technical data and start-up - brusa€¦ · technical data and start-up 10 bdc546 3.2 safety...

BRUSA Elektronik AG Neudorf 14 CH–9466 Sennwald +41 81 758 19 00 [email protected]

www.brusa.biz

DC/DC converter BDC546

TECHNICAL DATA AND START-UP

Translation of the original German operating instructions

Technical data

and start-up BDC546 2

LEGAL NOTICE

Publisher BRUSA Elektronik AG Neudorf 14 CH–9466 Sennwald T +41 8175 809–00 F +41 8175 809–99 www.brusa.biz [email protected]

Date of issue 10. Oct. 2016

Copyright © 2013 The content of this document may not be passed on to third parties without the written authorisation of the company BRUSA Elektronik AG - including extracts thereof. All technical information, drawings and photos used in this document are protected by copyright and any infringement constitutes a punishable offence!

Updates Due to the ongoing technical development of our products, we reserve the right to make changes to their designs. Any changes will be disclosed in individual manuals by replacing relevant pages and/or revising electronic data storage devices.

Writer/Author Manuel Tschumper

REVISIONS REVISION DATE NAME CHANGE 01 24th Feb.

2014 M.Tschumper Document issued

02 24th Feb. 2014

M.Tschumper List of parameters translation

03 25th June 2014

M. Schiedermeier Switching frequency, HS current limited, clock frequency is new switching frequency (Side 21)

04 30th Oct. 2014

J. Pitschi Integration of cable length

05 30th April 2015

J. Pitschi Update ULS to 600V

06 16.07.2016 A. Girod 5. information “evaluation kits” 07 25.10.2016 M. Gern Validity B05 (OEM Version), 5. “information removed” 08 23.11.2016 A. Girod 13. Warranty new

3

Technical data and start-up BDC546

VALIDITY

This manual is only valid for the devices listed in the following table:

BDC546-B04 BDC546-B05 (OEM Version) BDC546-B06

The breakdown of the device designation is as follows:

Technical data


TABLE OF CONTENTS 1 Foreword .............................................................................................................................. 8

2 List of abbreviations ........................................................................................................... 8

3 Safety and warning instructions ........................................................................................ 9

3.1 Symbols and their meaning ........................................................................................................ 9

3.2 Safety instructions and danger levels ....................................................................................... 10

3.3 Generally applicable safety measures ...................................................................................... 11

3.3.1 Safety instructions for cooling water systems .................................................................... 11

3.3.2 Safety instructions for mechanical systems ....................................................................... 11

3.3.3 Safety instructions for handling and operation ................................................................... 12

3.3.4 Safety instructions for electrical systems ........................................................................... 13

3.4 Safety installations / power limitations ...................................................................................... 14

3.4.1 Interlock ............................................................................................................................ 14

3.4.2 Pyrofuses .......................................................................................................................... 14

3.4.3 Over temperature protection (derating).............................................................................. 15

3.4.4 HV - Automatic intermediate circuit discharge ................................................................... 15

3.5 Requirements regarding the start-up personnel ........................................................................ 16

4 General ............................................................................................................................... 17

4.1 Content and scope of this manual ............................................................................................ 17

4.2 Scope of the entire documentation ........................................................................................... 17

4.3 Scope of delivery ...................................................................................................................... 18

4.4 Applicable standards ................................................................................................................ 19

4.5 Manufacturer contact information ............................................................................................. 19

5 Use and limits of the product ........................................................................................... 20

5.1 Proper use................................................................................................................................ 20

5.2 Improper use / Limits of the product ......................................................................................... 20

6 About this device............................................................................................................... 21

6.1 Technical data .......................................................................................................................... 21

6.2 Technical properties ................................................................................................................. 23

6.3 BDC546 block diagram ............................................................................................................ 23

6.4 Basic function / EMC concept ................................................................................................... 24

5


6.4.1 Topology benefits .............................................................................................................. 24

6.4.2 Filter concept for highside and lowside .............................................................................. 25

6.5 Warnings on the device ............................................................................................................ 26

6.6 Vehicle installation basic principle ............................................................................................ 27

6.7 Safety concept for vehicle installation ....................................................................................... 28

6.7.1 General interlock function .................................................................................................. 28

6.8 Interlock signal ......................................................................................................................... 29

6.9 Overview of the main structural components ............................................................................ 30

6.10 Dimensions and installation information ................................................................................... 31

6.10.1 Fastening points ................................................................................................................ 31

6.10.2 Dimensions ....................................................................................................................... 32

6.10.3 Installation position ............................................................................................................ 32

6.11 Type plate ................................................................................................................................ 33

7 Electrical interfaces ........................................................................................................... 34

7.1 Control connector pin assignment (device side) ....................................................................... 35

7.1.1 Pin 1 GND ......................................................................................................................... 36

7.1.2 Pin 2 AUX ......................................................................................................................... 37

7.1.3 Pin 6 TXD, pin 7 RXD, pin 8 P_GND ................................................................................. 38

7.1.4 pin 9 CNL, pin 10 CNH ...................................................................................................... 39

7.1.5 Pin 11 PFO_VC+, pin 12 PFI_VC+, pin 14 PFO_VC-, pin 15 PFI_VC- .............................. 40

7.1.6 Pin 13 PRO ....................................................................................................................... 41

7.1.7 Pin 16 EN .......................................................................................................................... 42

7.1.8 Pin 17 DO_MC .................................................................................................................. 43

7.1.9 Pin 19 IL ............................................................................................................................ 44

7.2 Earthing / grounding screw (equipotential bonding) .................................................................. 45

7.3 Highside and lowside power connections ................................................................................. 46

8 Connections ....................................................................................................................... 48

8.1 Control connector ..................................................................................................................... 48

8.2 Highside cable .......................................................................................................................... 49

8.3 Lowside cable .......................................................................................................................... 50

8.4 Cooling water connections ....................................................................................................... 51

9 Installation / initial start-up ............................................................................................... 52

9.1 Installation and connection of the DC/DC converter ................................................................. 52

Technical data


9.2 Building the HV wiring .............................................................................................................. 55

9.3 Ventilating the cooling system .................................................................................................. 58

9.4 Voltage pre-charging ................................................................................................................ 59

10 Parameterization and operation .................................................................................... 61

10.1 Parameterization by means of PARAM tool .............................................................................. 61

10.1.1 PARAM application ........................................................................................................... 61

10.1.2 Installation and operation of the PARAM software ............................................................. 62

10.2 Parameters............................................................................................................................... 63

10.2.1 Parameter representation .................................................................................................. 63

10.2.2 Parameter groups ............................................................................................................. 64

10.2.3 [01] CAN Configuration - CRC ........................................................................................... 66

10.2.4 [02] Device Configuration – CRC ....................................................................................... 67

10.2.5 [09] FW Gains, Offset – CRC ............................................................................................ 68

10.2.6 [0A] FPGA Gains, Offsets and Settings – CRC ................................................................. 68

10.2.7 [10] Digital IO .................................................................................................................... 69

10.2.8 [11] Analog Input ............................................................................................................... 69

10.2.9 [12] Analog Values calculated and Offsets ........................................................................ 70

10.2.10 [13] PWM Input .............................................................................................................. 70

10.2.11 [20] Status ..................................................................................................................... 70

10.2.12 [22] Temperatures ......................................................................................................... 71

10.2.13 [23] Stored App Data ..................................................................................................... 71

10.2.14 [23] Stored App Data ..................................................................................................... 72

10.2.15 [31] General Parameters ................................................................................................ 73

10.2.16 [32] Revision Info ........................................................................................................... 73

10.3 DC/DC converter operation ...................................................................................................... 74

10.4 Brusa CVI ................................................................................................................................. 75

10.4.1 CVI software installation .................................................................................................... 75

10.4.2 CVI operation .................................................................................................................... 76

11 Firmware update ............................................................................................................ 77

11.1 FDT installation and firmware download instructions ................................................................ 77

11.2 Additional information for firmware download ........................................................................... 77

12 Troubleshooting ............................................................................................................. 78

13 Warranty .......................................................................................................................... 78

7


14 Instructions for disposal ............................................................................................... 79

15 Index ................................................................................................................................ 80

16 Attachments ................................................................................................................... 82

16.1 Cable fitting .............................................................................................................................. 82

16.2 Cable lugs ................................................................................................................................ 86

Technical data


1 Foreword

Dear customer,

By purchasing the BRUSA BDC546, you have chosen an efficient and versatile product. As this device is a high-performance electronics product which uses dangerous levels of voltage and current, special expertise with respect to handling and operation is required!

Before installing the device or carrying out any other work on it, this manual – in particular chapter 3 Safety and warning instructions – is to be read thoroughly.

2 List of abbreviations

Throughout this manual, some specific technical abbreviations are used. You will find an overview of these abbreviations as well as their meanings in the following table:

ABBR. MEANING ABBR. MEANING BDC Bidirectional High Power DC/DC

Converter FC Fuel Cell

CAN Controller Area Network VC Traction intermediate circuit HV High Voltage PDU Power Distribution Unit HS Highside (higher of the two HV potentials

of the DC/DC converter) BMS Battery Management System

LS Lowside (lower of the two HV potentials of the DC/DC converter)

FCC Fuel Cell Converter

9


3 Safety and warning instructions

This chapter contains safety instructions applying to this device. These instructions refer to the assembly, start-up and running operation in the vehicle. Always read and observe these instructions in order to protect people's safety and lives and to avoid damage to the device!

3.1 Symbols and their meaning Throughout this manual, a variety of symbols are used. For an overview of symbols as well as their meanings, refer to the following table:

Prohibition symbols

SYMBOL MEANING SYMBOL MEANING

General prohibition

Warning! High voltage! Do not touch!

Do not switch!

Warning symbols SYMBOL MEANING SYMBOL MEANING

General hazard warning

Warning! Danger caused by suspended loads!

Warning! Explosive environment!

Warning! Danger caused by batteries!

Warning! Hot surface!

Warning! High voltage!

Warning! High pressure/fluid ejection!

Warning! Fire hazard!

Mandatory signs


Disconnect device from voltage

Disconnect device from mains

Wear protective glasses

Wear protective gloves

Information signs


Important information on avoiding possible damage to property

Important information

Technical data


3.2 Safety instructions and danger levels

DANGER

This notice is a warning against serious, irreversible risks of personal injury with possibly fatal consequences! Avoid these risks by observing this notice!

