultation ultérieure. Le non-respect de ces instructions peut altérer les performances et la sécurité des dispositifs
et impliquer des dangers pour les personnes et l’appareil.

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BCL25-700-8 22kW INVERTER/CHARGER 2

WARNING / AVERTISSEMENT
WARNING – This Charger is not provided with a GFDI device at HV-DC side. This Charger must be used with an external GFDI device as
required by the Article 690 of the National Electrical Code for the installation location.
This Inverter is not provided with a GFCI device at HV-AC side. This Inverter must be used with an external GFCI device as required by the
Article 690 of the National Electrical Code for the installation location.
AVERTISSEMENT – Ce chargeur n’est pas fourni avec un disjoncteur-détecteur de fuites à la terre du côté HT-DC. Ce chargeur doit être
utilisé avec un disjoncteur-détecteur de fuites à la terre externe tel que stipulé dans l’article 690 du National Electrical Code [Code électrique
national en vigueur aux États-Unis] pour le site d’installation.
Ce chargeur n’est pas fourni avec un disjoncteur-détecteur de fuites à la terre du côté HT-AC. Cet onduleur doit être utilisé avec un
disjoncteur-détecteur de fuites à la terre externe tel que stipulé dans l’article 690 du National Electrical Code [Code électrique national en
vigueur aux États-Unis] pour le site d’installation
WARNING – Do not operate Charger without proper cooling. Do not add cold coolant when the unit is hot as there is a risk of inducing cracks
in the chassis. Coolant needs to be added prior to any operation of unit.
AVERTISSEMENT – Ne pas utiliser le chargeur sans un refroidissement adapté. Ne pas ajouter de liquide de refroidissement froid lorsque
l’appareil est chaud, au risque de causer des fissures sur le châssis. Ajouter le liquide de refroidissement avant toute mise en fonctionnement
de l’appareil.
WARNING – External pre-charging circuit is required as part of battery management system.
AVERTISSEMENT – Un circuit de pré-charge externe est nécessaire à titre de composant du système de gestion de la batterie.
WARNING – Mounting holes are designed to support Charger only and cannot be used to support other assemblies.
AVERTISSEMENT – Les trous de montage sont destinés à supporter le chargeur uniquement et ne doivent pas être utilisés pour supporter
d’autres assemblages.
ENVIRONMENTAL CONDITIONS
TRANSPORTATION & Ambient Temperature Range: -40°C to +85°C
STORAGE: Relative Humidity Range: SAE J1455
Altitude: Non-operating up to 12200 m (18.6 kPa)

OPERATION: Ambient Temperature Range: -40°C to +80°C

Coolant Temp. Range: -40°C to +60°C (no derating)/ +60°C to +75°C(with derating, details see in datasheet)
Relative Humidity Range: SAE J1455
IP 67 and IP 6K9K *watertight when all mating connectors are installed.
Operating up to 4000 m.
SERVICING
In case of failure, the Charger must be returned to a Bel Fuse Authorized Service Centre for repair, with a Bel Fuse pre-assigned RMA number. Refer servicing to the
vehicle manufacturer.
LIMITED WARRANTY
Bel Fuse warrants each Charger of its manufacture for a period of two years from the date of original shipment. This warranty applies to defects in materials and
workmanship that result in non-performance to published specifications. Bel Fuse assumes no liabilities for consequential damages of any kind through the misuse of
its products by any user. No other obligations are expressed or implied.
NUCLEAR AND MEDICAL APPLICATIONS
Products are not designed, intended for use in, or authorized for use as critical components in life support systems, equipment used in hazardous environments, or
nuclear control systems without the express written consent of the respective divisional president.
TECHNICAL REVISIONS
The appearance of product, including safety agency certifications pictured on labels, may change depending on the date manufactured. Specifications are subject to
change without notice.

