FUSION High-Voltage Distribution Unit
The FUSION high-voltage distribution unit can be used to connect the main components battery, charger, inverter, motor and optionally the fast charging system. Typical applications are electrified machines and vehicles with increased demands on robustness and safety, such as construction machinery, commercial vehicles and municipal vehicles.
FUSION800M : High-voltage distribution unit 800 Volt
Features:
- 2x connections up to 600 A
- 4x connections up to 400 A
- 4x connections up to 150 A
- 6x connections up to 50 A
- Mainboard (interlock switch, temperature sensor)
- Potential equalization
- EMC glands
- Pressure compensation element
- Short-circuit bracket
- Access measuring tips with additional safety level
- Insulation monitor (optional)
Specifications:
System voltage
Up to 800 VDC
Rated current
500 A
Supply voltage
12 V / 24 V
Fuse protection
Positive pole
System weight
20 kg (fully assembled)
Ambient temperature
-40 - +85 °C
Protection class
IP67*
* higher class on request
INTERFUSION800M : High-voltage distribution unit 800 Volt
Features:
- 2x connections up to 600 A (1x reserved for fast charging)
- 4x connections up to 400 A
- 4x connections bis 150 A
- 6x connections bis 50 A
- EMC glands (plug optional)
- Short-circuit bracket
- Access measuring tips with additional safety level
- Insulation monitor (optional)
- CCS 2.0 communication according to DIN70121 and ISO15118
- Galvanically isolated HV current and voltage measurements
Specifications:
System voltage
Up to 800 VDC
Rated current
500 A
Supply voltage
12 V / 24 V
Fuse protection
Positive pole
System weight
25 kg (fully assembled)
Ambient temperature
-40 - +85 °C
Protection class
IP67*
* higher class on request
FUSION800L : High voltage distribution unit 800 Volt
Features:
- 1x connections up to 600A
- 2x connections up to 400 A
- 18x connections up to 150 A
- 8x connections up to 50 A
- Mainboard (interlock switch, temperature sensor)
- EMC glands
- Pressure compensation element
- Short-circuit bracket
- Access measuring tips with additional safety cover
- Insulation monitor (optional)
Spezifikationen:
System voltage
Up to 800 VDC
Rated current
480 A
Supply voltage
12 V / 24 V
Fuse protection
Positive and negative pole
System weight
65 kg (fully assembled)
Ambient temperature
-25 - +55 °C
Protection class
IP66*
* higher class on request
FUSION450 : High voltage distribution unit 450 Volt
Features:
- 4x connections up to 400 A
- 2x connections up to 125 A
- 4x connections up to 50 A
- Mainboard (interlock switch, temperature sensor)
- Potential equalization
- EMC glands
- Pressure compensation element
- Short-circuit bracket
Spezifikationen:
System voltage
Up to 450 VDC
Rated current
300 A
Supply voltage
12 V / 24 V
Fuse protection
Positive and negative pole
System weight
11 kg (fully assembled)
Ambient temperature
-20 - +60 °C
Protection class
IP65* and IK09
* higher class on request
FUSION80 : High voltage distribution unit 80 Volt
Features:
- 4x connections up to 150 A
- 4x connections up to 50 A
- 1x connections up to 160A
- Potential equalization
- EMC glands
- Pressure compensation element
- DC additional relay (optional)
Spezifikationen:
System voltage
Up to 80 VDC
Rated current
240 A
Supply voltage
12 V / 24 V
Fuse protection
Positive and negative pole
System weight
6 kg (fully assembled)
Ambient temperature
-20 - +60 °C
Protection class
IP66* and IK09
* higher class on request
Are you interested in one of our products, or do you need a customization?
We accompany you from the concept to the elaboration and up to the serial product.
The FUSION high-voltage distribution system
The all-connecting component
In the high-voltage distribution system (HVDU or High Voltage Distrubution Unit) also known as Power Distribution Unit (PDU) or Junction Box, all high-voltage components of a fully electric or hybrid machine are connected to each other. The batteries can be connected here to the charger, the fast charging interface as well as to the loads such as electric drive system and DC-DC converter.
Designed for use in construction equipment, in specialty and commercial vehicles such as municipal vehicles and in agricultural vehicles, the FUSION can withstand the harshest and most extreme conditions with its rugged aluminum housing, high-quality metal cable glands or connectors and IP67 protection rating. Thanks to expert design at our development facility in Switzerland, high-quality internal components, and meticulous in-house manufacturing and testing, voltages up to 800 V and currents up to 500 A (model dependent) can be handled reliably and continuously.
Versatile configurations
Various sizes and voltage classes of the FUSION are available - with individually configurable inputs and outputs to provide the perfect solution for every application. With the INTERFUSION800M, the high-voltage distribution of a FUSION800M is combined with the fast-charging interface of the INTERFLOW500, providing a more compact and elegant solution when both components are needed. Furthermore, with the optional additional development and manufacturing of the electrical system with the wiring harnesses by SUNCAR, a plug and play complete solution is available.
Safety has top priority
The FUSION high-voltage distribution system also features numerous safety features. Each individual input and output is reliably protected by high-quality fuses. A temperature sensor and a pressure compensation element are also installed. During maintenance work, the system can first be checked for the absence of voltage by means of dedicated measuring points before the safety cover is removed and a short-circuit bar in accordance with the high-voltage guideline guarantees the absence of voltage during maintenance. In addition, the FUSION is integrated into the machine-wide interlock system (HVIL) with the interlock switch. When a component of the HV system is opened, this triggers the interlock system and opens the battery contactors, which disconnect the machine from the power source. The enclosure can be grounded at the grounding stud and is also connected to the conductive cable sheath (shielding) of the input and output cables by means of the EMC cable glands to intercept and ground electromagnetic interference (EMI). If required, an insulation monitoring device (IMD) can be integrated for continuous insulation measurements, constantly monitoring the system for possible electrical leaks during operation.
SUNCAR also offers expert advice on the product and development support from electrical design to the construction of complete prototypes or small series. If you are interested in the FUSION high voltage distribution system or any other service, please contact us without obligation.