WARNING

This notice is a warning against serious but reversible risks of injury! Avoid these risks by observing this notice!

CAUTION

This notice is a warning against a minor risk of injury! Avoid these risks by observing this notice!

NOTICE

This notice is a warning against possible damage to property if the following instructions and work procedures are not observed.

INFORMATION

This type of notice discloses important information to the reader.

11


3.3 Generally applicable safety measures The following safety measures have been developed based on the knowledge of the manufacturer. They are not complete; they can be supplemented by place and/or country-specific safety instructions and guidelines for accident prevention!

These safety instructions from the system integrator and/or distributor must therefore be supplemented by specific country and local guidelines.

3.3.1 Safety instructions for cooling water systems

WARNING

Cooling fluid ejection! Skin burning hazard! Check the water tightness of the cooling water system, particularly the pipes, screw joints and

pressure tanks. Rectify any identifiable leaks immediately!

3.3.2 Safety instructions for mechanical systems

DANGER

Explosive environment! Danger of death! Do not store any highly flammable substances or combustible fluids in the direct vicinity of

the device! Sparks forming at the device's connections can set them on fire and lead to explosions!

CAUTION

Hot surfaces! Burn hazard! The device produces high temperatures when in operation! Therefore, the device is to be

handled with care and caution at all times!

Technical data


3.3.3 Safety instructions for handling and operation

NOTICE

Damage to the DC/DC converter: As a rule, it is to be ensured that the voltage ranges of all devices connected to the DC/DC

converter are identical. Only use technically suitable and high-quality cables! A high cooling water temperature and/or ambient temperature reduces the life span! Therefore,

ensure that the device is continuously cooled sufficiently! Do not place the device in direct sunlight and in direct proximity to heat sources! Even though the device has a high IP protection class, direct contact with water (rain, splashing

water) is to be avoided if possible! Never damage existing galvanic isolations (e.g. by connecting HV contacts with the device

casing) in the vehicle. Prevent any fluid ingress into the device (e.g. during assembly work). Fluid ingress will lead to a

short circuit and subsequently to damage to the device! In the case of any fluid ingress, do not start the device and immediately contact BRUSA

Elektronik AG! Always use an isolation monitoring unit to continuously monitor the galvanic isolation between

the HV and LV circuit! Never connect or disconnect the HV connectors without ensuring the absence of voltage

beforehand! Before connecting a voltage supply to the highside or lowside of the DC/DC converter (e.g.: HV

battery), the voltage must be pre-charged by means of a suitable pre-charging device. Refer to chapter 9.4 Voltage pre-charging.

INFORMATION

The device may be used up to a maximum altitude of 4,000 m above sea level!

13


3.3.4 Safety instructions for electrical systems

DANGER

High voltage! Danger of death! Never touch the HV wires or HV connections without ensuring the absence of voltage

beforehand! The device may only be connected by a qualified electrician! Safety installations must never be bypassed or circumvented! Any resulting malfunctions could

have life threatening consequences!

NOTICE

Never open the device without authorisation! Opening the device (sealed housing) voids any guarantee and warranty rights immediately!

INFORMATION

When working on an HV grid, the following 5 safety rules must generally be strictly adhered to: Disconnect the system from the voltage supply. Switch off the ignition (if applicable) Remove the service / maintenance plug and/or turn off the battery main switch (if applicable) Remove the fuse (if applicable)

Ensure that the system cannot be restarted. Keep the ignition key safe in order to prevent unauthorised access (if applicable) Keep the service / maintenance plug safe in order to prevent unauthorised access and/or use lockable covers to ensure that the battery main switch cannot restart. (if applicable)

Ensure that the device is de-energised by means of a suitable voltage tester (note voltage range!)

Earth and short-circuit the system. Cover or seal off adjacent live parts.

Technical data


3.4 Safety installations / power limitations

3.4.1 Interlock

The interlock loop is looped through all plug-in device connections to check them for proper connection (rectangular signal with frequency: 88 Hz ±2 Hz). The BDC546 continuously evaluates the signal from the interlock loop. If a plug-in connection becomes loose, the BDC546 is immediately switched off. A missing change in polarity for 9 ms. is regarded as an error.

3.4.2 Pyrofuses

The BDC546 offers two digital inputs/outputs for application in a fuel cell system as follows:

To protect the fuel cell in case of an overvoltage on the lowside, a pyrofuse is provided to disconnect the connection between the fuel cell and the BDC546. For this, a fuse with a resistance of approx. 2 Ohm can be applied. The BDC546 offers a digital input/output each for both connection wires from the DC/DC converter to the fuel cell. It can be connected with one pyrofuse each. The outputs are permanently supplied by the plus wiring system/terminal 30. For a permissible LS voltage, the input has almost the same potential. In this state, a current of approximately 20 mA flows through the fuse. This enables detection of correct wiring as well as their state (not triggered). The signal is evaluated with a frequency of 1.5 kHz through the micro controller.

If the voltage permissible on LS is exceeded, the two inputs are set to the potential of the minus wiring system/terminal 31. The resulting current flow ignites the pyrofuses and respectively leads to galvanic isolation of the fuel cell from the converter.

15


3.4.3 Over temperature protection (derating)

This protective system is a self-protection feature of the BDC546. If the device reaches a defined temperature threshold, the power rating is reduced (derating) to protect the device from damage caused by overheating. The maximum permissible lowside current (400 A) will subsequently be reduced in proportion to the temperature increase until the temperature falls back to the target range. The module and choke temperatures are measured.

Derating is activated if a temperature value of ≥ 95 °C is reached. The power or choke current is now reduced in stages to a temperature not lower than 115 °C (0 A). This means that the choke current is reduced by 20 A for every degree temperature increase. If a temperature sensor is defective, derating is activated at temperatures ≥ 80 °C for safety reasons, and, correspondingly, the lowside current is reduced to 0 A at a temperature of 100 °C.

3.4.4 HV - Automatic intermediate circuit discharge

The BDC546 is equipped with an active as well as passive feature for discharging the HV circuit. This includes the highside as well as the lowside. Active intermediate circuit discharge is implemented inherently via an internal HV supply and cannot be controlled. Passive discharge is achieved by means of a resistor string:

Active intermediate circuit discharge: As soon as the device is separated from the HV supply, the internal HV circuits discharge to a value of < 60 V within <5 s.

Passive intermediate circuit discharge:

As soon as the device is separated from the HV supply, the internal HV circuits discharge to a value of < 60 V within <300 s.

Technical data


3.5 Requirements regarding the start-up personnel All courses of action described in this manual may only be carried out by a qualified electrician! Specialist staff are defined as electricians who possess

professional training, knowledge and experience in the field of high voltage electronics / electric mobility, as well as knowledge of the relevant requirements and dangers

which they can demonstrate in practice. Furthermore, they must be able to assess the work assigned to them independently, identify possible dangers and establish necessary protection measures.

17


4 General

4.1 Content and scope of this manual This documentation provides the reader with an overview of all required operating steps for the installation and operation of the device and the safety measures necessary for these purposes.

Furthermore, it contains technical data, application information and a basic description of the device and its specific components.

The operational and safety instructions given are to be adhered to in order to ensure ongoing optimum functioning of the device and to meet the warranty requirements of BRUSA Elektronik AG.

4.2 Scope of the entire documentation

INFORMATION

To commission the device successfully, the entire set of documentation as well as diverse pieces of software are required. The provision of the customer package ensures that the documentation and software are complete and up-to-date. Specific documents are updated automatically and can be seen in the history.

The customer package includes the following indexes:

Manuals: Contains all information fundamentally necessary for installation and operation.

Firmware / CAN: Contains all necessary CAN data as well as current firmware.

PC software: Contains additional tools for the operation, parameter setting and maintenance as well as the required driver files.

CAD data: Contains various CAD data in 2D and 3D.

Measurements / tests: Contains different test results of validating measurements as well as qualifying tests, if applicable.

History: List of all updates within the customer package, indicating the affected documents or software/firmware etc.

Technical data


4.3 Scope of delivery

MEANING QUANTITY ILLUSTRATION 1. BDC546-B 1

2. Protective cap for cooling water connection pieces 2

3. M8 x 16 screws for the cable lugs 4

4. M8 washer for M8 x 16 screws 4

5. M10 x 16 hexagonal screw

(ground GND) 1

6. M10 washer for M10 x 16 screws

(ground GND) 1

7. M25 cable fittings

Pflitsch prod. no. 22554e-1814 2

8. M32 cable fittings

Pflitsch prod. no. 23255e-2520 2

9. crimp type cable lug, flat (HS), 70 mm²

Ferratec AG / Klauke – 16578 2

10. crimp type cable lug, flat (LS), 95 mm²

Ferratec AG / Klauke – 16588 2

11. 23-pole control connector with crimp contacts *

AMPSEAL – 770680-1 1

12. SN/LP contacts

AMPSEAL 770854-1 for wire diameter: 0.5 mm²

28

* customer side connector

19


4.4 Applicable standards This manual has been produced under application and consideration of the EC guidelines, national laws and harmonised standards (EN) valid at the time of production relevant to the product BDC546.

4.5 Manufacturer contact information

BRUSA Elektronik AG Neudorf 14 9466 Sennwald Switzerland Phone: +41 81 758 19 - 00 Fax: +41 81 758 19 - 99 Internet: www.brusa.biz Email: [email protected]

Technical data


5 Use and limits of the product

5.1 Proper use Taking into consideration the limits indicated in chapter 5.2 Improper use / Limits of the product, the product BDC546 has been designed for the following applications:

Installation in a drive train for hybrid vehicles (cars, utility vehicles, buses) Installation in a drive train for electric vehicles (cars, utility vehicles, buses) Installation in a drive train for fuel cell vehicles (cars, utility vehicles, buses) On-board charger for DC quick charging (in combination with a stationary transformer) Installation in a drive train for electric boats Test bench applications

If the device is to be used for applications in areas other than those previously defined, the buyer is obliged to coordinate these applications with the manufacturer and to obtain a written approval for these uses.

5.2 Improper use / Limits of the product Applications that do not conform to the conditions and requirements stated in the technical documents and data sheets of the manufacturer are regarded as improper use. Taking into consideration the proper use indicated in chapter 5.1 , the following limit values have been stipulated for the operation of the product BDC546. The product may not be used outside these limit values. Operation outside these limit values can lead to life-threatening situations.

