technical data and start-up - brusa.biz · and photos used are copyrighted and failure to respect...

BRUSA Elektronik AG Neudorf 14 CH-9466 Sennwald +41 81 758 19 00

[email protected]

www.brusa.biz

HSM1 TRANSAXLE

TECHNICAL DATA

AND START-UP

Translation of the original German operating instructions

Technical data

and Start-up

HSM1 / ASM1 Transaxle 2

LEGAL NOTICE

Publisher BRUSA Elektronik AG

Neudorf 14 CH-9466 Sennwald T +41 81 758 19- 00 Fax: +41 81 758 19 - 99 www.brusa.biz [email protected]

Date of issue 17. October 2011

Copyright © 2011

The content of this document may not be passed on to third parties without the written authorisation of the company BRUSA Elektronik AG - not even in extracts. Any technical information, drawings and photos used are copyrighted and failure to respect this constitutes a punishable offence!

Updates In light of the further technical development of our products, we reserve the right for structural changes. Any changes will be disclosed in the relevant manuals through the replacement of the relevant pages and/or a revision of the electronic data storage device.

Writer / Author Holger Schmidt

REVISIONS

REVISION DATE NAME CHANGE

rev01 24.01.2012 H. Schmidt 4.3 updated, 4.4. added to, 6.11.1 new, 7 profiles added to, 10.3 new, content revised

rev02 18.01.2013 H.Schmidt 6.1 aktualisiert, 6.2 aktualisiert, 6.11.4 Toleranzen berichtigt

rev03 23.07.2013 M.Tschumper 6.1 aktualisiert

rev04 24.09.2013 M.Tschumper 6.8.2 M10x1.25 metric fine thread

rev05 30.09.2013 M.Tschumper 6.6 graphic safety concept

rev06 18.11.2013 M.Tschumper 6.11.3 Parking lock

rev07 27.03.2014 M.Tschumper 6.8.2 Fixing points / 6.12.2 sensor parking look

rev08 04.06.2015 F. Müller 8.1 add informations about cable and terminal insert

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HSM1 / ASM1 Transaxle

VALIDITY

This manual is valid only for the following motor/gear box combinations:

MOTOR TYPE

DTSX1–064–HSM1–10.18.13–A01

DTSX1–080–HSM1–10.18.13–A01

DTSX1–064–HSM1–6.17.12–A01

DTSX1–080–HSM1–6.17.12–A01

DTSX1–102–HSM1–6.17.12–A01

Decoding of the motor designation is as follows:

Technical data

and Start-up


TABLE OF CONTENTS

1 Foreword .............................................................................................................................. 7

2 List of abbreviations ........................................................................................................... 7

3 Safety and warning instructions ........................................................................................ 8

3.1 Symbols and their meaning .......................................................................................................... 8

3.2 Safety instructions and danger levels .......................................................................................... 9

3.3 Generally applicable safety measures ....................................................................................... 10

3.4 Safety installations / power limitations ....................................................................................... 13

3.4.1 Derating .............................................................................................................................. 13

3.4.2 Overload protection ............................................................................................................. 13

3.5 Requirements of the start-up personnel ..................................................................................... 13

4 General ............................................................................................................................... 14

4.1 Content and scope of this manual .............................................................................................. 14

4.2 Scope of the entire documentation ............................................................................................ 14

4.3 Delivery contents ........................................................................................................................ 15

4.4 Optional delivery contents .......................................................................................................... 16

4.5 EU Guidelines ............................................................................................................................ 17

4.6 Contact information of the manufacturer .................................................................................... 17

5 Use and limits of the product ........................................................................................... 18

5.1 Proper use .................................................................................................................................. 18

5.2 Improper use / limits of the product ............................................................................................ 18

6 About this device ............................................................................................................... 19

6.1 Technical data ............................................................................................................................ 19

6.2 Technical Properties .................................................................................................................. 21

6.3 Function ..................................................................................................................................... 21

6.3.1 Basic function HSM1 hybrid synchronous motor ................................................................ 21

6.3.2 Basic function of the GX629 gear box ................................................................................ 22

6.3.3 Position sensor ................................................................................................................... 22

6.4 Warnings on the motor ............................................................................................................... 23

6.5 Basic principle for vehicle installation ......................................................................................... 24

6.6 Safety measures for vehicle installation ..................................................................................... 25

6.6.1 Principle of operation Interlock ............................................................................................ 25

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6.7 Overview of the main structural components ............................................................................. 26

6.8 Dimensions and installation information ..................................................................................... 26

6.8.1 Rotor offset ......................................................................................................................... 26

6.8.2 Fixing points ........................................................................................................................ 27

6.8.3 Dimensions ......................................................................................................................... 30

6.8.4 Installation position ............................................................................................................. 30

6.8.5 Filling up and checking of gear oil ....................................................................................... 32

6.9 Regulation and control system ................................................................................................... 33

6.10 Stator and temperature measurement ....................................................................................... 34

6.11 Mechanical connections ............................................................................................................. 35

6.11.1 Cooling system ................................................................................................................... 35

6.11.2 Cooling water connections .................................................................................................. 36

6.11.3 Parking lock ........................................................................................................................ 37

6.11.4 Drive shaft flange connections ............................................................................................ 38

6.12 Connections electrical ................................................................................................................ 39

6.12.1 Grounding Screw ................................................................................................................ 39

6.12.2 Parking lock sensor ............................................................................................................. 40

6.12.3 PIN assignment of motor sensor connection ...................................................................... 41

6.13 Motor type plate ......................................................................................................................... 42

6.14 Gear box serial number .............................................................................................................. 42

7 Profiles and diagrams ....................................................................................................... 43

7.1 HSM1–6.17.12 ........................................................................................................................... 43

7.1.1 Power / torque depending on speed ................................................................................... 43

7.1.2 Level of motor efficiency ..................................................................................................... 44

7.1.3 Level of generator efficiency (recuperation) ........................................................................ 45

7.1.4 S1 torque ............................................................................................................................ 46

7.1.5 Thermal behaviour / derating .............................................................................................. 47

7.1.6 Induced motor voltage ........................................................................................................ 50

7.1.7 Short circuit torque .............................................................................................................. 50

7.2 HSM1–10.18.13 ......................................................................................................................... 51


7.2.2 Level of motor efficiency ..................................................................................................... 52


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7.3 HSM1–10.18.13-Co ................................................................................................................... 54




7.4 GX629 gear box ......................................................................................................................... 56

7.4.1 Level of efficiency GSX1-102-240-A01 ............................................................................... 56

8 Installation / start-up ......................................................................................................... 57

8.1 Connecting the HV supply .......................................................................................................... 60

8.2 Ventilating the cooling system .................................................................................................... 63

8.3 Carrying out the HV test ............................................................................................................. 64

9 Error correction ................................................................................................................. 66

10 Maintenance ................................................................................................................... 67

10.1 Changing the O-ring connection box .......................................................................................... 67

10.2 Changing the terminal board ...................................................................................................... 68

10.3 Changing the gear oil temperature sensor ................................................................................. 70

11 Spare parts ..................................................................................................................... 73

12 Warranty and guarantee ................................................................................................ 75

13 Index ................................................................................................................................ 76

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1 Foreword

Dear customer!

With the BRUSA drive unit you have obtained a very capable and versatile product. As this is a component of high

performance electronics, we require specialist knowledge in the dealing with as well as the operation of the

product!

Read this manual – particularly the chapter Safety and Warning Instructions – carefully before you install the drive

unit or carry out any other work on it!

2 List of abbreviations

Throughout this manual, some specific technical abbreviations are used. You will find an overview as well as their

meaning in the following table:

ABBR. MEANING ABBR. NAME

HSM Hybrid synchronous motor NTC Resistor with negative temperature coefficient

GND Minus wiring System, vehicle earth Terminal 31

PDU Power Distribution Unit (HV distribution box)

HV High Voltage, DC Link Voltage

PTC Resistor with positive temperature coefficient

LV Low voltage PWM Pulse Width Modulation

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3 Safety and warning instructions

In this chapter you will find safety instructions which apply to this device. These refer to 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, some specific technical symbols are used. You will find an overview as well as their

meaning in the following table:

PROHIBITION SYMBOLS

SYMBOL MEANING SYMBOL MEANING

General prohibition

Warning high voltage

Touching forbidden

Switching on forbidden

WARNING SYMBOLS


General hazard warning

Electromagnetic field warning

Potentially explosive warning

Battery hazard warning

Hot surface warning

High electrical voltage warning

High pressure warning / fluid spurting out

Fire hazard warning

MANDATORY SIGNS


Disconnect device from voltage

Disconnect device from mains

INFORMATION SIGNS


Important information on avoiding possible damage to property

Important information

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3.2 Safety instructions and danger levels

DANGER

This instruction warns against serious, irreversible risks of injury and in some cases death!

