Manual service disconnects for battery systems

A manual service disconnect for opening and closing a high current fused electrical path of a battery distribution unit used to switch and control operation of components of a battery system, the manual service disconnect comprising:

• a disconnect header discrete from and configured to be mounted proximate to a battery distribution unit of a battery pack of the battery system, the disconnect header comprising a housing defining a receptacle isolated from an interior of the battery distribution unit, a high current terminal connector within the receptacle, a high voltage interlock (HVIL) connector within the receptacle and a low current control device terminal connector within the receptacle, the low current control device terminal connector operating at a lower current than the high current terminal connector, the high current terminal connector, the HVIL connector and the low current control device terminal connector are electrically connected to the battery distribution unit;
• a disconnect plug removably coupled to the disconnect header by a lever rotatable between closed and open positions for a manual connection and disconnection process for servicing the battery system, the disconnect plug having a high current fuse electrically connected to the high current terminal connector when the disconnect plug is coupled to the disconnect header and unmated from the high current terminal connector when the disconnect plug is removed from the disconnect header, the high current fuse forming part of a high current circuit controlling power to the battery pack, the disconnect plug having a HVIL shunt terminal electrically connected to the HVIL connector when the disconnect plug is coupled to the disconnect header and unmated from the HVIL connector when the disconnect plug is removed from the disconnect header, the HVIL shunt terminal controlling power supply on the high current circuit;
• and
• a low current power control device received in the receptacle, the low current power control device being electrically connected to the low current control device terminal connector, the low current power control device being exposed within the receptacle of the disconnect header of the manual service disconnect for servicing when the disconnect plug of the manual service disconnect is removed from the disconnect header without directly accessing the battery distribution unit, the low current power control device being inaccessible when the disconnect plug is coupled to the disconnect header.

A battery system comprising:

• a battery pack having a plurality of battery cells in an outer casing;
• a battery distribution unit controlling power distribution to the battery cells, the battery distribution unit being used to switch and control operation of components of the battery system;
• and
• a manual service disconnect for opening and closing a high current fused electrical path of the battery distribution unit, the manual service disconnect comprising:
• a disconnect header coupled to the outer casing of the battery pack proximate to the battery distribution unit of the battery system, the disconnect header being discrete from the battery distribution unit, the disconnect header comprising a housing defining a receptacle isolated from an interior of the battery distribution unit, a high current terminal connector within the receptacle, a high voltage interlock (HVIL) connector within the receptacle and a low current control device terminal connector within the receptacle, the high current terminal connector, HVIL connector and low current control device terminal connector being electrically connected to the battery distribution unit, the low current control device terminal connector operating at a lower current than the high current terminal connector, the high current terminal connector, the HVIL connector and the low current control device terminal connector are electrically connected to the battery distribution unit;
• a disconnect plug removably coupled to the disconnect header by a lever rotatable between closed and open positions for a manual connection and disconnection process for servicing the battery system, the disconnect plug having a high current fuse electrically connected to the high current terminal connector and a HVIL shunt terminal electrically connected to the HVIL connector, the disconnect plug being removed to disconnect the high current fuse and the HVIL shunt terminal from the high current terminal connector and the HVIL connector, respectively;
• and
• a low current power control device received in the receptacle, the low current power control device being electrically connected to the low current control device terminal connector, the low current power control device being exposed within the receptacle of the disconnect header of the manual service disconnect for servicing when the disconnect plug of the manual service disconnect is removed from the disconnect header without directly accessing the battery distribution unit, the low current power control device being inaccessible when the disconnect plug is coupled to the disconnect header.