BDC546-B UNIT Highside overvoltage, the switch-off threshold of the power stage can be set up to 800 VDC

Lowside overvoltage, the switch-off threshold of the power stage can be set up to 650 VDC

Max. voltage on highside, no operation, max. 1 min 900 VDC

Max. voltage on highside, no operation, max. 1 min 900 VDC

Max. voltage for signals at the control connector (AUX) 16 VDC

Max. pre charging current on lowside / highside 50 A

Min. coolant temperature at the input -40 °C

Max. coolant temperature at the input 65 °C

Cooling water flow rate max. 17 l/min

Cooling water flow rate min. 15 l/min

Ambient temperature range for storage -40 to +105 °C

Ambient temperature range in operation -40 to +85 °C

Max. cooling system pressure 2.0 bar

21


6 About this device

6.1 Technical data

HIGHSIDE BDC546-B UNIT Min. operating voltage (full performance, highside must not be below lowside) 150 VDC

Max. operating voltage (full performance) 750 VDC

Overvoltage, the switch-off threshold of the power stage can be set up to 800 VDC

Max. voltage, no operation, max. 1 min 900 VDC

LOWSIDE BDC546-B UNIT

Min. starting voltage 0 VDC

Min. operating voltage (full performance) 50 VDC

Max. operating voltage (full performance) 600 VDC

Overvoltage, switch-off threshold of the power stage (default value) 650 VDC

Max. voltage, no operation, max. 1 min 900 VDC

POWER DATA BDC546-B UNIT

Lowside continuous current (at Tcoolant = 60 °C) 300 A

Lowside peak current 400 A

Highside peak current 350 A

Continuous output power in buck mode (at ULS = 600 V) 180 kW

Continuous output power in boost mode (at ULS = 600 V) 180 kW

Peak output line 220 kW

Switching frequency 41 kHz

DYNAMIC BEHAVIOUR BDC546-B UNIT

Highside voltage step response (in boost mode at UHS = 200 V, 400 V, ILS = 100 A, ULS = 150 V)

< 3 ms

Lowside voltage step response (in buck mode at ULS = 50 V, 300 V, ILS = -200 A, UHS = 500 V)

< 3 ms

Limiting frequency of the superordinate control 1 kHz

STANDBY MODE BDC546-B UNIT

Type. Current consumption at AUX (control connector) at UHV = 0 V, ULV = UAUX = 14 V, enable = low 0.731 mA

Type. Current consumption at AUX (control connector) at UHV = 0 V, ULV = UAUX = 14 V, enable = high 247.0 mA

GALVANIC ISOLATION BDC546-B UNIT

Voltage resistance between highside/lowside and control circuit (2 s test voltage) 3000 VDC

Technical data


CONTROL CIRCUIT BDC546-B UNIT Min. voltage for signals at the control connector (AUX / Kl.30) 9 VDC

Max. voltage for signals at the control connector (AUX / Kl.30) 16 VDC

Lowside voltage measuring range 0 to 828 VDC

Lowside voltage signal accuracy (1 V at < 100 V, 1 % of the measuring value at > 100 V) +/-1 V /%

Highside voltage measuring range 0 to 1020 VDC

Highside voltage signal accuracy (1 V at < 100 V, 1 % of the measuring value at > 100 V) +/-1 V /%

Lowside current measuring range +/-640 A

Lowside current signal accuracy (1 A at < 100 A, 1 % of the measuring value at > 100 A) +/-1 A /%

Highside current measuring range +/-409 A

Highside current signal accuracy (1 A at < 100 A, 1 % of the measuring value at > 100 A) +/-1 A /%

Min. required highside voltage for valid T, U and I measurements 150 VDC

THERMAL / COOLING SYSTEM BDC546-B UNIT

Coolant (water / glycol mixing ratio) 50 / 50 ---

Amount of coolant in device 1100 ml

Min. coolant temperature at the input -40 °C

Max. coolant temperature at the input 65 °C

Coolant pressure drop at 15 l / min, Tcoolant = 25 °C < 0.25 bar

Cooling water flow rate max. 17 l/min

Cooling water flow rate min. 15 l/min

Max. cooling system pressure 2.0 bar

Ambient temperature range for storage -40 to +105 °C

Ambient temperature range in operation -40 to +85 °C

EFFICIENCY BDC546-B UNIT

Efficiency (in buck mode at UHS = 600 V, ULS = 400 V, ILS = 300 A) 98.9 %

BASIC MECHANICAL DATA BDC546-B UNIT

Weight (without cooling water) 25.2 kg

Housing material AlMgSi1 ---

IP protection IP6K6 / IP6K7 ---

Housing volume 14.3 l

Length 640 mm

Width 280 mm

Height 80 mm

External diameter of cooling water connection ports 18.0 mm

Water-tight pressure compensation membrane integrated ---

23


6.2 Technical properties Half bridge converter with free-wheeling diode from the lowside to the highside Bi-directional function Common minus for highside and lowside Galvanic isolation between control circuit and HV circuit Full suitability for automotive applications High power density (6.4 kW/kg) Low ripple current due to high clock frequency Vibration-resistant construction for mobile usage High efficiency (up to 98.9 %) CAN interface integrated by default Tested according to ECE directives / Certified according to E13 Interlock function evaluation FGPA implemented, highly dynamic control circuit Patented Liquid Pin© cooling system SoftSwing® topology for minimum switching loss at above average EMC properties

6.3 BDC546 block diagram

Technical data


6.4 Basic function / EMC concept The BDC546 is a bi-directional DC/DC converter that is applied as connection between different HV voltage ranges in vehicles. Specifically, the component can be used as connection between HV batteries and battery systems with other voltage levels. It is also possible to use the BDC546 as coupling between a HV battery and power electronic devices like frequency inverters, on-board converters, etc. Ideally, the component is used as interface between fuel cell systems and HV batteries. These are only a few of the potential applications of the BDC546.

The BDC546 works with eight phases with phase-shifted clocking. Each phase corresponds to a boost/buck converter. For half bridge clocking, the patented switching strategy SoftSwing® is applied. It not only enables highly efficient operation of the component but also guarantees very low EMC emissions. Additionally, the low switching losses enable clocking at very high switching frequencies. In combination with the high number of phase-shifted, clocking half bridges, this makes it possible to achieve excellent ripple reduction.

6.4.1 Topology benefits

The switching processes in the phases of the BDC546 are realized by means of the resonant topology SoftSwing®. Power semiconductors are disconnected from the mains and de-energised. During deactivation, the choke current is taken up by the commutation capacities that enable slow “zero current switching”. Thanks to this process, very low switching losses can be achieved. On the other hand, the EMC interferences caused by transient processes are considerably reduced due to the slow changes during the switching processes in comparison to hard-switching topologies.

25


6.4.2 Filter concept for highside and lowside

The three HV chokes are principally designed as common-mode chokes (Lh). However, they also help to filter the push-pull interferences by means of the existing leakage inductance (LS).

The wired Y capacitors (Cy5 to Cy10) and the common-mode choke (Lh) form the common-mode filter. The X capacitors (Cb1, Cb2, Cb3) and the leakage inductance of the HV chokes (LS) form the push-pull filter.

Due to the high clock frequencies, the capacitors may have very small dimensions. Thus, a rapid discharge of the intermediate circuit is possible.

Technical data


COMPONENT VALUE UNIT CHS1 1.0 µF

CLS1 1.0 µF

CY1 68.0 nF

CY2 68.0 nF

CY3 68.0 nF

CY4 68.0 nF

CY5 136.0 nF

CY6 136.0 nF

CY7 136.0 nF

CY8 204.0 nF

CY9 204.0 nF

CY10 204.0 nF

Cb1 80.0 µF

Cb2 120.0 µF

Cb3 80.0 µF

Lh 1.30 mH

Ls 500 nH

6.5 Warnings on the device Warning signs are installed on the device to warn the operator of possible dangers. Should one of these warning signs be missing or become illegible due to wear and tear, it is to be replaced immediately! In order to obtain an original label, please contact the BRUSA support at the manufacturer’s address provided in chapter 4.5 !

Das Bild kann zurzeit nicht angezeigt werden.

27


6.6 Vehicle installation basic principle

Technical data


6.7 Safety concept for vehicle installation

INFORMATION

This safety concept is a recommendation of BRUSA Elektronik AG and is a general requirement for the safe operation of electric vehicles!

6.7.1 General interlock function

The interlock switches (1) are closed if the respective interlock conditions of the individual devices are met (closed service cap, HV connections plugged-in...). The interlock evaluation system of the PDU switches the 12 V supply voltage (2) of the HV contactors (4) in the battery if the interlock circuit is closed. The emergency off switch (3) also disconnects the 12 V supply voltage of the HV contactors (4). The second interlock switch (5) of the insulation monitoring unit disconnects the interlock circuit if an error is detected at the HV insulation.

29


6.8 Interlock signal

The interlock signal is to be guided through all HV-carrying connectors in a HV system. The signal of the BDC546 can be evaluated via pin 19 of the control connector. A rectangular signal frequency of 86 Hz ≤ f ≤ 90 Hz is regarded by the component as permissible. The range of a valid duty cycle lies between 48 % and 52 %. The signal is to be generated from AUX/terminal30 (logic “HIGH”) and GND/terminal31 (logic “LOW”). An invalid signal sequence is regarded as error state and potential operation of the component is prevented by deactivation of the power stages. If it is required, this function can also be deactivated.

Technical data


6.9 Overview of the main structural components

1. Lowside cable fitting 2. Service cap 3. Housing cover 4. Housing 5. Water duct cover 6. Cooling water connections 7. Control connector 8. Grounding connection for grounding cable 9. Highside cable fitting

31


6.10 Dimensions and installation information For the installation of the device, the following points must be generally adhered to:

Despite the existing IP protection, the device should only be exposed to environmental influences to the extent required by the application.

The device may not be installed in the direct vicinity of heat sources (e.g. combustion motor). The mechanical fastening is to be aligned in such a way that the device is installed in a secured position and

with as few vibrations as possible. The cable inlets and cooling water ducts should have enough space and must never touch components with

sharp edges. All cable connections must be secured with strain relief elements near the device (not included in the scope

of delivery).

6.10.1 Fastening points

NOTICE

The housing has been designed for a maximum admissible fastening screw torque of 8 Nm! For fastening the device at the fastening points, eight M6 screws are to be used and tightened with a tightening torque of 8 Nm.