Avoid these dangers by observing these instructions!

WARNING

This instruction warns against serious, irreversible risks of injury!


CAUTION

This instruction warns against serious, irreversible risks of injury!


INSTRUCTION

This instruction warns against possible damages to property if the following instructions and work procedures are not observed.

INFORMATION

This type of instruction discloses important information for the reader.

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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 local and/or country-specific safety instructions and guidelines for accident

prevention!

The system integrator and/or distributor of the device must therefore supplement the present general safety

instructions by country-specific and local guidelines.

3.3.1 Safety instructions for cooling water systems

WARNING

Spurting cooling fluid!

Skin burning hazard!

Check the tightness of the cooling water system, particularly the pipes, screw joints and pressure tanks.

Resolve recognisable leakages immediately!

3.3.2 Safety instructions for mechanical systems

DANGER

Potential explosion area!

Danger to life!

Do not store any highly flammable materials or combustible fluids in the direct surroundings of the device!

Sparks at the device connections can set these on fire and lead to explosions!

CAUTION

Hot surfaces!

Burn hazard!

The device produces high temperatures when in operation!

Handle the device with care and caution!

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3.3.3 Safety Instructions for handling and operation

INSTRUCTION

A high cooling water temperature reduces the life span! So take ongoing care to ensure sufficient cooling of the device!

Under no circumstances should you use cleaning agents containing solvents to clean the motor! These can damage the seals and lead to leaks in the motor!

Do not place the device in direct sunlight and in close proximity to heat sources!

Although if the device has high IP protection, you should avoid placing it in direct contact with water (rain, spurting water) if possible!

Under no circumstances should you put a low-resistance connection between the HV contacts, the housing contacts and the LV contacts! This will lead to malfunctions and furthermore to the destruction of the device!

Prevent any penetration of fluids into the device (e.g. during assembly work)! The penetration of fluids will lead to a short circuit and subsequent damage to the device!

Under no circumstances should you operate the device if liquid is leaking in anywhere. Refer immediately to the company BRUSA Elektronik AG!

During installation and the laying of cables, observe the maximum bending radii given by the manufacturer! Avoid laying the cables alongside sharp edges and mechanical components!

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3.3.4 Safety instructions for electrical systems

DANGER

High voltage!

Danger to life!

Under no circumstances should you touch the HV wires or HV connections without ensuring that there is no voltage beforehand!

The device may only be connected by a qualified electrician!

Under no circumstances should you bypass or avoid security installations! Any malfunctions resulting from this could have life threatening consequences!

Always use an insulation monitoring unit for ongoing monitoring of the galvanic isolation between HV and LV circuits!

Before starting work with the device, the shut-down of the coupled motors must be ensured! Even when the HV supply is switched off, a turning motor can still produce voltage!

INSTRUCTION

Under no circumstances should the device be opened without authorisation! The opening of the device (housing sealed-up) leads directly to the forfeit of any guarantee and warranty rights!

INFORMATION

Adhere strictly to the following 5 safety rules when working on an HV grid:

Disconnect system from power. Switch off the ignition. Remove service / maintenance plug and/or turn off main battery switch. Remove fuse.

Ensure that the system does not reconnect. Keep ignition key safe to prevent unauthorised access. Keep service / maintenance plug safe to prevent unauthorised access and/or use lockable cover cap to ensure that the main battery switch does not reconnect.

Check that it is not live with a suitable voltage tester (note voltage range!).

Ground and short-circuit the system.

Cover or seal off adjacent live parts.

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3.4 Safety installations / power limitations

3.4.1 Derating

This security installation is the motor's self-protection. If the motor reaches a defined temperature, this means a

decrease in power (derating) to protect the motor from damage through overheating. The power will subsequently

be reduced until the temperature falls back to the target range.

The temperature measurement takes place through an NTC in the stator winding head. Derating becomes active at

around 100°C through the variable resistance value. The inverter processes the signal from the motor and begins

to gradually reduce the phase current from this motor temperature onwards:

at a temperature of < = 100℃ I_max

at a temperature of > = 160°C I = 0 A

For this see chapt. 7.1.5 Thermal behaviour / derating

3.4.2 Overload protection

If the motor reaches the defined maximum temperature of 170°C despite derating, an emergency shut-down

(overload protection) takes place to protect the motor from damage.

The temperature measurement takes place through 3 PTCs in the stator winding head (1 unit per phase). If one of

the PTCs reaches the defined maximum value, the linked up inverter recognises this and using the CAN sends the

error message E_TempMot. In this case the inverter disconnects the phase current immediately.

To resume operation, the fault in the linked inverter must be acknowledged.

3.5 Requirements of 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 dispose of

professional training,

knowledge and experience in the field of electronics / electric mobility,

as well as knowledge of relevant requirements and dangers

which they can display in practice. Furthermore, they must be able to assess the work assigned to them

independently, detect possible dangers and establish necessary protection measures.

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and Start-up


4 General

4.1 Content and scope of this manual

The present documentation gives the reader an overview of all required working steps in the installation and

operation of the device and the safety measures necessary for these.

Furthermore, you can find technical information, usage information and a basic description of the hybrid

synchronous motor and its specific components.

The operational and safety instructions given in the previous chapters must be strictly adhered to in order to ensure

the ongoing optimum functioning of the hybrid synchronous motor and to meet the guarantee requirements of

BRUSA Elektronik AG.

All work sequences and illustrations are based on the HSM1–6.17.12 model and are applicable to all models

mentioned in this handbook. In the case of model-specific deviations, corresponding instructions are available.

4.2 Scope of the entire documentation

INFORMATION

To set the motor up successfully, besides this manual you will need the appropriate motor table for this motor! The motor table is usually included in the delivery content and must be loaded onto the linked up inverter (see the technical information for the inverter).

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4.3 Delivery contents

NAME PIECES ILLUSTRATION

1. HSM1 hybrid synchronous motor 1

2. GX629 gear box (Transmission ratio 1:10.2) * 1

GX629 gear box (Transmission ratio 1:8)

GX629 gear box (Transmission ratio 1:6.4)

3. Quick connection cooling water connection pieces 90° Norma PS3

Cooling Water Pressure Drop around 150 mbars

For dimensions see chapt. 6.11.2 Cooling water connections

2

4. M18 x 1.5 cooling water connection pieces for PS3 Norma quick connector

2

5. Cable length of sensor cable: 1 m

(Connection Motor / Inverter)

1

6. M6 hexagonal nut

(Fixing of the cable lugs to the motor phases)

3

7. M6 washer without DIN125A chamfer 3

8. M8 x 16 hexagonal screw

(Ground GND)

1

9. M6 cable lug without insulation

(Compression Cable Lugs for Motor Phases Connection)

3

10. M8 cable lug without Insulation

(Compression Cable Lug for Connecting Ground)

1

11. Protective cap for cooling water connection pieces 2

12. O-ring connection box 1

13. O-ring end-shield cover 1

* only possible in connection with the HSM1-6.17.12

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4.4 Optional delivery contents

INFORMATION

These accessories can be obtained optionally from BRUSA Elektronik AG.

MEANING TYPE ILLUSTRATION

1. Special key for HV cable fitting RAAA041 ---


cooling water pressure drop around 140 mbars


MHAA775

3. M18 x 1.5 cooling water connection pieces

Cooling Water Pressure Drop around 105 mbars


MAAA366

4. 14 pole Lemo connecting cable (inverter - motor) 1 m 11139



7. Plug for parking lock sensor (See chapt. 6.12.2 Parking lock sensor)

Direct purchase: GETRAG AG http://www.getrag.com Product no: 900 4412 91 or

1

---

Product no: 900 4412 31 1 ---

http://www.getrag.com/

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4.5 EU Guidelines

This manual has been produced under application and consideration of the HSM1 hybrid synchronous motor EC

guidelines, national laws and harmonised standards (EN) valid at the time of production relevant to the product.