CONNECTOR DESCRIPTION UNIT SIDE

AC INPUT
Charger side: MFG: TE CONNECTIVITY; PN: HVA630-5P: 0-2141619-1
Mating connector: MFG: TE CONNECTIVITY; PN: HVA630-5P :114-94114-1
Use copper conductors only with an insulation rating of 120 °C, 6 mm 2, OD 16.3 mm.
Follow connector MFG instructions for correct connector assembly.
We highly recommend using screened connecting cables.
(e.g. Coroplast, FHLR2GCB2G 5x6.0mm² T180). Fig. 1: AC input connector, Charger side
Note: HVIL pins shall be shorted on mating part (cable side).
PIN 3 PHASE 1 PHASE EU 1 PHASE US
DESCRIPTION
NUMBER CONNECTION CONNECTION CONNECTION
1. PE PE PE PE
2. Phase L3 Phase L3 Phase L2
3. Phase L2 Phase L2
4. Phase L1 Phase L1 Phase L1 Phase L1
5. Neutral Neutral Neutral
Fig. 2: AC input connector, Cable side
DC OUTPUT

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 BCL25-700-8 22kW INVERTER/CHARGER 3

Charger side: MFG: Amphenol; PN: HVSLS600022A1H6

Mating connector: MFG: Amphenol; PN: HVSLS600062A125

Use copper conductors only with an insulation rating of 120 °C, 25 mm2, OD 11.9 mm.
Follow connector MFG instructions for correct connector assembly.

We highly recommend using screened connecting cables.

(e.g. Coroplast, FHLR2GCB2G 1x25mm² T180).
Fig. 3: DC output connector, Charger side
Note: HVIL pins shall be shorted on mating part (cable side).

PIN
DESCRIPTION
NUMBER
1. HV DC negative
2. HV DC positive
Fig. 4: DC output connector, Cable side

SIGNAL CONNECTION
Charger side: MFG: TE Connectivity; PN: DRC23-40PAN012
Mating connector: MFG: TE Connectivity; PN: DRC26-40SA ,
max. 2 Amps per pin (wire AWG 20)
Pin PN: 1062-20-0144

We recommend using screened connecting cables.

Fig 5: Signal connector, Charger side

Fig 6: Signal connector, Cable side

PIN NAME FUNCTION REFERENCE PIN
1 PROXIMITY Function and levels according to SAE J1772 / IEC 61851-1 PE
2 SGND Internally connected with pin 12 -
Wake Output goes high when Control Pilot is active (max delay 100ms) and goes low when
3 EVSE_WAKE_OUT Pin 2
CAN command from VCU is received or when goes into sleep mode or delayed sleep mode.
4 HVIL_IN Input pin for HVIL loop. (To detect if connectors are properly inserted.) Pin 5
5 HVIL_OUT Output pin for HVIL loop Pin 4
6 +VBAT Internally connected with pin 16, connect both pin Pin 26,Pin 36
7 LOCK_LOOP_A Plug motor interlock signal -
8 LOCK_LOOP_B Plug motor interlock signal -
9 LOCK_ACTUATOR_A Plug motor lock A Pin 10
10 LOCK_ACTUATOR_B Plug motor lock B Pin 9
11 CONTROL PILOT Function and levels according to SAE J1772 / IEC 61851-1 PE
12 SGND Internally connected with pin 2 -
13 KEY_SWITCH This is signal for CAN communication enable (Level HIGH=enable) Pin 6
14 TEMP_EXT+ External temperature sensor + Pin 15
15 TEMP_EXT- External temperature sensor - Pin 14
16 +VBAT Internally connected with pin 6, connect both pin Pin 26, Pin 36
17
18 SGND Max current 0.5A -
Setting of the CAN baud rate (no connected 500kB, connect to SGND 250kB, connected to
19 CAN_SPEED Pin 20
+VBAT custom speed)
20 SGND Max current 0.5A -
21 SGND Internally connected with pin 22 and 23 -
22 SGND Internally connected with pin 21 and 23 -
23 SGND Internally connected with pin 21 and 22 -
24 BUTTON_A Pin 23
25 BUTTON_B Pin 23
26 -VBAT Internally connected with pin 36, connect both pin -
Inputs to set addresses of 4 parallel units. Internally pulled-up for logic level Hi. Connection to
27 ADDR_0 Pin 28
SGND.
28 SGND Internally connected with pin 38 -
29 CAN_H_INT Diagnostic line for service -
30 CAN_L_INT Diagnostic line for service -
31 LED_A Pin 21
32 LED_B Pin 22
33 LED_C Pin 23
34 BUTTON_LED_A Pin 23
35 BUTTON_LED_B Pin 23
36 -VBAT Internally connected with pin 26, connect both pin -
Inputs to set addresses of 4 parallel units. Internally pulled-up for logic level H. Connection to
37 ADDR_1 Pin 38
SGND.
38 SGND Internally connected with pin 28 -
39 CAN_H_EXT CAN communication for customer Pin 40
40 CAN_L_EXT CAN communication for customer Pin 39