1. 8 screws with M6 thread, stud hole with 18 mm depth

Technical data


6.10.2 Dimensions

6.10.3 Installation position

Generally, no special installation position for the device is prescribed as the internal components are mounted in a vibration-resistant manner. However, the following installation positions are NOT advisable:

Connector side to the top: This causes the danger of a condensate accumulation on the connectors, which in turn increases the risk of corrosion.

Connector side to the bottom: The water cooling circuit of the device has a U shape, which would now be upside down. In such case, the ventilation of the cooling circuit is difficult, and the device may be cooled insufficiently.

33


6.11 Type plate

1. Classification 2. Serial number 3. Date of production 4. Product number (specified by the customer) 5. Supplier number (specified by the customer) 6. Highside voltage range for operation 7. Efficiency 8. Max. admissible cooling water temperature at the

input 9. Lowside voltage range for operation 10. Lowside peak current 11. Peak power 12. IP protection class

Technical data


7 Electrical interfaces

1. Control connector Chapter 7.1Control connector pin assignment (device side)(device side)

2. Grounding connection Chapter 7.2 Earthing / grounding screw (equipotential bonding)

3. Highside plus Chapter 7.3 Highside and lowside power connections

4. Highside minus Chapter 7.3 Highside and lowside power connections

5. Lowside plus Chapter 7.3 Highside and lowside power connections

6. Lowside minus Chapter 7.3 Highside and lowside power connections

35


7.1 Control connector pin assignment (device side)

INFORMATION

Information on the pins required and/or recommended for operation or necessary for programming can be found in chapter 8.1 Control connector

1. GND Signal ground

(Minus wiring system, terminal 31) 2. AUX +12 V

(Plus wiring system, terminal 30) 3. NC Not connected 4. NC Not connected 5. NC Not connected 6. TXD RS232 Transmit (9 pole D-Sub: pin 2) 7. RXD RS232 Receive (9 pole D-Sub: pin 3) 8. P_GND RS232 ground (9 pole D-Sub: pin 5) 9. CNL CAN low 10. CNH CAN high 11. PFO_VC+ Pyrofuse output VC+ (+12 V) 12. PFI_VC+ Pyrofuse input VC+ (open drain) 13. PRO Enable firmware download 14. PFO_VC- Pyrofuse output VC- (+12 V) 15. PFI_VC- Pyrofuse input VC- (open drain) 16. EN Enable (power ON, terminal 15) 17. DO_MC Digital main contactor output 18. NC Not connected 19. IL HV interlock input 20. NC Not connected 21. NC Not connected 22. NC Not connected 23. NC Not connected

Technical data


7.1.1 Pin 1 GND

INFORMATION

If control signals of the device are connected with other vehicle components, the vehicle's ground is to be connected at this pin.

Internal wiring

Direct connection to the ground of the control unit. The signal earth is only capacitively connected to the housing. When wiring BDC546 control signals with other vehicle components (e.g. traction drive, vehicle battery,

battery management (BMS), fuel cell), the vehicle ground is to be connected here.

37


7.1.2 Pin 2 AUX

Internal wiring

If there is no voltage at the highside, the supply to the switching components that are responsible for the

voltages generated inside the device of 3.3 V and 5 V (µC, FPGA, …) is ensured via Pin 2 AUX. Then, it is possible to communicate with the device by means of pin 16 EN = high, via CAN or RS232. For a highside voltage of 150V or higher, the internal 15 V supply is activated and takes over the supply. This relieves the wiring system. The pins 11 PFO_VC+ and 14 PFO_VC- are always supplied via pin 2 AUX. The following functions are ensured in the case of exclusive supply from the wiring system (control connector):

CAN communication (sending and receiving)

Communication via RS232 (monitoring)

Microprocessor programming (firmware)

Pyrofuse control

Main contactor control

Voltage Pin 2 AUX (V)

Pin 16 EN (terminal 15)

RUN command (sent via CAN)

HV voltage (V) Type. Current draw at Pin 2 AUX (mA)

12.0 0 0 0 0.641 14.0 0 0 0 0.731 12.0 1 0 0 272.3 14.0 1 0 0 247.0

Technical data


7.1.3 Pin 6 TXD, pin 7 RXD, pin 8 P_GND

INFORMATION

This RS232 interface is exclusively designed for firmware updates, monitoring or adjustments of CAN parameters.

The RS232 interface enables a direct serial connection between the device and a PC. For test benches or prototype vehicles in particular, this connection is highly recommended to be able to execute a firmware update if required!

Should you have any questions regarding this subject, please refer to the BRUSA support at the manufacturer's address provided in chapter 4.5.

Internal wiring

For wiring of the RS232 ground, an additional grounding connection P_GND is provided. It is connected with

the GND supply ground via one PTC fuse. The microprocessor firmware can be downloaded via this interface (provided by BRUSA). Pin 13 PRO must

be high for this.

Pin assignment of the 9 pole D-Sub cable bushing

39


7.1.4 pin 9 CNL, pin 10 CNH

Internal wiring

CAN 2.0 B (baud rate can be set, e.g. 250 k, 500 k, 1 Mbit) Termination of the CAN interface is not intended in the DC/DC converter (CAN terminating resistor) Via the CAN interface, messages can be transmitted in accordance with the CAN matrix provided by BRUSA

as dbc file. The following parameters of the CAN messages can be modified via the PARAM software:

Identifier

Baud rate

Bit timing

Technical data


7.1.5 Pin 11 PFO_VC+, pin 12 PFI_VC+, pin 14 PFO_VC-, pin 15 PFI_VC-

INFORMATION

If pyrofuses are applied, this function can be activated by means of the PARAM software. For further information on the function and wiring of pyrofuses, refer to chapter 3.4.2 Pyrofuses.

Internal wiring

Pyrofuses can be connected directly to these pins. If an overvoltage is detected, the pyrofuses are triggered. The pins 11 PFO_VC+ and 14 PFO_VC- are internally always connected to pin 2 AUX via a fuse. The pins 12 PFI_VC+ and 15 PFI_VC- are open drain connections. If an overvoltage is detected, the two pins

are drawn to GND and the pyrofuses are triggered. If no pyrofuses are applied, the respective function can be deactivated by means of the PARAM software. The

pins 11, 12, 14 and 15 do not need to be connected in this case.

41


7.1.6 Pin 13 PRO

NOTICE

Programming an incorrect firmware may damage the device! Therefore, programming may only be carried out after consultation with BRUSA Elektronik AG!

INFORMATION

This pin is only activated for programming of a new firmware (pin 13 PRO = high). For this purpose, pin 16 EN does not need to be high.

Internal wiring

It is highly recommended to disconnect the device from the HV supply prior to programming!

The device has to be supplied via the AUX wiring system and pin 13 PRO = high (7-16 V) when it is set to programming mode. Afterwards, programming can be carried out via the serial interface.

Technical data


7.1.7 Pin 16 EN

INFORMATION

The admissible voltage range for pin 3 EN = high is 7 – 16 V. For a pin 16 EN = low, a voltage of < 1 V is required.

Internal wiring

To programme a new firmware, pin 13 must be PRO = high. For this purpose, pin 16 EN = high is not necessary.

If voltage is applied at pin 2 AUX and if pin 16 is EN = high, the device is put into the operational mode. Most appropriately, this is implemented by connecting pin 16 EN to the Plus wiring system via a switch.

43


7.1.8 Pin 17 DO_MC

Internal wiring

Pin 17 DO_MC is a digital output switching between signal ground GND and wiring system Plus AUX and designed for a peak current of 4 A for 120 ms and 200 mA continuous current.

This way, two main contactors between the HV battery and the BDC546 can be directly controller.

Technical data


7.1.9 Pin 19 IL

INFORMATION

For details on the required signal form for interlock detection, refer to chapter 6.8 Interlock signal.

Internal wiring

Via pin 19 IL, the signal of an external interlock loop can be recorded and evaluated. As the BDC546 itself is

not part of the loop, it cannot be disconnected by the interlock loop. However, it can detect errors that are caused by external devices in the interlock loop.

In case of an invalid signal sequence or missing interlock signal, the signal Interlock_In* is set and the error DC_Err_Interlock is returned via CAN.

Detection of the interlock error leads to an immediate shut down of the device. If no interlock monitoring system is applied, the respective function can be deactivated by means of the

PARAM software. In this case, pins 19 IL does not need to be connected.

45


7.2 Earthing / grounding screw (equipotential bonding)

WARNING

Sparking! Fire hazard! Ensure that the grounding circuit is connected correctly! A loose grounding circuit can lead to sparking and subsequent fires!

1. M10 x 16mm grounding screw 2. M10 washer The grounding screw (1) must be connected with the ground of the vehicle and/or test bench. A washer (2) is to be positioned between the grounding screw (1) and the cable lug. Grounding screw (1) torque = 28 Nm

Technical data


7.3 Highside and lowside power connections

DANGER

High voltage! Danger of death! Before starting the installation, ensure that the device and power cables are de-energised. The service cap may only be opened if the device has been de-energised.

NOTICE

Ensure proper connection of the highside and lowside! Observe the polarity!

INFORMATION

Before crimping the cable lugs to the power cables, the cable fittings have to be guided over the power cables. Do not install the cable fittings at the device housing yet

1. Highside cable fittings 2. Lowside cable fittings 3. Highside plus screw 4. Highside minus screw 5. Lowside plus screw 6. Lowside minus screw

47


The pre-assembled screws for the cable lugs of the power connections can be found under the service cap.

Required highside cable cross section: 70 mm² Required lowside cable cross section: 95 mm² Tightening torque of the screws for the cable lugs (3, 4, 5, 6): 13 Nm Mount the cable fittings (1, 2) at the housing

Lowside tightening torque: M32 x 1.5 with 45 Nm Highside tightening torque: M25 x 1.5 with 35 Nm

Use the union nut to mount the cables in the cable fitting. For the tightening torque, refer to the cable specifications.

Technical data


8 Connections

8.1 Control connector

NOTICE

The control connector has been designed for a maximum number of 10 cycles of connector operation! The manufacturer guarantees the full functioning (conductance, tightness) up to this quantity.

For a professional mounting of the AMPSEAL contacts SN/LP, we recommend the usage of the following crimping tool: Tyco 58440-1

INFORMATION

Control connectors included in the scope of delivery are to be converted in accordance with the respective requirements (EMC, environmental impacts etc.). Here, only the actually used pins are to be wired (mandatory* or highly recommended**). Pin 16 EN is to be connected to pin 2 AUX via a switch (e.g.: in the vehicle by means of the ignition key with the Plus wiring system).