4.6 Contact information of the manufacturer

BRUSA Elektronik AG

Neudorf 14

9466 Sennwald

Switzerland

Phone: +41 81 758 09 - 00

Fax: +41 81 758 09 - 99

Internet: www.brusa.biz

E-mail: [email protected]

Technical data

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5 Use and limits of the product

5.1 Proper use

The BRUSA HSM1 hybrid synchronous motor has been designed for the following uses. In the case of planned

operations in other areas, please contact the company BRUSA Elektronik AG beforehand at the manufacturer

address as given in chapt. 4.6.

Installation in a drive train for hybrid vehicles

Full drive for electric vehicles / Linking up with several hybrid synchronous motors possible

Installation in a drive train for fuel cell vehicles

Use as a high performance drive (racing sports)

Full drive for electric motorbikes

Full drive for utility vehicles (electric and hybrid)

Full drive for electric boats

Test stand applications

5.2 Improper use / limits of the product

The carrying out of applications which do not conform to the conditions and requirements stated in the technical

documents and datasheets of the manufacturer is viewed as improper use.

The following limit values are set for the operation of the HSM1 hybrid synchronous motor . Operation outside of

the defined limits can lead to life-threatening situations!

Max HV input voltage (operation): 450 V

Max. permitted phase voltage: 690 VACeff

Min. ambient temperature: – 40°C

Max. ambient temperature: + 85°C

Min. coolant temperature at Inlet: – 40°C

Max. coolant temperature at Inlet: + 65°C

Max. cooling circuit pressure: 1.0 bar

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6 About this device

6.1 Technical data

BASIC MOTOR DATA HSM1–

6.17.12

HSM1–

10.18.13

HSM1–

10.18.13-CO

UNIT

360 V 400 V 360 V 400 V 360 V 400 V

Corner speed max. Torque / max. Power 3‘800 4‘200 4‘400 4‘900 3‘200 3‘600 rpm

Nominal speed S1 / 25°C* 4‘700 5‘200 4‘900 5‘400 3‘800 4‘200 rpm

Continuous torque / S1-Torque at 25°C* 130 130 165 165 185 185 Nm

Max. torque at max. inverter current 220 220 305 305 495 495 Nm

Inverter current 300 300 450 450 600 600 Aeff

Continuous power / S1 power 64 70 83 93 73 81 kW

Maximum power 87 96 140 156 166 187 kW

Maximum speed 12‘000 12‘000 13‘000 13‘000 12‘000 12‘000 rpm

*coolant temperature

BASIC ELECTRICAL DATA HSM1–

6.17.12

HSM1–

10.18.13

HSM1–

10.18.13-CO

UNIT

Compatible inverter DMC524 DMC534 DMC544 ––

Recommended input voltage of device (min / max) 360 - 450 360 - 450 360 - 450 V

Level of efficiency 95 95 95 %

Number of pole pairs 3 5 5 ––

Number of turns 7 9 9 ––

Insulation class H H H ––

Circuitry Star (Y) Star (Y) Star (Y) ––

Nominal frequency (400 V) 210 410 300 Hz

Maximum frequency 600 1‘083 1‘000 Hz

Cos(φ) at max. S1 power 0.94 0.94 0.93 ––

Constant power range (400 VDC, 80% Pmax) 3‘000 – 12‘000 4‘000 – 13‘000 3‘000 – 12‘000 rpm

Max. motor flux 0.725 0.042 0.0385 Vs

Stator leakage inductance 47 22 22 µH

Stator resistor (25°C) 20 12 12 mOhm

CONNECTIONS HSM1–

6.17.12

HSM1–

10.18.13

HSM1–

10.18.13-CO

UNIT

Phases U, V, W: 3 M6 cable lugs, recommended cable diameter 35 50 50 mm2

Ground GND M8 cable lug, recommended cable diameter 35 50 50 mm2

Motor sensor switch pin number 14 14 14 ––

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BASIC MECHANICAL DATA HSM1–

6.17.12

HSM1–

10.18.13

HSM1–

10.18.13-CO

EINHEIT

Cooling jacket diameter 270 270 270 mm

Total length 245 245 245 mm

Stator diameter 240 240 240 mm

Rotor diameter 165 175 175 mm

Active length 123 130 130 mm

Active mass 36.4 33.9 36.7 Kg

Weight without gear box 51.5 52.0 54.0 Kg

Rotor inertia torque 0.06 0.065 0.07 Kg/m²

IP protection IP67 IP67 IP67 –––

Magnet material NeFeB NeFeB NeFeB –––

Magnet temperature coefficient -0.095 -0.095 -0.095 %/C°

THERMAL / COOLING SYSTEM HSM1–6.17.12 HSM1–10.18.13 HSM1–

10.18.13-CO

EINHEIT

Coolant mixture ratio (water / glycol) 50 / 50 50 / 50 50 / 50 –––

Derating temperature range 132 - 160 117 - 160 117 - 160 °C

Maximum operational temperature (activation of overload protection)

170 170 170 °C

Amount of coolant in device 0.6 0.6 0.6 l

Minimum coolant temperature at inlet - 40 - 40 - 40 °C

Maximum coolant temperature at inlet 65 65 65 °C

Flow rate 6 - 8 6 - 8 6 - 8 l/min

Pressure drop @ 6l / min Tcoolant = 25°C

(at standard Norma PS3 90° quick connector)

ca. 150 ca. 150 ca. 150 mbar

Ambient temperature range for storage - 40...+85 - 40...+85 - 40...+85 °C

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

GX629 GEAR BOX INFORMATION GSX1-064-320-

A01

GSX1-080-320-

A01

GSX1-102-240-

A01

UNIT

Oil type Mobil ATF SHC ---

Oil-fill capacity 1.5 1.5 1.5 l

Total length 372 372 372 mm

Total width 235 235 235 mm

Total height 292 292 292 mm

Transmisson 6.4:1 8:1 10.2:1 ---

Max. speed (number of revolutions) 12‘000 12‘000 12‘000 rpm

Weight (incl. oil) 23.7 24 24.2 Kg

Max. output torque 2‘500 2‘500 2‘500 Nm

Max. torque on park lock lever (to disengage at a 30% slope) 3.4 3.4 3.4 Nm

Rejection speed parking lock ≥ 4.8 ≥ 4.8 ≥ 4.8 km/h

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6.2 Technical Properties

Very high power / weight ratio at 3.5 kW / kg

High torque density up to 9 Nm / kg

High power density 13.5 kW / litre

Extremely compact design

Highly efficient with a wide speed and torque curve

Minimal torque fluctuations

Constant power over a very high speed range

Intrinsically safe (induced voltage at max. speed and passive inverter < 520 V)

Dynamic torque control through high PWM frequency

Suitable for high speed uses of up to 12’000 rpm

Torque, speed and power control

CAN-BUS driving

Minimal drag losses

Low short circuit torque

6.3 Function

6.3.1 Basic function HSM1 hybrid synchronous motor

The HSM1 hybrid synchronous motor is a water-cooled 3-phase AC motor. The motor is based on the combination

of a permanent synchronous motor and a reluctance motor whereby the advantages of both versions have been

coordinated and combined with one another. The HSM works with internal magnets which have an optimum flow

direction at low magnetic resistance due to a self-developed alignment to one another.

Through this a remarkably high and consistent power delivery can be achieved while using less energy. The power

delivery takes place over a large speed range. In addition, the HSM1 is extremely efficient and is best suitable for

use as a traction drive with constant transmission ratio. With these properties, the HSM1 is a very good choice for

drive systems which require constant and high power over a large speed range.

To achieve optimum results with this motor, it is paramount that the connected inverter is exactly adjusted to the

motor. Inverters of the company BRUSA Elektronik AG are already specially optimised for use in these motors.