EARTH CONNECTION
Wire of protective earth PE screwed to grounding stud (located on the chassis) needs to be 10 mm2. Cable lug suitable for M6 needs to be used.

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BCL25-700-8 22kW INVERTER/CHARGER 4

COOLANT REQUIREMENTS
The Charger shall be liquid cooled.
Minimum Inlet Coolant Temperature: -40°C.
Maximum Inlet Coolant Temperature: +60°C (no derating)
+75°C (with derating)
Operational ambient air temperature is -40°C to +80°C.

Coolant Medium/Mixture: 50/50 Ethylene Glycol/Water.

Coolant Flow: min.10 LPM.
Max. pressure drop: 2.9 psi (0.2 bar).
Max. coolant pressure: 29psi ~ 2 bar.

COOLANT CONNECTION
Inlet/Outlet Coolant Connection: QUICK CONNECTOR PS3-NW12
Material of fittings: Aluminum alloy
Fittings provided with charger: NORMAQUICK 40061033X - PS3 NW12

MAXIMUM WORKING RATINGS AND DERATINGS

Power and Current rating three phase

27000 34
25000 33
32
Input Current
Input Power

23000 31
21000 30
19000 29
28
17000 27
15000 26
330 350 370 390 410 430 450 470 490 510 530
Input Voltage phase to phase

Input Power Input Current

Power and Current rating

26000 65
24000 60
22000 55

Output Current
Output Power

20000 50
18000 45
16000 40
14000 35
12000 30
10000 25
240
260
280
300
320
340
360
380
400
420
440
460
480
500
520
540
560
580
600
620
640
660
680
700
720
740
760
780
800

Output Voltage

Output Power @480Vac Output Power @400Vac Output Current @480Vac Output Current @400Vac

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BCL25-700-8 22kW INVERTER/CHARGER 5

MOUNTING REQUIREMENTS
Charger shall be mounted securely on the supporting frame by all 6 pcs of self-locking screws.
Mounting holes are designed to support charger only and cannot be used to support other assemblies.
The charger can be mounted in the below mentioned positions.
Deviating installation may lead to insufficient cooling.
Use provided anti vibration bushings and washers.
Recommended screw size is M8 x 50mm or 5/6” UNC x 2.
Recommended tightened torque 20Nm.
The user is responsible for ensuring the reliability of mounting in final application and testing its safety.

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 BCL25-700-8 22kW INVERTER/CHARGER 6

RECOMMENDED POWER WIRING DIAGRAM:

SIGNAL WIRING DIAGRAM:

Notes:
- CAN_SPEED is open => CAN baud rate = 500 kbps;
- ADDR_0 and ADDR_1 are open => CAN address = 0xD0
- CAN communication manual reference document: BCA.00290 (provided on the customer request).
- HVIL loop is possible to disable, but it is not recommended. HVIL loop is possible to create from 12V/24V battery. +VBAT should be connected to HVIL IN.
On HVIL OUT is necessary to connect resistor (600 Ohm for 12V or 1200 Ohm for 24V) to -VBAT for achieve 20mA current loop.

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© 2021 Bel Power Solutions & Protection BCM.00563_A