1. GND * Signal ground

(Minus wiring system, terminal 31) 2. AUX * +12 V

(Plus wiring system, terminal 30) 3. NC 4. NC 5. NC 6. TXD ** RS232 Transmit (9 pole D-Sub: pin 2) 7. RXD ** RS232 Receive (9 pole D-Sub: pin 3) 8. P_GND

** RS232 ground (9 pole D-Sub: pin 5)

9. CNL * CAN low 10. CNH * CAN high 11. PFO_VC+ 12. PFI_VC+ 13. PRO ** Enable firmware download 14. PFO_VC- 15. PFI_VC- 16. EN * Enable (power ON, terminal 15) 17. DO_MC 18. NC 19. IL ** HV interlock input 20. NC 21. NC 22. NC 23. NC

49


8.2 Highside cable

DANGER

High voltage! Danger of death! Before starting the manufacturing process, ensure that the power cables are de-energised.

NOTICE

To assemble the cable lugs, an appropriate crimping tool must be used! We recommend the following crimping tool: Klauke ultra EK 120 UNV-L

INFORMATION

The cable lugs included in the scope of delivery are to be assembled with cables in accordance with the following specifications. On request, this process may also be carried out by BRUSA. For installation of a shielded cable with connection to the shielding braid, refer to chapter 9.2 Building the HV wiring In case of longer cable lengths then 1.5 m consult the manufacturer BRUSA. Chapter 4.5 Manufacturer contact information.

1. M25 cable fittings (HS) 2. Cable lug, flat (HS), 70 mm² In order to guarantee reliable operation of all controllers - in particular of the HV voltage controller in boost mode - the following instructions are to be strictly adhered to:

Required cable cross section: 70 mm² Max. cable length between device and connected load/source = 1.5 m Guide the cable fitting (1) over the power cable. Square crimping of the cable lug (2). Each prepared cable has to be checked for proper fitting of the cable lug and if for proper fastening of the

crimping (pull test). When installing the cables (Highside plus and minus) in the vehicle, ensure that the spanned area remains as

small as possible and that no sensitive control signals are implemented in between.

Technical data


8.3 Lowside cable

DANGER

High voltage! Danger of death! Before starting the manufacturing process, ensure that the power cables are de-energised.

NOTICE


INFORMATION

The cable lugs included in the scope of delivery are to be assembled with cables in accordance with the following specifications. On request, this process may also be carried out by BRUSA. For installation of a shielded cable with connection to the shielding braid, refer to chapter 9.2 Building the HV wiring In case of longer cable lengths than 1.5 m consult the manufacturer BRUSA. Chapter 4.5 Manufacturer contact information.

1. M32 cable fittings (LS) 2. Cable lug, flat (LS), 95 mm² Required cable cross section: 95 mm² Max. cable length between device and connected load/source = 1.5 m Guide the cable fitting (1) over the power cable. Square crimping of the cable lug (2). Each prepared cable has to be checked for proper fitting of the cable lug and if for proper fastening of the

crimping (pull test). When installing the cables (Lowside plus and minus) in the vehicle, ensure that the spanned area remains as

small as possible and that no sensitive control signals are implemented in between.

51


8.4 Cooling water connections

NOTICE

When connecting the cooling system, ensure that the cooling water inlet and outlet are connected correctly. Swapping the connections leads to malfunctions in the cooling systems and respectively to overheating of the device.

1. Cooling water inlet connection (18 mm external Ø) 2. Cooling water outlet connection (18 mm external Ø)

The cooling water hoses (18 mm internal hose diameter) are to be implemented in accordance with the cooling water connection pieces (1, 2) in order to guarantee a water tight connection.

Ensure that the cooling water hoses are properly mounted on the connection pieces in order to avoid leaks. Fitting is realized with hose clamps.

Technical data


9 Installation / initial start-up

9.1 Installation and connection of the DC/DC converter

DANGER

High voltage! Danger of death! Never touch the HV wires or HV connections without ensuring the absence of voltage

beforehand! The device may only be connected by a qualified electrician! Safety installations must never be bypassed or circumvented! Any resulting malfunctions could

have life threatening consequences!

NOTICE

All electrical connections near the device have to be secured with a strain relief in order to protect the cable and/or the cable tree at the control connector against vibration and consequential damage.

Ensure that the HV battery used is equipped with a pre-charging unit. Any connection without pre-charging unit may lead to sparks / voltage peaks and damage to the device!

INFORMATION

Prior to installation, visually check the packing material and particularly the device itself for damage. Each device undergoes a strict quality and function test at BRUSA before distribution. However, we do not have any influence on the shipping routes, some lengthy, or loading of our products.

PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 1. Mechanically install the device in its specified

position.

Please refer to the installation instructions Refer to chapter 6.10 Dimensions and installation information

---

2. Establish the grounding connection (1) to the chassis.

For information on the grounding connection, refer to chapter 7.2 Earthing / grounding screw (equipotential bonding)

The cable length should be as short as possible.

53


PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 3. Remove the 9 countersunk screws (1) at the service

cap (2) and open it.

To remove the screws, a 2.5 mm hexagon socket screwdriver is required.

As long as the service cap is open, ensure that the device is not contaminated by foreign material or water.

4. Establish the highside / lowside connection. The

cable fittings are not yet permanently installed; however, they are already over the power cables.

For information on assembling the power cables, refer to chapter 9.2 Building the HV wiring

Ensure proper connection of lowside minus (1) / lowside plus (2) and highside minus (3) / highside plus (4). Observe the polarity. Refer to chapter 7.3 Highside and lowside power connections

5. Mount the cable fittings at the housing.

For the tightening torques of the connections (1, 2, 3), refer to chapter 7.3 Highside and lowside power connections

Use the union nut to mount the cables in the cable fittings (3).

6. Close the service cap (2). Attach the cap with the

countersunk screws (1).

Tightening torque: 3 Nm

Technical data


PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 7. Connect the control connector (1) to the device.

Manually check if the control connector (1) is secure!

Always ensure suitable mounting of the required strain relief elements!

8. Connect the cooling water hoses.

Refer to chapter 8.4 Cooling water connections

Always check for correct connection of the cooling water inlet (1) and cooling water outlet (2)!

9. Manually check that all cable and hose connections

are tightly secured.

All cable connections near the device must be secured with a strain relief in order to protect the cable against vibration and consequential damage.

---

10. Ventilate the cooling system.

Ensure that no air is trapped in the cooling system!

Refer to chapter 9.3 Ventilating the cooling system

---

11. Ensure that the converter is connected to the power source via a suitable pre-charging unit.

Refer to chapter 9.4 Voltage pre-charging

Any connection without pre-charging contactor may lead to voltage peaks and damage to the charger!

---

INFORMATION

The device is now completely installed and can be commissioned. The device can be set by means of customer-specific CAN tools or using the BRUSA-specific PARAM software. This software is ideally suited for the device and can be purchased optionally. For further information, please contact the manufacturer under the address provided in chapter 4.5 Manufacturer contact information.

55


9.2 Building the HV wiring The building of the HV wiring must be carried out in accordance with the following instructions. Here, it is important that no strands are damaged and that none stick out at the sides on the assembled cable. Check that the screw connections are correct for each completed cable and that the cable lug is secured properly (pull test).

For the HV connections, the following is recommended:

Shielded, insulated automotive cable (e.g. by Huber & Suhner). A cable lug, refer to chapter 4.3 Scope of delivery To assemble the cable lugs, an appropriate crimping tool must be used!

NOTICE

Ensure that no individual strands of the braid (step 4) are protruding! Once installed, this will damage the sealing lip and subsequently cause an ingress of water into the housing! For this reason, all protruding strands have to be shortened to the admissible length!

PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION

1. Strip the HV cable coating (1) to a length of 60 mm.

Ensure that the shielding braid (2) underneath is not damaged!

2. Shorten the shielding braid (1) by 50 mm.

The shielding braid (1) on the cable side requires a length of approx. 10 mm.

Technical data


PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 3. For the high side cables (70 mm² cross section),

strip the internal insulation of the HV cable (1) to a length of 20 mm. For the lowside (95 mm² cross section), 22 mm are required.

Ensure that the copper strands (2) underneath are not damaged!

4. Guide the pressure screw (1) and the sealing insert

(2) over the HV cable (3). Guide the cone of the grounding insert under the shielding braid (4).

5. Slide the connection thread (1) over the HV cable (2)

up to the cone of the grounding insert.

57


PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 6. Assemble the cable lug (1) at the end of the cable.

No strands may protrude at the sides!


7. Manually check the tight fit of the cable lug. --- 8. Attach a shrinking tube (1) over the cable lug (2).

The shrinking tube (1) must be attached to prevent contact with the housing after installation.

Technical data


9.3 Ventilating the cooling system

NOTICE

Trapped air in the cooling duct along with generally insufficient cooling of the device will lead to overheating of the device and increased wear and tear! Ensure that no air is trapped in the cooling system! The ventilation may also be carried out by means of pressure or vacuum filling. Ensure that the admissible maximum system pressure is not exceeded. Ensure that the cooling circuit is fault-free!

PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 1. Check the cooling water connections on the device

for water tightness and proper fit. Always check for correct connection of the cooling water inlet (1) and cooling water outlet (2)!

2. Switch on the cooling circuit. --- 3. Leave the cooling circuit turned on for around 30 s. --- 4. Switch off the cooling circuit. ---

59


9.4 Voltage pre-charging

NOTICE

In order to avoid the formation of sparks as well as damage to the device during activation, the connected consumer loads must always be pre-charged via a pre-charging resistor.

When using a PTC as pre-charging resistor, it is heated by means of multiple subsequent pre-charging processes. If the PTC overheats, another pre-charging process is temporarily impossible. In this case, the pre-charging resistor has to be cooled down for a certain period of time.

If the system is only connected to one power source at the highside, the pre-charging unit on the highside is sufficient.

Technical data


The functional routine of the pre-charging unit is as follows:

1. The pre-charging contactor (1) closes.

Ensure that the pre-charging contactor (1) as well as the pre-charging resistor RP (4) are designed for the maximum pre-charging current. Please note that the pre-charging contactor (1) must be able to interrupt the pre-charging current in case of an error!

2. The main contactor - (3) closes.

Monitor the pre-charging time and open the pre-charging contactor (1) again if the voltage of the power source is not achieved at the converter after a specific maximum time.