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6.3.2 Basic function of the GX629 gear box

The GX629 gear box is attached on the right (right of the driving direction) of the motor. The gear box is basically

made up of a a drive pinion, a gear ring, an axle drive and a differential. Because an electric motor does not

generate a torque when idle, a linkage been the motor and the gear box is not necessary. In all gear box versions

there is a fixed transmission (final drive) with the ratio 3.706. The transmission of the intermediate gear depends on

the gear box (1.73, 2.14 and 2.75). That is why there are three gear box versions with different transmissions to

choose from (see chapt. 4.3 Delivery contents).

The gear turns in the reverse direction while reversing. During this the speed should be limited to 50km/h for safety

reasons.

The power transmission of the drive shaft is as follows:

The drive shaft to the left of the driving direction is connected via wedge toothing to a shaft which runs through the

hollow shaft of the motor. The drive shaft to the right of the driving direction is directly connected to the differential.

To secure the vehicle against rolling away, a mechanical parking lock in installed. The parking lock can be

electronically monitored with a sensor.

6.3.3 Position sensor

The position sensor is located between the posterior end-shield and the end-shield cover. The position sensor

transmits the position and speed information of the rotor via the motor sensor connection on the inverter. The NTC

and PTC resistors are connected to the inverter over the motor sensor connection as well.

23

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6.4 Warnings on the motor

Warning signs are attached to the motor to warn the operator of possible dangers. Should one of these warning

signs fail or become illegible due to wear and tear, it must be immediately renewed! To get an original label, please

contact BRUSA support at the manufacturer address given in chapt. 4.6!

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6.5 Basic principle for vehicle installation

25

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6.6 Safety measures for vehicle installation

INFORMATION

This safety measure is a recommendation by the company BRUSA Elektronik AG and is understood as a basic requirement for the safe operation of electric vehicles!

6.6.1 Principle of operation Interlock

The interlock switch (1) is closed if the corresponding interlock condition of each devices is met (closed service

cover, plugged HV connections ...). The interlock evaluation of the PDU switches the 12V supply voltage (2) of the

HV contactors (4) in the battery if the interlock circuit is closed. The emergency stop switch (3) also interrupts the

12V supply voltage of the HV contactors (4). The second interlock (5) of the line insulation guard interrupts the

interlock circuit, if a fault in the HV- insulation is detected.

INSTRUCTION

The interlock function is currently not implemented in BRUSA motors. Therefore the interlock function

of the motors has to be guaranteed by the vehicle manufacturer.

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6.7 Overview of the main structural components

1. Parking Lock 2. Terminal Board

3. Cooling Jacket 4. Position Sensor

5. Posterior End-Shield 6. End-Shield Cover

7. Transaxle Shaft 8. Code Disc

9. Connection box phases U, V, W (R, S, T) 10. Cooling water connections

11. Connection Box Cover 12. Anterior End-Shield / Gear Box Housing

13. Parking Lock Sensor 14. Type plate

15. Oil Drain Plug 16. Gear Oil Temperature Sensor

17. Oil Fill Plug 18. GX629 Gear Box

6.8 Dimensions and installation information

6.8.1 Rotor offset

The rotor offset is determined during assembly and is noted on a sticker on the motor housing (usually near the

type plate). Parameters for the rotor offset must be set during the start-up of the inverter. You can find further

information on the process in the technical information for the inverter.

If the sticker on the housing is illegible or missing, please contact BRUSA support, stating the serial number, at the

manufacturer address given in chapt. 4.6..

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Technical data

and Start-up


6.8.2 Fixing points

DETAIL BEFESTIGUNGSPUNKTE

1 --- Suspension point Ø 10 mm

Technical data

and Start-up


2

The use of adapter sleeves (outer–Ø 13 mm) is possible at this positions (illustration)

Fixing points M12 without Helicoil:

hexagon head screw with fine thread

ISO 8676-M12x1.5x35-8.8-A2K

typical tightening torque: 70 ± 10 Nm

Fixing points M10 with Helicoil

hexagon head screw standard thread

ISO 4017-M10x35-8.8-A2K


29

Technical data

and Start-up


DETAIL BEFESTIGUNGSPUNKTE

3

Fixing points M12 without Helicoil:

hexagon head screw with fine threads

ISO 8676-M12x1.5x35-8.8-A2K


Fixing points M10 with Helicoil

hexagon head screw standard thread

ISO 4017-M10x35-8.8-A2K


4 braced length for M10 fixing screws M10 = 20 mm

M10 x 1.25 / 20 mm deep (fine thread!)


INSTRUCTION

Assembly instructions fixing point 2 and 3:

BRUSA recommends using a Helicoil insert, type: HELICOIL ® M12x1.5 x 10mm.

A minimum thread oft he screws ≥ 10mm is recommended (note devices drawing).

Technical data

and Start-up


6.8.3 Dimensions

6.8.4 Installation position

INFORMATION

In any event the motor must be installed in such a way that the oil drain plug points downwards. Here the connecting port of the parking lock (1) must point vertically upwards. An installation tolerance of +/- 3 degrees is permissible. Exceeding this tolerance value requires additional measures. For this please refer to the manufacturer address given in chapt. 4.6.

The following diagram shows the correct installation position.

31

Technical data

and Start-up


Technical data

and Start-up


6.8.5 Filling up and checking of gear oil

INFORMATION

Upon the intial start-up, the gear box must be newly filled by the customer! The gear box is not filled during the transportation as a precautionary measure. The right gear oil filling quantity (1.5 l) is included in the packaging

ATF Lifecycle oil is used for filling. There is therefore no need to change the gear oil at any point throughout the entire lifespan.

1. Oil Fill Plug 2. Oil Drain Plug

3. Filling Level (oil level) 4. Gear Oil Temperature Sensor

PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION

1. Open the oil fill plug (1). ---

2. Pour around 1.5 l of gear oil in. For information on the oil specification see chapt. 6.1 Technical data

The gear oil must be filled up to the bottom edge of the oil fill plug (1). Screw torque: 43 +/-4 Nm

3. Close the oil fill plug (1)

Screw torque: 43 +/-4 Nm ---

33

Technical data

and Start-up


6.9 Regulation and control system

AC_CurrAct Phase current generated by inverter

(U, V, W)

TempMot Current motor temperature

PosAct Current motor position E_TempMot Excessive temperature (phase current cut-off)

SpdAct Current speed

Technical data

and Start-up


6.10 Stator and temperature measurement

35

Technical data

and Start-up


6.11 Mechanical connections

6.11.1 Cooling system

INSTRUCTION

Observe the cooling liquid mixture ratio (water / glycol) which is adapted to the outside temperature! You can find information on the mixture ratio in the manufacturer's technical data.

1. Cooling water outlet connection 2. Cooling water inlet connection

3. Cooling system ventilation screw

Technical data

and Start-up


6.11.2 Cooling water connections

Quick connector for cooling Water connection pieces

90° Norma PS3 (MHAA776)


0° Norma PS3 (MHAA775)


M18 x 1.5 (MAAA366)

37

Technical data

and Start-up


6.11.3 Parking lock

INFORMATION

The GX629 gear box is generally delivered without an operating lever (1)! The operating lever (1) must be constructed by the customer correspondingly for the operational environment (e.g. entire vehicle weight, driving, drive torque, etc.).

Disengage parking lock with max. torque of 3.4 Nm. Engage parking lock in drive direction and in reverse direction, the rejection speed parking lock is ≥ 4.8 km/h.

Through the operating lever (1) a locking lever engages with the ratchet wheel of the gear box via the shaft (2). The

position of the parking lock open (4) or closed (3) is monitored via the parking lock sensor (5). The parking lock can

be controlled both mechanically and electrically via an actuator.

Technical data

and Start-up


6.11.4 Drive shaft flange connections

Left Spline Gear Right Spline Gear

NAME VALUE UNIT

Pitch circle diameter 26.219 mm

Module 0.771 ---

Number of teeth 34 ---

Pressure angle 30 Degree

Addendum modification -0.044 mm

Outside diameter 24.40 +0.08 mm

Root diameter 27.68 … 27.93 Nm

Base diameter 22.7067 mm

Gap width eff. (gauge dimension) 1.2113 ---

Gap width (individual measurement) min. 1.254 max. 1.286 ---

Measuring ball diameter 1.5 mm

39

Technical data

and Start-up


6.12 Connections electrical

You will find the required cable types and diameters in chapt. 6.1 Technical data

1. Phase U 2. Phase V

3. Phase W 4. Parking lock sensor connection

5. Gear oil temperature sensor connection 6. Motor sensor switch

7. Ground (GND)

6.12.1 Grounding Screw

WARNING

Sparking!

