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.

Product comparison

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  • System voltage
  • Rated current
  • Supply voltage
  • Fuse protection
  • System weight (fully assembled)
  • Ambient temperature
  • Protection class
  • Dimensions (L x W x H)
  • Short-circuit bracket
  • Potential equalization
  • EMC glands
  • Pressure compensation element
  • Insulation monitor
  • DC-Charging
  • Mainboard
  • Connections
  • Optional connections
FUSION800M

FUSION800M

  • System voltage: Up to 800 VDC
  • Rated current: 500 A
  • Supply voltage: 12 V / 24 V
  • Fuse protection: Positive pole
  • System weight (fully assembled): 20 kg
  • Ambient temperature: -40 - +85 °C
  • Protection class: IP67*
  • Dimensions (L x W x H): 404 x 313 x 141 mm
  • Short-circuit bracket:
  • Potential equalization:
  • EMC glands:
  • Pressure compensation element:
  • Insulation monitor: (optional)
  • DC-Charging:
  • Mainboard: Interlock switch, Temperature sensor
  • Connections: 2x 175 A to 600 A
    4x 60 A to 400 A
    4x 60 A to 150 A
    6x 5 A to 50A
  • Optional connections: -

* higher class on request

Datasheet
FUSION850M

FUSION850M

  • System voltage: Up to 850 VDC
  • Rated current: 500 A
  • Supply voltage: 12 V / 24 V
  • Fuse protection: Positive pole
  • System weight (fully assembled): 20 kg
  • Ambient temperature: -40 – +85 °C
  • Protection class: IP67*
  • Dimensions (L x W x H): 404 x 313 x 141 mm
  • Short-circuit bracket:
  • Potential equalization:
  • EMC glands:
  • Pressure compensation element:
  • Insulation monitor: (optional)
  • DC-Charging:
  • Mainboard: Interlock switch, Temperature sensor
  • Connections: 2x 225 A to 400 A
    4x 70 A to 300 A
    6x 5 A to 50 A

  • Optional connections: (see datasheet)

* higher class on request

Datasheet
INTERFUSION800M

INTERFUSION800M

  • System voltage: Up to 800 VDC
  • Rated current: 500 A
  • Supply voltage: 12 V / 24 V
  • Fuse protection: Positive pole
  • System weight (fully assembled): 25 kg
  • Ambient temperature: -40 - +85 °C
  • Protection class: IP67*
  • Dimensions (L x W x H): 600 x 350 x 136 mm
  • Short-circuit bracket:
  • Potential equalization:
  • EMC glands: (Plug optional)
  • Pressure compensation element:
  • Insulation monitor: (optional)
  • DC-Charging:
  • Mainboard: Interlock switch, Temperature sensor
  • Connections: 2x 175 A to 600 A**
    4x 60 A to 400 A
    4x 60 A to 150 A
    6x 5 A to 50 A
  • Optional connections: -

* higher class on request
** 1x reserved for fast charging

 

Datasheet
INTERFUSION850M

INTERFUSION850M

  • System voltage: Up to 850 VDC
  • Rated current: 500 A
  • Supply voltage: 12 V / 24 V
  • Fuse protection: Positive pole
  • System weight (fully assembled): 25 kg
  • Ambient temperature: -40 – +85 °C
  • Protection class: IP67*
  • Dimensions (L x W x H): 600 x 350 x 136 mm
  • Short-circuit bracket:
  • Potential equalization:
  • EMC glands:
  • Pressure compensation element:
  • Insulation monitor: (optional)
  • DC-Charging:
  • Mainboard: Interlock switch, Temperature sensor
  • Connections: 2x 225 A to 400 A**
    4x 70 A to 300 A
    6x 5 A to 50 A

  • Optional connections: (see Datasheet)

* higher class on request
** 1x reserved for fast charging

Datasheet
FUSION800L

FUSION800L

  • System voltage: Up to 800 VDC
  • Rated current: 480 A
  • Supply voltage: 12 V / 24 V
  • Fuse protection: Positive and negative pole
  • System weight (fully assembled): 65 kg
  • Ambient temperature: -25 - +55 °C
  • Protection class: IP66*
  • Dimensions (L x W x H): 804 x 604 x 285 mm
  • Short-circuit bracket:
  • Potential equalization:
  • EMC glands:
  • Pressure compensation element:
  • Insulation monitor: (optional)
  • DC-Charging:
  • Mainboard: Interlock switch, Temperature sensor
  • Connections: 1x 175 A to 600 A
    2x 175 A to 400 A
    18x 60 A to 150 A
    8x 10 A to 50 A
  • Optional connections: -

* higher class on request

Datasheet
FUSION450S

FUSION450S

  • System voltage: Up to 450 VDC
  • Rated current: 300 A
  • Supply voltage: 12 V / 24 V
  • Fuse protection: Positive and negative pole
  • System weight (fully assembled): 11 kg
  • Ambient temperature: -20- +60°C
  • Protection class: IP65* and IK09
  • Dimensions (L x W x H): 280 x 230 x 111 mm
  • Short-circuit bracket:
  • Potential equalization:
  • EMC glands:
  • Pressure compensation element:
  • Insulation monitor:
  • DC-Charging:
  • Mainboard: Interlock switch, Temperature sensor
  • Connections: 4x 150 A to 400 A
    2x 60 A to 125 A
    4x 5 A to 50 A

  • Optional connections: -

* higher class on request

Datasheet
FUSION80

FUSION80

  • System voltage: Up to 80 VDC
  • Rated current: 240 A
  • Supply voltage: 12 V / 24 V
  • Fuse protection: Positive and negative pole
  • System weight (fully assembled): 6 kg
  • Ambient temperature: -20- +60°C
  • Protection class: IP65* and IK09
  • Dimensions (L x W x H): 330 x 230 x 111 mm
  • Short-circuit bracket:
  • Potential equalization:
  • EMC glands:
  • Pressure compensation element:
  • Insulation monitor:
  • DC-Charging:
  • Mainboard:
  • Connections: 1x up to 160 A
    4x up to 150 A
    4x up to 50 A

  • Optional connections: -

* höhere Klasse auf Anfrage

Datasheet

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The FUSION High Voltage Distribution Unit

The all-connecting component

In the High Voltage Distribution Unit (HVDU) 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 to the charger, the fast charging interface, and 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 unit 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 unit 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 unit 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 unit or any other service, please contact us without obligation.