3. The main contactor + (2) closes.

The main contactor (2) may only close if the converter is successfully pre-charged to the voltage of the power source.

4. The pre-charging contactor (1) opens.

The HV connection to the device is now established.

61


10 Parameterization and operation

10.1 Parameterization by means of PARAM tool

INFORMATION

For further information on the PARAM tool, refer to PARAM_Manual_Installation_Usage.pdf For customer support with regard to the PARAM tool, a support package has to be ordered at BRUSA Elektronik AG. Support in connection with the PARAM tool is only to be requested after purchasing this support package. (chapter 4.5 Manufacturer contact information).

10.1.1 PARAM application

The PARAM software provided by BRUSA is used for parameterization and configuration of BRUSA devices. PARAM provides access to the various parameters and functions of the BDC546 via CAN interface. This provides the possibility of individually adjusting parameters (e.g. activation of interlock signal evaluation or overvoltage shut-down functions at a specific voltage).

Parameters and functions or their addresses may deviate for various software versions. For this reason, it is crucial to always use the latest firmware XML file!

With the password monitor, the customer can log into PARAM or the BDC546. Changes can be applied to the non-volatile memory of the BDC546 by pressing Update & Reset Target.

PARAM

Technical data


10.1.2 Installation and operation of the PARAM software

The PC software folder of the customer package includes the software PARAM_2.0.zip. For the PARAM_Manual_Installation_Usage manual, refer to Manuals. This manual describes the installation of the required PCAN-USB OEM and PEAK drivers as well as of the PARAM tool. Additionally, the user interface and the operating functions of the PARAM tool are generally described.

INFORMATION

All CAN applications are based on the CAN hardware of PEAK System (www.peak-system.com). For CAN communication, it is recommended to use the visually separated USB adapter with suitable 120 OHM terminating resistor: IPEH-002022 (PCAN USB adapter) IPEK-003003 (PCAN terminating resistor)

http://www.peak-system.com/

63


10.2 Parameters

10.2.1 Parameter representation

Name: Name of the individual parameters

Meaning: Description regarding the parameter

DATA TYPE DATA TYPE MINIMUM VALUE MAXIMUM VALUE INT_DEZ 4 Byte / 32 Bit -2147483648 2.147.483.647

UINT_DEZ 4 Byte / 32 Bit 0 4294967295 UINT_HEX 4 Byte / 32 Bit 0x0000`0000 0xFFFF`FFFF

FLOAT 4 Byte / 32 Bit -3.4028235E+38 3.4028235E+38 CONV_FLOAT 4 Byte / 32 Bit -3.4028235E+38 3.4028235E+38

Default value: Default value for parameters prior to initial start-up, factory settings.

Unit: The physical unit.

R/W user. Read and write permissions for the values “R” - Values can be read “R/W” - Values can be read and written

Technical data


10.2.2 Parameter groups

NUMBER PARAMETER GROUP DESCRIPTION 01 CAN configuration - CRC In this category, the CAN Ids for the various messages required for

communication between the device and superordinate control systems are defined (e.g.: vehicle control unit, CVI, PARAM, etc.) The messages are separated into messages that are sent by the control system to the device and messages that are returned by the device to the system.

02 Device configuration - CRC These parameters are used to calibrate the device. This way, the voltage and current values of the device as well as the efficiency are optimally coordinated. These parameters are set by BRUSA and cannot be changed by the customer. In this category, users can define the thresholds of the limiting voltage and current controller. Respectively, the same limits can be set via CAN as well as via PARAM. The controller prefers always the value that is set “closer”, i.e. applies first.

03 FPGA ULS controller configuration - CRC

Configuration by BRUSA, content not relevant for the customer

04 FPGA UHS controller configuration - CRC

05 FPGA IHS controller configuration - CRC


06 FPGA ILS controller configuration - CRC


07 FPGA HR NVM data - CRC Configuration by BRUSA, content not relevant for the customer 08 FPGA BR NVM data - CRC Configuration by BRUSA, content not relevant for the customer 09 FW gains, offset - CRC Configuration by BRUSA, content not relevant for the customer 0A FPGA gains, offsets and

settings - CRC Configuration by BRUSA, content not relevant for the customer

10 Digital IO Device-internal signals, content not relevant for the customer 11 Analogue input Device-internal signals, content not relevant for the customer 12 Analogue values calculated and

offsets Measuring values of analogue signals like the internal 15 V supply, redundant UHS/ULS measurements and resistor values of the pyrofuse.

13 PWM input Contains the measured frequency and the duty cycle of the active interlock signal.

20 Status Different bitmaps and states for BRUSA support. 21 FPGA error history Content not relevant for the customer 22 Temperatures In this category, the currently measured temperatures of the modules

and main chokes in the device are displayed. 23 Stored App Data In this category, the measured minimum and maximum temperatures

are listed. If required, the recorded extreme values can be deleted. 30 stInit Contains information on the used module versions, content not relevant

for the customer 31 General parameters In this category, the serial number as well as the operating hours of the

device are provided.

65


32 Revision information Here, the original version of the device and potential actions during manufacturing are documented. This way, any device modifications can be traced.

33 Event log Content not relevant for the customer 40 FPGA: General functions Configuration by BRUSA, content not relevant for the customer 41 FPGA: Choke current

measuring value block Configuration by BRUSA, content not relevant for the customer

42 FPGA: Voltage and IB measuring value block


43 FPGA: Filter block Configuration by BRUSA, content not relevant for the customer 44 FPGA: PWM and PI current

controller Configuration by BRUSA, content not relevant for the customer

45 FPGA: Main controller block Configuration by BRUSA, content not relevant for the customer 46 FPGA: Debug control block Configuration by BRUSA, content not relevant for the customer 47 FPGA: SoftSwing functions Configuration by BRUSA, content not relevant for the customer 48 FPGA: Scratch Pad Configuration by BRUSA, content not relevant for the customer

Technical data


10.2.3 [01] CAN Configuration - CRC

NAME BEZEICHNUNG / EINHEIT / DEFAULTWERT DATENTYP R/W

CAN1 Baudrate

Damit kann die Baudrate für die CAN-Kommunikation mit dem Gerät eingestellt werden [kBit/sec] FLOAT RW

CAN1 Sampling point

Damit kann der gewünschte Abtastpunkt für die CAN-Kommunikation mit dem Gerät eingestellt werden [%] FLOAT RW

CAN2 Baudrate kBit/sec FLOAT RW CAN2 Sampling point % FLOAT RW CAN Msg Send1 ID Default 0x10 (0x00 = deaktiviert) UINT_HEX RW CAN Msg Send1 Rate Default 10ms UINT_DEZ RW CAN Msg Send2 ID Default 0x11 (0x00 = deaktiviert) UINT_HEX RW CAN Msg Send2 Rate Default 200ms UINT_DEZ RW CAN Msg Send3 ID Default 0x12 (0x00 = deaktiviert) UINT_HEX RW CAN Msg Send3 Rate Default 200ms UINT_DEZ RW CAN Msg Recv1 ID Default 0x01 (0x00 = deaktiviert) UINT_HEX RW CAN Msg Recv1 Timeout Default 100ms (10 x SendTime) UINT_DEZ RW CAN Msg Recv2 ID Default 0x02 (0x00 = deaktiviert) UINT_HEX RW CAN Msg Recv2 Timeout Default 100ms (10 x SendTime) UINT_DEZ RW CAN Msg Recv3 ID Default 0x03 (0x00 = deaktiviert) UINT_HEX RW CAN Msg Recv3 Timeout Default 100ms (10 x SendTime) UINT_DEZ RW DBG COM Master ID Default 0x6C2 UINT_HEX RW DBG COM Slave ID Default 0x6C3 UINT_HEX RW DBG_CAN_EnableMask Defines which Dbg Msgs will be sent (hex value). UINT_HEX RW DBG_CAN_Rate Interval of the Dbg Msgs in [ms]. UINT_DEZ RW DBG_CAN_Base ID Base ID for DbgCAN-Messages UINT_HEX RW

DBG_CAN_EnableSlowMask Defines which Dbg Msgs will be sent slow (hex value). UINT_HEX RW

67


10.2.4 [02] Device Configuration – CRC


FPGA HR Device Configuration

Die Konfiguration vom Hauptregler kann nur von BRUSA eingestellt werden. 1= ILS; 2=ULS; 3=UHS; 4=IHS UINT_DEZ R

Interlock Disable Mit einem Wert >0 wird der Interlock nicht mehr ausgewertet. UINT_HEX RW

MainContactor Output Configuration Einstellung vom digitalen Ausgang für Relais: 0 = Aus; 1 = wie Pyrofuse; 2 = Digital Out (CAN) UINT_HEX RW

Highside OV Value Spannungswert für die kundenspezifische HS Überspannungsbegrenzung in V CONV_FLOAT RW

Highside OV Activation 1 = Überspannungsbegrenzung HS aktiviert (nur Begrenzung und Warnung) UINT_HEX RW

Highside OV Error 1 = Bei Überspannung HS wird Fehler ausgelöst UINT_HEX RW

Lowside OV Value Spannungswert für die kundenspezifische LS Überspannungsbegrenzung in V CONV_FLOAT RW

Lowside OV Activation 1 = Überspannungsbegrenzung LS aktiviert (nur Begrenzung und Warnung) UINT_HEX RW

Lowside OV Error 1 = Bei Überspannung LS wird Fehler ausgelöst UINT_HEX RW

Kl.15 Shutdown Activation

0 = Solange CAN Kommunikation vorhanden bleibt das Gerät auch bei Low-Pegel von Klemme 15 aktiviert 1 = Bei Low-Pegel von Klemme 15 schaltet das Gerät immer komplett ab UINT_HEX RW

Pyrofuse Configuration 0:Aus; 1:Überwacht ULS; 2: Überwacht UHS UINT_HEX RW Pyrofuse Voltage Auslösespannung Pyrofuse in V CONV_FLOAT RW HR Sollwert Steuerung 0x00=direkt; 0x01=Rampe; 0x02: Filter UINT_HEX RW HR Sollwert Rampe Steilheit in [A/V] pro Sek. (Minimum = 32) CONV_FLOAT RW

Derating Start Temp HLs Bei dieser Drossel-Temperatur startet das Derating CONV_FLOAT R

Derating End Temp HLs Bei dieser Drossel-Temperatur ist das Derating voll aktiv (I = 0A). CONV_FLOAT R