Fire hazard!

A loose ground circuit can lead to sparking and subsequent fires!

Ensure that the earth connection is connected correctly!

INFORMATION

The grounding screw (1) must be connected with the earth of the vehicle and/or testing bay. The cable diameter of the earth cable must correspond to the dimensions of the HV wiring.

For EMC reasons we generally recommend an additional ground connection (25 mm2) to the

inverter!

Torque earthing screw (1) M8 x 10 = 15 Nm

Technical data

and Start-up


6.12.2 Parking lock sensor

CHARACTERISTICS PARKING LOOK SENSOR

Switch contact potential-free

Switch is closed in position P

Nominal switching current on 12 V 4 mA

typical tightening torque 10 ± 1 Nm (hexagonal flange bolt)

INFORMATION

To connect the parking lock sensor, you will need one of the following plug types:

Parking lock sensor plug type: 900 4412 91 Parking lock sensor plug type: 900 4412 31

41

Technical data

and Start-up


6.12.3 PIN assignment of motor sensor connection

INFORMATION

The pin assignment of the motor sensor connection is BRUSA specific and deviates from the standard pin assignment of the cable manufacturer!

1. POS3 6 bit absolute position bit 3 2. POS4 6 bit absolute position bit 4

3. POS5 6 bit absolute position bit 6 4. GND-NTC Earth NTC / PTC

5. NTC Motor temperature sensor 6. PTC Motor overheat switch-off

7. VCC-GEB Motor sensor – supply voltage 6 VDC 8. POS0 6 bit absolute position bit 0

9. POS1 6 bit absolute position bit 1 10. POS2 6 bit absolute position bit 2

11. GND Earth 12. MOTB Motor B (incremental)

13. MOTA Motor A (incremental) 14. UPD Position update data

15. --- Centering groove

Technical data

and Start-up


6.13 Motor type plate

1. Classification 2. Construction standards classification

3. Serial number 4. Year of construction

5. Number of phases 6. Motor type

7. Continuous power in kW 8. Cos(φ) (typical) at S1 power

9. Phase voltage at S1 power 10. Circuitry type

11. S1 torque / S1 phase current (Arms) 12. Nominal speed

13. Insulation class 14. IP protection category

15. Nominal frequency at nominal speed 16. Operating modes

17. Limit values

6.14 Gear box serial number

The serial number is engraved with the manufacture date (calendar week and year) on the top side of the gear box

in the housing (see diagram).

43

Technical data

and Start-up


7 Profiles and diagrams

7.1 HSM1–6.17.12

7.1.1 Power / torque depending on speed

400 V HSM1-6.17.12

0

20

40

60

80

100

120

0

40

80

120

160

200

240

0 2000 4000 6000 8000 10000 12000

Mech

. p

ow

er

[kW

]

To

rqu

e [

Nm

]

Speed [rpm]

cont. torque [Nm]

max. torque [Nm]

cont. power [kW]

max. power [kW]

Technical data

and Start-up


7.1.2 Level of motor efficiency

400 V HSM1-6.17.12

TIGHTENING TORQUE [NM]

10 20 30 40 50 60 70 80 100 120 140 160 180 200 220

SP

EE

D [

RP

M]

100 84,14 80,37 77,43 74,28 71,57 68,94 66,41 64,28 60,33 57,14 53,75 50,86 48,26 45,82 43,98

200 89,03 87,64 86,16 84,30 82,67 80,83 79,36 77,74 75,84 72,07 69,52 66,94 64,64 62,50 60,36

300 91,25 90,19 89,57 88,19 87,49 85,89 84,66 83,54 81,43 79,56 77,25 75,41 73,26 71,44 69,62

400 92,02 91,79 91,52 90,51 89,53 88,55 87,65 86,70 84,94 83,23 81,50 79,72 78,06 76,49 74,86

500 94,82 94,19 92,94 92,25 91,37 90,55 90,04 89,02 87,43 86,00 84,65 83,06 81,60 80,21 78,69

1000 94,24 95,65 95,23 94,90 94,56 94,18 93,88 93,48 92,57 91,92 91,02 90,19 89,28 88,40 87,60

2000 91,09 94,93 94,93 95,29 95,29 95,26 95,26 95,14 94,82 94,68 94,14 93,76 93,30 92,85 92,37

3000 91,32 93,96 95,00 95,26 95,61 95,63 95,76 95,69 95,62 95,44 95,23 94,90 94,66 94,27 93,97

3400 91,37 94,09 94,85 95,31 95,64 95,77 95,95 95,93 95,89 95,70 95,51 95,29 95,01 94,77 94,42

3600 91,02 93,81 94,55 95,23 95,40 95,69 95,81 95,88 95,87 95,76 95,57 95,31 95,07 94,79 94,52

3800 90,72 93,90 94,60 95,23 95,50 95,74 95,82 95,86 95,94 95,80 95,64 95,41 95,17 94,95 94,69

4000 90,82 93,69 94,70 95,11 95,50 95,68 95,93 95,92 95,84 95,90 95,61 95,45 95,25 95,08 94,70

4200 94,05 95,04 95,36 95,70 95,91 96,08 96,10 96,06 95,95 95,81 95,63 95,40 94,74 NaN NaN

4400 91,85 94,17 94,81 95,37 95,67 95,88 96,17 96,00 96,05 95,98 95,89 95,69 95,31 NaN NaN

4600 92,88 93,89 95,11 95,47 95,76 95,76 95,96 96,06 96,05 96,10 95,84 95,54 95,03 NaN NaN

4800 91,08 94,24 94,82 95,31 95,79 95,92 96,07 96,09 96,16 95,99 95,69 95,22 94,56 NaN NaN

5000 91,94 93,75 94,70 95,32 95,66 95,99 96,04 96,11 96,15 96,00 95,51 95,16 NaN NaN NaN

5200 91,21 93,61 94,65 95,26 95,82 95,88 96,11 96,06 96,09 95,82 95,43 94,78 NaN NaN NaN

6000 89,76 92,98 94,40 95,14 95,49 95,66 95,75 95,67 95,21 95,01 94,06 NaN NaN NaN NaN

7000 89,03 93,19 94,76 95,07 95,18 95,26 95,28 94,99 94,44 93,02 NaN NaN NaN NaN NaN

8000 88,69 92,58 93,97 94,33 94,47 94,46 94,23 93,86 92,47 NaN NaN NaN NaN NaN NaN


10000 87,37 90,92 92,24 92,88 92,83 92,22 91,50 90,88 NaN NaN NaN NaN NaN NaN NaN

11000 84,53 89,20 91,19 91,49 91,73 87,77 90,11 NaN NaN NaN NaN NaN NaN NaN NaN

12000 84,56 89,01 90,44 90,63 90,53 89,42 88,80 NaN NaN NaN NaN NaN NaN NaN NaN

45

Technical data

and Start-up


7.1.3 Level of generator efficiency (recuperation)

400 V HSM1-6.17.12

SP

EE

D [

RP

M]


-10 -20 -30 -40 -50 -60 -70 -80 -100 -120 -140 -160 -180 -200 -220

100 80,65 75,34 70,07 64,47 58,79 53,41 47,78 42,27 41,36 40,44 39,52 38,61 37,69 36,78 35,86

200 87,55 86,18 83,82 81,12 78,81 76,06 73,31 70,55 65,43 60,28 54,99 49,34 43,68 38,40 36,63

300 88,87 89,38 88,42 87,06 85,29 83,81 82,21 80,51 77,31 73,93 70,54 66,91 63,33 60,24 55,18

400 89,18 91,08 89,98 89,06 88,08 86,89 85,86 84,69 82,30 79,95 77,44 74,73 71,94 69,53 66,65

500 93,95 93,19 92,57 91,68 90,66 89,70 88,79 87,77 85,85 83,84 81,89 79,67 77,43 75,27 73,04

1000 95,63 95,09 94,77 94,41 94,17 93,71 93,42 92,92 92,06 91,13 90,07 89,10 87,99 86,90 85,83

2000 91,68 94,05 94,46 94,96 95,06 95,01 95,05 94,88 94,62 94,28 93,83 93,26 92,80 92,27 91,68

3000 89,95 93,29 94,95 95,02 95,27 95,33 95,48 95,43 95,37 95,23 94,97 94,68 94,35 94,00 93,57

3400 90,28 93,53 94,25 94,90 95,43 95,50 95,62 95,61 95,61 95,43 95,19 94,96 94,61 94,42 94,04

3600 89,69 93,08 94,30 94,95 95,28 95,41 95,59 95,54 95,63 95,49 95,32 95,02 94,78 94,49 94,18

3800 89,83 93,41 94,38 94,98 95,26 95,51 95,66 95,71 95,72 95,60 95,47 95,27 94,97 94,72 94,39

4000 89,90 93,42 94,13 94,76 95,27 95,48 95,61 95,69 95,69 95,63 95,50 95,25 95,03 94,76 94,53

4200 89,82 93,44 94,61 95,14 95,37 95,50 95,72 95,78 95,81 95,77 95,58 95,34 95,21 94,97 94,69

4400 90,86 93,44 94,54 95,21 95,53 95,67 95,82 95,89 95,78 95,69 95,45 95,24 94,93 94,66 94,40

4600 90,64 93,41 94,45 95,25 95,47 95,63 95,73 95,85 95,96 95,84 95,67 95,57 95,40 95,14 94,85

4800 90,29 93,45 94,39 95,13 95,45 95,62 95,87 95,89 96,05 95,88 95,74 95,61 95,38 95,16 NaN

5000 90,15 93,39 94,37 95,09 95,43 95,64 95,68 95,83 96,03 95,94 95,85 95,62 95,39 95,04 NaN

5200 89,16 93,25 94,51 94,97 95,42 95,72 95,74 95,96 96,13 96,08 95,74 95,62 95,28 NaN NaN

6000 89,00 92,85 94,21 94,70 95,32 95,54 95,73 95,77 95,72 95,53 95,23 94,71 NaN NaN NaN

7000 89,15 92,52 94,14 94,93 95,10 95,34 95,41 95,31 95,16 94,64 NaN NaN NaN NaN NaN




11000 85,75 90,88 91,34 92,08 91,88 91,96 91,52 90,30 NaN NaN NaN NaN NaN NaN NaN

12000 81,48 85,79 85,69 91,61 90,97 NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN

Technical data

and Start-up


7.1.4 S1 torque

S1 TORQUE AT 25°C / 5200 RPM HSM1-6.17.12

S1 TORQUE AT 65°C / 5600 RPM HSM1-6.17.12

0

20

40

60

80

100

120

140

160

0:0

0

0:0

5

0:1

0

0:1

5

0:2

0

0:2

5

0:3

0

0:3

5

0:4

0

0:4

5

0:5

0

0:5

5

1:0

0

1:0

5

1:1

0

1:1

5

1:2

0

1:2

5

1:3

0

1:3

5

1:4

0

1:4

5

1:5

0

1:5

5

2:0

0

Sh

aft

To

rqu

e [

Nm

] T

em

pera

ture

[°

C]

Mech

an

ica

l P

ow

er

[KW

]

time [hh:mm ] Shaft torque

DMC motor temperature

Mechanical power

Power losses

0

20

40

60

80

100

120

140

160

0:0

0

0:0

7

0:1

4

0:2

1

0:2

8

0:3

6

0:4

3

0:5

0

0:5

7

1:0

4

1:1

2

1:1

9

1:2

6

1:3

3

1:4

0

1:4

8

Sh

aft

To

rqu

e [

Nm

] T

em

pera

ture

[°

C]

Mech

an

ica

l P

ow

er

[KW

]

time [hh:mm] Shaft torque

DMC motor temperature

Mechanical power

Power losses

47

Technical data

and Start-up


7.1.5 Thermal behaviour / derating

AT 25°C HSM1-6.17.12

Test period 30 min

Voltage 400 V

Speed (number of revolutions) 5200 rpm

Maximum power 74,2 kW

Cooling water temperature 25 °C

AT 65°C HSM1-6.17.12

Test period 30 min

Voltage 400 V


Maximum power 63,4 kW


0

50

100

150

200

00:00 05:00 10:00 15:00 20:00 25:00 30:00

time [min]

Mech. Power [kW]

Shaft Torque [Nm]

Stator Winding Temp. [˚C]

0

50

100

150

200

00:00 05:00 10:00 15:00 20:00 25:00 30:00

time [min]

Mech. Power [kW]

Shaft Torque [Nm]


Technical data

and Start-up


AT 25°C HSM1-6.17.12

Test period 5 min

Voltage 400 V


Maximum power 77.7 kW


AT 25°C HSM1-6.17.12

Test period 5 min

Voltage 400 V




0

50

100

150

200

250

00:00 00:30 01:00 01:30 02:00 02:30 03:00 03:30 04:00 04:30 05:00

time [min]

Mech. Power [kW]

Shaft Torque [Nm]


0

50

100

150

200

250

00:00 00:30 01:00 01:30 02:00 02:30 03:00 03:30 04:00 04:30 05:00

time [min]

Mech. Power [kW]

Shaft Torque [Nm]


49

Technical data

and Start-up


AT 65°C HSM1-6.17.12

Test period 5 min

Voltage 400 V


Maximum power 62 kW


AT 65°C HSM1-6.17.12

Test period 5 min

Voltage 400 V




0

50

100

150

200

250

00:00 00:30 01:00 01:30 02:00 02:30 03:00 03:30 04:00 04:30 05:00

time [min]

Mech. Power [kW]

Shaft Torque [Nm]


0

50

100

150

200

250

00:00 00:30 01:00 01:30 02:00 02:30 03:00 03:30 04:00 04:30 05:00

time [min]

Mech. Power [kW]

Shaft Torque [Nm]


Technical data

and Start-up


7.1.6 Induced motor voltage

HSM1-6.17.12

7.1.7 Short circuit torque

SHORT CIRCUIT MEASUREMENT 3PH. AT 25°C HSM1-6.17.12

0

50

100

150

200

250

300

350

400

450

500

0 2000 4000 6000 8000 10000 12000

Vo

lta

ge

[V

]

Speed [rpm]

Phase voltage RMS

Rectified induced motorvoltage

0

60

120

180

240

-80

-70

-60

-50

-40

-30

-20

-10

0

0 2'000 4'000 6'000 8'000 10'000 12'000

Ph

as

e C

urr

en

t [A

rms]

To

rqu

e [

Nm

]

Speed [rpm] Shaft torque

Phase current

51

Technical data

and Start-up


7.2 HSM1–10.18.13


400 V HSM1-10.18.13

0

40

80

120

160

0

40

80

120

160

200

240

280

320

0 2000 4000 6000 8000 10000 12000 14000

Mech

. p

ow

er

[kW

]

To

rqu

e [

Nm

]

Speed [rpm]

cont. torque [Nm]

max. torque [Nm]

cont. power [kW]

max. power [kW]

Technical data

and Start-up


7.2.2 Level of motor efficiency

HSM1-10.18.13


SP

EE

D [

RP

M]

10 20 30 40 50 60 70 80 100 120 140 160 180 200 220 240 260 280 300

4000 89,19 93,17 94,36 94,89 95,38 95,76 95,88 96,10 96,12 96,09 96,06 95,88 95,68 95,45 95,17 94,86 94,51 94,15 93,94

4500 89,17 93,17 94,41 95,02 95,55 95,80 95,93 96,04 96,22 96,22 96,06 96,01 95,71 95,52 95,25 94,94 94,65 94,29 93,92

4800 89,69 90,46 92,48 93,62 94,31 94,77 95,12 95,29 95,56 95,67 95,67 95,59 95,49 95,31 95,03 94,80 94,45 93,95 NaN

5000 89,66 93,37 94,51 95,01 95,58 95,87 96,05 96,14 96,29 96,26 96,16 96,07 95,87 95,68 95,41 95,07 94,55 NaN NaN

5500 89,21 93,17 94,45 95,06 95,49 95,74 95,89 96,09 96,19 96,21 96,18 96,00 95,77 95,40 94,89 94,23 93,51 NaN NaN

6000 89,39 92,97 94,23 94,97 95,33 95,72 95,84 96,01 96,18 96,16 96,01 95,71 95,29 94,76 93,97 92,97 NaN NaN NaN