Derating Error Temp HLs Um diesen Wert startet das Derating früher, wenn ein Sensor defekt ist. CONV_FLOAT R

Derating Value HLs Steilheit des Derating in A/°C CONV_FLOAT R Derating Start Temp Module Bei dieser Modul-Temperatur startet das Derating CONV_FLOAT R

Derating End Temp Module Bei dieser Modul-Temperatur ist das Derating voll aktiv (I = 0A). CONV_FLOAT R

Derating Error Temp Module Um diesen Wert startet das Derating früher, wenn ein Sensor defekt ist. CONV_FLOAT R

Derating Value Module Steilheit des Derating in A/°C CONV_FLOAT R FPGA Sollwert Rampen Configuration 1 = Rampe aktiviert UINT_HEX R Hauptregler Selection FW HR selection UINT_HEX R FPGA PARAM Configuration 1= only PARAM can Change FPGA Values UINT_HEX R

Technical data


10.2.5 [09] FW Gains, Offset – CRC

Kapitel nicht Kundenrelevant

NAME BEZEICHNUNG / EINHEIT / DEFAULTWERT DATENTYP R/W IL Gain 1/8192Lsb per bit INT_DEZ R UHS Red Gain Default = 4.88218 (Skalierung der HW in mV/V) FLOAT R UHS Red Offset V FLOAT R ULS Red Gain Default = 4.88218 (Skalierung der HW in mV/V) FLOAT R ULS Red Offset V FLOAT R U15V Gain Default = 232.6 (Skalierung der HW in mV/V) FLOAT R U15V Offset V FLOAT R Pyro VC + Gain Default = 425 (Skalierung der HW in mV/Ohm) FLOAT R Pyro VC + Offset Ohm FLOAT R Pyro VC - Gain Default = 425 (Skalierung der HW in mV/Ohm) FLOAT R Pyro VC - Offset Ohm FLOAT R

10.2.6 [0A] FPGA Gains, Offsets and Settings – CRC


NAME BEZEICHNUNG / EINHEIT / DEFAULTWERT DATENTYP R/W IL Gain 1/8192Lsb per bit INT_DEZ R Automatischer Offsetabgleich starten 1 => Start UINT_DEZ R IL Offset 0 A FLOAT R IL Offset 1 A FLOAT R IL Offset 2 A FLOAT R IL Offset 3 A FLOAT R IL Offset 4 A FLOAT R IL Offset 5 A FLOAT R IL Offset 6 A FLOAT R IL Offset 7 A FLOAT R Ub Gain 1/2048Lsb per bit INT_DEZ R Ub Offset 1/1Lsb per bit INT_DEZ R Ua Gain 1/2048Lsb per bit INT_DEZ R Ua Offset 1/1Lsb per bit INT_DEZ R U15V Gain 1/2048Lsb per bit INT_DEZ R U15V Offset 1/1Lsb per bit INT_DEZ R Ib Gain 1/2048Lsb per bit INT_DEZ R Ib Offset A FLOAT R SS Delay OU 0 INT_DEZ R SS Com Time 0 INT_DEZ R SS Max Demag Delay 0 INT_DEZ R

69


NAME BEZEICHNUNG / EINHEIT / DEFAULTWERT DATENTYP R/W SS OWN HZ Min Time 0 INT_DEZ R SS OPP HZ Min Time 0 INT_DEZ R SS OPP HZ Time Out 0 INT_DEZ R IL Max A CONV_FLOAT R Ua Max V CONV_FLOAT R Ub Max V CONV_FLOAT R U15V Max V CONV_FLOAT R Ib Max A CONV_FLOAT R PWM VProp 0 INT_DEZ R PWM VInte 0 INT_DEZ R PWM Channel Enabel 0 UINT_HEX R IL Gain 1/8192Lsb per bit INT_DEZ R

10.2.7 [10] Digital IO


NAME BEZEICHNUNG / EINHEIT / DEFAULTWERT DATENTYP R/W User-Enable = ein 1/0 (PE0,Pin 25 SHC) UINT_DEZ R Hauptschütz schließen 1/0 (PE7,Pin 26 SHC) UINT_DEZ R Enable Power Supply 1/0 (PE8,Pin 27 SHC) UINT_DEZ R HV Supply abschalten 1/0 (PE9,Pin 28 SHC) UINT_DEZ R Beide Pyrofuse zünden 1/0 (PE11,Pin 29 SHC) UINT_DEZ R SH_ENA_POWERSTAGE 1/0 (PB5) UINT_DEZ R

10.2.8 [11] Analog Input


NAME BEZEICHNUNG / EINHEIT / DEFAULTWERT DATENTYP R/W Spannung low side 0 ... 5V (ADC0, Pin96 SHC) FLOAT R Spannung high side 0 ... 5V (ADC1, Pin95 SHC) FLOAT R Temp. der Hauptdrossel A 0 ... 5V (ADC3, Pin93 SHC) FLOAT R Temp. der Hauptdrossel B 0 ... 5V (ADC4, Pin92 SHC) FLOAT R Temp. der Hauptdrossel C 0 ... 5V (ADC5, Pin91SHC) FLOAT R Temp. der Hauptdrossel D 0 ... 5V (ADC6, Pin90 SHC) FLOAT R Messwert Pyrofuse + 0 ... 5V (ADC8, Pin88 SHC) FLOAT R Messwert Pyrofuse - 0 ... 5V (ADC9, Pin87 SHC) FLOAT R Versorgung 3.3V 0 ... 5V (ADC13, Pin83 SHC) FLOAT R Versorgung 1.2V 0 ... 5V (ADC14, Pin82 SHC) FLOAT R Referenz 2.5V 0 ... 5V (ADC15, Pin81 SHC) FLOAT R

Technical data


10.2.9 [12] Analog Values calculated and Offsets


UHS Red Wert der redundanten UHS Spannungsmessung [V] FLOAT R

ULS Red Wert der redundanten ULS Spannungsmessung [V] FLOAT R

U15V Wert der internen Spannungsversorgung [V] FLOAT R Pyro VC + Widerstand +Pyrofuse [Ohm] CONV_FLOAT R Pyro VC - Widerstand -Pyrofuse [Ohm] CONV_FLOAT R

10.2.10 [13] PWM Input


Interlock DutyCycle Gemessener DutyCycle vom Interlock 0.0 ... 100.0% CONV_FLOAT R

Interlock Frequenz Gemessene Frequenz in Hz vom Interlock CONV_FLOAT R

10.2.11 [20] Status

NAME BEZEICHNUNG / EINHEIT / DEFAULTWERT DATENTYP R/W CAN1 MsgLostBitmap hex UINT_HEX R Feature Bitmap hex UINT_HEX R Error Bitmap hex UINT_HEX R Temp Error Bitmap hex UINT_HEX R Warning Bitmap hex UINT_HEX R

IntStat hex (gespeicherter Wert beim Auftreten des Fehlers) UINT_HEX R

IntHist hex (gespeicherter Wert beim Auftreten des Fehlers) UINT_HEX R

lFpgaIsrTick dez INT_DEZ R BDC State dez UINT_DEZ R BDC Supply State dez (State der Supply Statemachine) UINT_DEZ R Supply 3.3V 0 FLOAT R Supply 1.2V 0 FLOAT R Ref 2.5V 0 FLOAT R

71


10.2.12 [22] Temperatures

NAME BEZEICHNUNG / EINHEIT / DEFAULTWERT DATENTYP R/W TempErrorBitmap 0 FLOAT R Temp Max 0 FLOAT R Temp A1 (L1x) 0 FLOAT R Temp A2 (L1y) 0 FLOAT R Temp B1 (L2x) 0 FLOAT R Temp B2 (L2y) 0 FLOAT R Temp C1 (L3x) 0 FLOAT R Temp C2 (L3y) 0 FLOAT R Temp D1 (L4x) 0 FLOAT R Temp D2 (L4y) 0 FLOAT R Module Max Temp 0 FLOAT R Hauptdrossel A 0 FLOAT R Hauptdrossel B 0 FLOAT R Hauptdrossel Max Temp 0 FLOAT R

10.2.13 [23] Stored App Data

NAME BEZEICHNUNG / EINHEIT / DEFAULTWERT DATENTYP R/W Min Temperatur Modul 1x Minimale T des Moduls CONV_FLOAT R Max Temperatur Modul 1x Maximale T des Moduls CONV_FLOAT R Min Temperatur Modul 1y Minimale T des Moduls CONV_FLOAT R Max Temperatur Modul 1y Maximale T des Moduls CONV_FLOAT R Min Temperatur Modul 2x Minimale T des Moduls CONV_FLOAT R Max Temperatur Modul 2x Maximale T des Moduls CONV_FLOAT R Min Temperatur Modul 2y Minimale T des Moduls CONV_FLOAT R Max Temperatur Modul 2y Maximale T des Moduls CONV_FLOAT R Min Temperatur Modul 3x Minimale T des Moduls CONV_FLOAT R Max Temperatur Modul 3x Maximale T des Moduls CONV_FLOAT R Min Temperatur Modul 3y Minimale T des Moduls CONV_FLOAT R Max Temperatur Modul 3y Maximale T des Moduls CONV_FLOAT R Min Temperatur Modul 4x Minimale T des Moduls CONV_FLOAT R Max Temperatur Modul 4x Maximale T des Moduls CONV_FLOAT R Min Temperatur Modul 4y Minimale T des Moduls CONV_FLOAT R Max Temperatur Modul 4y Minimale T des Moduls CONV_FLOAT R Min Temperatur HL A Minimale T der Hauptdrossel CONV_FLOAT R

Technical data


10.2.14 [23] Stored App Data

NAME BEZEICHNUNG / EINHEIT / DEFAULTWERT DATENTYP R/W Max Temperatur HL A Maximale T der Hauptdrossel CONV_FLOAT R Min Temperatur HL B Minimale T der Hauptdrossel CONV_FLOAT R Max Temperatur HL B Maximale T der Hauptdrossel CONV_FLOAT R Min Temperatur HL C Minimale T der Hauptdrossel CONV_FLOAT R Max Temperatur HL C Maximale T der Hauptdrossel CONV_FLOAT R Min Temperatur HL D Minimale T der Hauptdrossel CONV_FLOAT R Max Temperatur HL D Maximale T der Hauptdrossel CONV_FLOAT R Max kommandierter Sollwert Höchster kommandierter Sollwert CONV_FLOAT R Min kommandierter Sollwert Kleinster kommandierter Sollwert CONV_FLOAT R Max ULS Max U Low Side CONV_FLOAT R Min ULS Min U Low Side CONV_FLOAT R Max IHS Max I High Side CONV_FLOAT R Min IHS Min I High Side CONV_FLOAT R Max UHS Max U High Side CONV_FLOAT R Min UHS Min U High Side CONV_FLOAT R Max ILS Max I Low Side CONV_FLOAT R Min ILS Min I Low Side CONV_FLOAT R Max IL1x Max I in Modul 1x CONV_FLOAT R Max IL1y Max I in Modul 1y CONV_FLOAT R Max IL2x Max I in Modul 2x CONV_FLOAT R Max IL2y Max I in Modul 2y CONV_FLOAT R Max IL3x Max I in Modul 3x CONV_FLOAT R Max IL3y Max I in Modul 3y CONV_FLOAT R Max IL4x Max I in Modul 4x CONV_FLOAT R Min IL4y Max I in Modul 4y CONV_FLOAT R Reset AppData NVM Min I in Modul 1x CONV_FLOAT R

73


10.2.15 [31] General Parameters

NAME BEZEICHNUNG / EINHEIT / DEFAULTWERT DATENTYP R/W Serial Number Zeigt die Seriennummer des Geräts an UINT_HEX R

Standby Hours

Zeigt die Standby-Zeit in Stunden an. Dabei ist Klemme 15 aktiviert und CAN-Kommunikation möglich aber der Startbefehl für Leistungstransfer nicht gesetzt FLOAT R

Operating Hours Zeigt die tatsächlichen Betriebsstunden an FLOAT R SwVer SW-Version codiert als Hex-Wert UINT_HEX R ProdDate Produktionsdatum codiert als Hex-Wert UINT_HEX R

10.2.16 [32] Revision Info

NAME BEZEICHNUNG / EINHEIT / DEFAULTWERT DATENTYP R/W FE_0 0 - Original, not 0 - FE'number' was done. R FE_1 0 - Original, not 0 - FE'number' was done. R FE_2 0 - Original, not 0 - FE'number' was done. R FE_3 0 - Original, not 0 - FE'number' was done. R FE_4 0 - Original, not 0 - FE'number' was done. R FE_5 0 - Original, not 0 - FE'number' was done. R FE_6 0 - Original, not 0 - FE'number' was done. R FE_7 0 - Original, not 0 - FE'number' was done. R FE_8 0 - Original, not 0 - FE'number' was done. R FE_9 0 - Original, not 0 - FE'number' was done. R

Technical data


10.3 DC/DC converter operation The BDC546 is implemented in a CAN communication network and is usually controlled by a control unit. The CAN commands required for operation are listed in the customer package in the CAN matrix. The CAN matrix is available in the Firmware/CAN folders as BDC546_Gen.dbc.zip (dbc file) and BDC546_Gen.html (html file) It includes the entire list with all CAN signals such as messages, errors and warnings.

INFORMATION

The document BDC546-B Operating instructions describes the process for setting the main controller (set value) and the limiting controllers (limits). Additionally, the priorities of the individual controllers are provided.

As an alternative, the BDC546 can also be operated via a user-created CAN user interface on a computer. In this case, the CAN control commands have to be generated by the respective software. As an example for this type of user interface, the CVI software by BRUSA can be applied. It is presented in the following section.

INFORMATION

If the device is not integrated into an existing CAN communication network, a customer-specific CAN user interface can also be created by BRUSA, if required.

75


10.4 Brusa CVI

NOTICE

The CVI software serves as user interface for internal laboratory applications for BRUSA Elektronik AG. It is used as test bay software and does not guarantee save operating states. The CVI is provided to customers as example for a custom user interface for first tests with no

guarantee. If the BDC546 is operated via CVI, no superordinate control unit can be applied. (CAN collision) BRUSA Elektronik AG cannot assume any liability for damage to the BDC546 or other devices

due to operation with the CVI software! BRUSA Elektronik AG does not assume any liability for operation with the CVI software!

10.4.1 CVI software installation

The CVI CAN user interface can be found in the PC software folder as CVI.zip.

If the PARAM software has already been installed with the required drivers, the CVI folder of the Zip files only needs to be copied to the PARAM installation folder. The CVI software does not require any further installation steps.

If the PCAN USB adapter (dongle) is connected to the PC, the CVI software can be started.

Technical data


10.4.2 CVI operation

As illustrated below, the CVI software can be used to comfortably specify voltage values, voltage limits and current limits for the DC/DC converter. Voltages and temperatures measured by the BDC546 as well as error and warning messages are transmitted to the CVI and displayed.

BRUSA CVI

Please observe that the highside / lowside of the BDC546 has to be pre-charged by means of a pre-charging resistor as described in chapter 9.4 Voltage pre-charging.

Connect pin 16 EN with pin 2 AUX (e.g. actuate ignition key, close switch etc.).

Start the CAN user interface and press the Go button in order to enable communication with the device.

Press the Run button in order to activate the power stage. Communication with the device is ensured when the displays Tx and Rx are flashing.

To enable the main controller to fulfil its function, it is to be guaranteed that no limiting controller is meshed.

The device can be switched off in every operating mode by pressing the BDC Activation button again and deactivation of pin 16 EN. In case of an emergency, the high voltage can immediately be disconnected by opening the contactors.

77


11 Firmware update

NOTICE

Programming an incorrect firmware may damage the device! Therefore, a firmware update may only be carried out after consultation with

BRUSA Elektronik AG! Firmware updates may only be carried out at error-free, functioning devices!

11.1 FDT installation and firmware download instructions The customer package includes the SW-FW-SHC3_Firmware_download.pdf in the manuals folder.

This manual describes the installation of the Flash Development Toolkit (FDT) required for programming as well as its system requirements. Additionally, the required procedures for downloading the new firmware to the BDC546 are described.

11.2 Additional information for firmware download For programming, the device has to be supplied via pin 2 AUX.

To set the device to programming mode, pin 13 PRO of the control connector has to be additionally connected to pin 2 AUX (pin 13 PRO = high). Refer to chapter 7.1.6 Pin 13 PRO

After successful programming, pin 13 PRO has to be disconnected again from pin 2 AUX.

Technical data


12 Troubleshooting

INFORMATION

Error messages can generally be divided in the following categories: E (Error): Error (generally leads to shut down of the system) W (Warning): Warning (indicates approximation to or reaching of a

limit value)

For a list of all possible errors, please refer to manual BDC546 Documentation of Errors and Warnings.pdf.

Always try to clear all occurring errors with the help of this manual. If errors repeatedly occur, please refer to the BRUSA support under the manufacturer address indicated in chapter 4.5 Manufacturer contact information!

13 Warranty

The warranty corresponds to the regulations in our currently valid general terms and conditions see under www.brusa.biz/en/support/terms-conditions.html.

http://www.brusa.biz/en/support/terms-conditions.html

79


14 Instructions for disposal

The correct disposal is a basic requirement for the re-use and recycling of used electronic devices.

The Electric and Electronic Device Regulation (ElektroG), in place since 24 March 2006, stipulates that electronic devices may no longer be disposed of along with ordinary household waste but must be separately collected and recorded by a specialist service.

Disposal via a specialist service significantly helps to avoid dangers to people and the environment. For this reason, it is recommended to contact a recognised specialist disposal service for disposal of the device.

Technical data


15 Index

B Block diagram

BDC546 Block diagram .......................................................... 22 Installation in the vehicle ...................................................... 26

Building the HV wiring ............................................................... 54

C Cable manufacturing

Highside ................................................................................ 48 Lowside ................................................................................. 49

CAN signals CAN interface ........................................................................ 38 Description ............................................................................ 77

Contact Support ......................................................................... 18 Control connector

Pin assignment on device side .............................................. 34 Pin assignment, connector side ............................................ 47

Controller ................................................................................... 37 Cooling system

Cooling water connections ................................................... 50 Specifications ........................................................................ 21

Customer package ..................................................................... 16 CVI.............................................................................................. 74

D Derating ..................................................................................... 14 Designation of the device

Breakdown .............................................................................. 3 Device assembly ........................................................................ 51 Device specification ................................................................... 21 Dimensions ................................................................................ 30 Disposal ..................................................................................... 78 Documentation

Further documents ............................................................... 16

E Earthing / Grounding connection .............................................. 44 Electrical interfaces ................................................................... 33 EMC concept .............................................................................. 23 Error messages .......................................................................... 77

F Filter concept ............................................................................. 24 Firmware

Important instructions .......................................................... 74 Update .................................................................................. 76

G GND / signal ground ................................................................... 34 Ground connection .................................................................... 35 Guarantee .................................................................................. 12

H Highside cable ............................................................................ 48 HV power connections ............................................................... 45 HV voltage pre-charging ............................................................ 58

I Installation ................................................................................. 51 Interlock ............................................................................... 13, 43

Function ................................................................................ 27 Signal ..................................................................................... 28

L Limits of the product .................................................................. 19 List of parameters ...................................................................... 62 Lowside

Installation instructions ......................................................... 49 Lowside cable ............................................................................. 49

M Main Contactor .................................................................... 36, 42 Main structural components ..................................................... 29 Manufacturer contact information ............................................ 18

N Notes on life span ...................................................................... 11

O Operating ranges ....................................................................... 19

P PARAM tool ................................................................................ 60 Parameter groups ...................................................................... 64 Preventing damage to the device ...................... 11, 51, 57, 58, 74 Programming ........................................................... 36, 37, 40, 41 Protective functions ....................................................... 13, 14, 58 Pyrofuse ............................................................................... 13, 39

S Safety

81


Safety rules ........................................................................... 12 Safety instructions

Danger levels .......................................................................... 9 General ................................................................................. 10 Handling and operation ........................................................ 11

Scope of delivery ....................................................................... 17 Serial number ............................................................................ 32 Start-up ...................................................................................... 51 Symbols ....................................................................................... 8

T Technical properties .................................................................. 22

Topology .................................................................................... 23 Type plate .................................................................................. 32

V Validity of the manual .................................................................. 3 Voltage pre-charging .................................................................. 58

W Warnings on the device ............................................................. 25 Warranty .................................................................................... 77

Technical data


16 Attachments

16.1 Cable fitting

83


Technical data


85


Technical data


16.2 Cable lugs

87


technical data and start-up - brusa€¦ · technical data and start-up 10 bdc546 3.2 safety...

Documents