6500 88,82 92,75 94,04 94,68 95,13 95,57 95,83 95,95 96,05 95,95 95,66 95,28 94,69 93,76 92,47 NaN NaN NaN NaN

7000 86,30 91,41 93,08 93,92 94,83 95,21 95,47 95,67 95,63 95,52 95,12 94,57 93,61 92,06 NaN NaN NaN NaN NaN

7500 84,80 90,72 92,70 93,07 94,70 94,96 95,24 95,31 95,27 95,12 94,57 93,65 92,11 NaN NaN NaN NaN NaN NaN

8000 84,19 90,19 94,13 94,15 94,56 94,90 95,07 95,09 94,94 94,64 93,92 92,08 NaN NaN NaN NaN NaN NaN NaN

9000 83,39 90,36 92,93 93,68 94,19 94,41 94,49 94,42 94,29 93,52 91,35 NaN NaN NaN NaN NaN NaN NaN NaN

10000 83,13 90,39 92,38 93,26 93,63 93,74 93,82 93,70 93,17 NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN

11000 82,56 89,44 91,80 92,28 92,91 93,03 93,12 92,83 NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN

12000 81,16 88,10 90,70 91,62 92,48 91,84 91,83 91,36 NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN NaN


HSM1-10.18.13

0

50

100

150

200

250

300

350

400

450

500

0 2000 4000 6000 8000 10000 12000

Vo

ltag

e [V

]

Speed [rpm]

Phase voltage RMS

Rectified induced motorvoltage

53

Technical data

and Start-up



SHORT CIRCUIT MEASUREMENT 3PH. AT 25°C HSM1-10.18.13

0

50

100

150

200

250

300

-100

-90

-80

-70

-60

-50

-40

-30

-20

-10

0

0 2'000 4'000 6'000 8'000 10'000 12'000

Cu

rren

t [A

rms]

Sh

aft

_T

orq

ue [

Nm

]

Rotational_speed [rpm] Shaft_Torque

Current_RMS

Technical data

and Start-up


7.3 HSM1–10.18.13-Co


400 V HSM1-10.18.13-CO


HSM1-10.18.13-CO

0

40

80

120

160

200

0

100

200

300

400

500

0 2000 4000 6000 8000 10000 12000M

ech

. p

ow

er

[kW

]

To

rqu

e [

Nm

]

Speed [rpm]

cont. torque [Nm]

max. torque [Nm]

cont. power [kW]

max. power [kW]

0

50

100

150

200

250

300

350

400

450

500

0 2000 4000 6000 8000 10000 12000

Vo

lta

ge [

V]

Speed [rpm]

Phase voltage RMS

Rectified inducedmotor voltage

55

Technical data

and Start-up



SHORT CIRCUIT MEASUREMENT 3PH. AT 25°C HSM1-10.18.13-CO

0

50

100

150

200

250

-80

-70

-60

-50

-40

-30

-20

-10

0

0 1000 2000 3000 4000 5000 6000 7000

Ph

as

e C

urr

en

t [A

rms]

To

rqu

e [

Nm

]

Speed [rpm] Shaft_Torque

Current_RMS

Technical data

and Start-up


7.4 GX629 gear box

7.4.1 Level of efficiency GSX1-102-240-A01

AT 30°C

AT 80°C

0

20

80140200260

90

91

92

93

94

95

96

97

10

02

00

40

08

00

100

0150

0200

0250

0300

0350

0400

0450

0500

0600

0700

0800

0900

0100

00

110

00

120

00

130

00

140

00

150

00

To

rqu

e [

Nm

]

Eff

icie

nc

y [

%]

Speed [rpm]

0

20

80140200260

90

91

92

93

94

95

96

97

98

10

02

00

40

08

00

100

0150

0200

0250

0300

0350

0400

0450

0500

0600

0700

0800

0900

0100

00

110

00

120

00

130

00

140

00

150

00

To

rqu

e [

Nm

]

Eff

icie

ncy [

%]

Speed [rpm]

57

Technical data

and Start-up


8 Installation / start-up

INSTRUCTION

Damage to the motor!

You must ensure that you upload the appropriate motor table for this motor! The wrong data can lead to damage to the motor and to the inverter!

INSTRUCTION

Damage to the cable!

During installation and the laying of cables, observe the maximum bending radii given by the manufacturer! Avoid laying the cables alongside sharp edges and mechanical components!

INFORMATION

Visually check the packing material and the motor in particular for damages (e.g. cracks in the motor and gear box housing) before installation. Each motor undergoes a strict quality and function test at BRUSA before distribution. However, we have no control over transportation routes which can sometimes take a long time and the shipping of our products.


18. Insert the motor into its position and connect the mechanical coupling components.

Please adhere to the installation instructions, see

chapt. Fehler! Verweisquelle konnte nicht

efunden werden. Fehler! Verweisquelle konnte

nicht gefunden werden.

---

19. Check that all connecting elements are secure. ---

20. Unscrew the screws (1).

Take the connection box cover (2) with the O-ring (3) off.

Technical data

and Start-up




Remove the washers (2).

22. Connect the HV supply and the ground wiring.

See chapt. 8 Fehler! Ungültiger Eigenverweis auf Textmarke.

---

23. Connect the ground wire (1) with the car body and the screw (2).

For EMC reasons we generally recommend an additional ground connection (25 mm

2) to

the inverter!

Torque = 15 Nm

NOTE

Ensure that you connect the phases correctly! Mixing up the phases will lead to a change in the rotating direction of the motor or to malfunctions in the motor depending on the connection version.

24. Connect the HV supply.

Phase U (1)

Phase V (2)

Phase W (3)

Ensure that the cable fittings are positioned correctly and that they are secure.

Torque of screws M6 = 3 Nm

Torque of M25 screw-in plug on connection box = 15 Nm

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INFORMATION

The motor is now ready for operation. During the initial start-up, start the motor with care and caution!


25. Put the O ring (1) in the guide slot (2).

Screw down the connection box cover (3).

Torque = 5 Nm

26. Connect the motor sensor cable (1) with the motor sensor switch (2).

27. Connect the cooling water pumps (1) and (2).

Pay attention while doing so to the cooling water inlet (1) and the cooling water outlet (2).

28. Ventilate the cooling system.

See chapt. 8 Fehler! Ungültiger Eigenverweis auf Textmarke.

---

Technical data

and Start-up


8.1 Connecting the HV supply

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. So check that the screw

connections are correct for each completed cable and that the cable lug is fixed properly (pull test).

For the HV connections we recommend:

A shielded, insulated automotive cable (e.g. Huber & Suhner).

Cable lug, for the type see chapter Fehler! Verweisquelle konnte nicht gefunden werden. Fehler! Verweisquelle konnte nicht gefunden werden.

To assemble the cable lugs, using the appropriate crimping tool is absolutely necessary!

INSTRUCTION

Make absolutely sure that the individual strands of the shielding braid (1) do not jut out over the

sealing ring (3) under any circumstances! Once in the integrated state, this will lead to leakages and

subsequently to the leaking of water into the housing!


29. Insulate 35 mm of the HV cable (1).

Ensure that you do not damage the shielding braid underneath it!

The lengths of the phase cables in the connection box are different, so this will have to be adjusted accordingly for U V W.

30. Shorten the shielding braid (1) by 20 mm.

The cable-side shielding braid (2) must be a length of around 15 mm.

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31. Lead the HV cable (1) through the union nut (2).

Lead the HV cable (1) through the terminal insert (3).

32. Place the terminal insert (1) with the front edge flush with the cable insulation (2).

33. Put the shielding braid (1) over the terminal insert (2).

During this, the shielding braid (1) may overlap the O-Ring (3) by a maximum of 2 mm. Fix the terminal insert (2) in position on the HV cable, eg with electrical tape (4).

You must absolutely make sure that the individual strands of the shielding braid (1) do not jut out over the sealing ring (3) under any circumstances! Once in the integrated state, this will lead to leakages and subsequently to the leaking of water into the housing!

Technical data

and Start-up



34. Insulate 16 mm of the HV cable (1).

The lengths of the phase cables in the connection box are different, so this will have to be adjusted accordingly for U V W.

35. Assemble the cable lug (1) at the end of the cable.

No strands should stick out at the sides!

The crimping must be hexagonal. Ensure that the crimping has no deformations at the sides because this will make later installations in the housing difficult!

36. Check the secure positioning of the cable lug manually.

---

37. Assemble a shrinkage tube (1) on the cable lug (2).

The assembly of a shrinkage tube (1) is absolutely necessary because otherwise contacting can result in the housing!

INSTRUCTION

During the layout of the cable take care that the first part of the cable is at least 5cm straight before it will be bend to a radius.

INSTRUCTION

If you have to reassembly the cable you have to use a new terminal insert. Otherwise it can cause a leakage. The terminal inserts can be ordered from BRUSA Elektronik AG or directly from hummel.com.

5cm

http://www.hummel.com/en.html

63

Technical data

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8.2 Ventilating the cooling system

INSTRUCTION

Air pockets in the cooling passage along with generally insufficient cooling of the motor lead to increased wear!

Ensure that the cooling circuit is fault-free.


1. Switch on the cooling circuit. ---

2. Place a suitable collection container under the ventilation hole.

---

3. Open the ventilation screw (1).

4. Leave the cooling circuit on until no more air bubbles come out of the ventilation hole.

---

5. Tighten the ventilation screw.

Torque = 7 Nm

---

6. Check the cooling water level. ---

Technical data

and Start-up


8.3 Carrying out the HV test

DANGER

High voltage!

Danger to life!

The motor housing can be live with high voltage during the HV test! Under no circumstances should you touch the motor housing!

Only carry out the test in a secure environment (no access by outside persons possible)!

INSTRUCTION

Destruction of the stator windings!

You must adhere to the given test voltage and testing time!

Exceeding this test voltage and testing time can lead to damage to the motor!

INFORMATION

The HV test ensures that there are no ground short circuits present within the windings and from the windings and temperature sensors to the housing.

The HV test must only be carried out after working on the HV supply (e.g. after the changing of the terminal board).

65

Technical data

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7. Connect the HV measuring device as is demonstrated in the diagram:

HV- to the ground connection of the motor. HV+ to the phases U, V, W.

---

8. Set the test voltage on the HV measuring device to 2000 VAC (2800 VDC).

The test duration after reaching the test voltage (2000 VAC or 2800 VDC) is 5 seconds.

Rampe Trise / Tfall = 2 seconds.

---

9. Switch the HV measuring device on and carry out the test.

Note the test result.

Max. Leakage current = 10 mA

---

10. Switch off the HV measuring device.

Disconnect the HV measuring device from the motor.

In the event of a negative test result (leakage current > 10 mA), the phase cables and the phase connections to the

terminal block must be checked for damage. If no damage or short-circuit is apparent, the motor must be examined

by the company BRUSA. For this please refer to the manufacturer address given in chapt. 4.6.

Technical data

and Start-up


9 Error correction

As the motor does not have its own control architecture, control faults are always set by the connected inverter.

Use the technical information of the inverter as an aid in the event of any faults occurring. If you cannot find an

appropriate solution there, please contact BRUSA support at the manufacturer address given in chapt. 4.6.

Likewise, if mechanical problems or direct damage to the motor should occur in spite of our high quality standards,

we would ask you to refer directly to our support team.

67

Technical data

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10 Maintenance

DANGER

High voltage!

Danger to life!

Even when the HV supply is switched off, a turning motor can still produce voltage! In general, disconnect the HV supply before starting work on the motor and ensure that no voltage is live in the components in question!

10.1 Changing the O-ring connection box


1. Disconnect the HV supply. Ensure that there is no high voltage present.



3. Clean the sealing surface (1) and the nut (2) with a suitable tool and cleaning agent.

There should be no dirt particles in the nut (2).

4. Put the new O-ring in the cleaned nut. ---

5. Position the connection box cover carefully.

Tighten the screws.

Torque = 5 Nm

---

Technical data

and Start-up


10.2 Changing the terminal board





3. Loosen the screws (1).

Take the screws (1) with washers (2) out.

Remove the cable lugs (3).


Take the screws (1) with washers (2) out.

Remove the cable lugs (3).

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Technical data

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5. Remove the washers (1).


Remove the terminal board (2).

INSTRUCTION

Ensure that you connect the phases correctly! Mixing up the phases will lead to a change in the rotating direction of the motor or to malfunctions in the motor depending on the connection version.

7. Insert the new terminal board (1). The assembly takes place logically in reverse order.

You must adhere to the installation sequence depicted (1) - (9).

M6 Screw torque = 3 Nm

M5 Screw torque = 3 Nm

8. Carrying out the HV Test

See chapt. 8.3 Carrying out the HV test

---

Technical data

and Start-up


10.3 Changing the gear oil temperature sensor

CAUTION

Hot gear oil!

Burn hazard!

Before starting any work on it check that the gear oil has cooled down!

Never drain the gear oil immediately after a long drive!

Carefully check the gear box temperature with your hand before beginning work on the gear box housing.



2. Carefully check the temperature of the gear box housing with your hand.

---

3. Open the oil drain plug (1).

Catch the running gear oil in a clear container! The gear oil is an ATF Lifecycle oil and can therefore be reused!

4. Close the oil drain plug. ---

5. Disconnect the temperature sensor (1) connection.

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Technical data

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6. Unscrew the temperature sensor (1) from the gear box housing.

7. Check that the sealing surface (1) is clean and clean it if need be.

Ensure that the used sealing ring does not remain stuck to the sealing surface (1)!

8. Put the new sealing ring on the temperature sensor. ---

9. Screw the new temperature sensor (1) into the gear box housing and tighten it.

10. Check that the oil drain plug and the temperature sensor are secure.

---

Technical data

and Start-up



11. Connect the temperature sensor (1).

Check that the plug connector is secure and that the plug locks in.

12. Pour in the gear oil which was drained earlier.

See chapt. 6.8.5 Filling up and checking of gear oil

---

INSTRUCTION

After a mileage of around 50 km make sure there are no leaks in the gear box! A high loss of oil will lead to a reduction in lubricating properties and thereby to damage to the gear box!

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11 Spare parts

For more spare parts see chapt. 4.4 Optional delivery contents

NAME PIECES PROD. NO. ILLUSTRATION

1. Terminal board 1 RAAA093

2. M6 hexagonal nut

(Fixing of the cable lugs to the motor phases)

1 RAAA094

3. M6 washer without DIN125A chamfer 1 RAAA095

4. M6 cable lug without insulation

(Compression cable lugs for motor phases connection)

Direct purchase: Vogt AG http://www.vogt.ch Product no: 3582A

1 ---

5. M8 cable lug without Insulation

(Compression cable lug for connecting ground)

Direct purchase: Vogt AG http://www.vogt.ch Product no: 3584A

1 ---

6. O-ring connection box 1 MAAA354

7. Bleeder screw (M6 x 10) 1 MAAA377

8. USIT sealing ring for M6 bleeder screw 1 CJAA055

9. M8 x 16 hexagonal screw

(Ground GND)

1 RAAA297

10. Connection box cover 1 MAAA289


1 MHAA776

12. M18 x 1.5 cooling water connection pieces for quick coupling 1 MHAA777

13. Cable glands for 13 mm - 18 mm cable diameter 1 RAAA040

http://www.vogt.ch/

http://www.vogt.ch/

Technical data

and Start-up


NAME PIECES PROD. NO. ILLUSTRATION

14. Gear oil temperature sensor

Direct purchase: GETRAG AG http://www.getrag.com Product no: 900.9.0055.02

1 ---

15. Parking lock sensor Direct purchase: GETRAG AG http://www.getrag.com Product no: 900.9.0530.02

1 ---



75

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12 Warranty and guarantee

The company BRUSA Elektronik AG provides a guarantee period of 24 months after the date of purchase provided

there are uniquely verifiable material and workmanship defects.

The guarantee acceptance becomes invalid immediately if the seal on the housing is damaged through

unauthorised opening or if it is not there at all!

Furthermore, BRUSA Elektronik AG accepts absolutely no liability for damage which results from incorrect or

improper handling of the device!

For damage to persons which results from non-observance of the general and product-specific safety guidelines,

no liability claims can be asserted against BRUSA Elektronik AG!

For damage to peripheries which results in connection with this device, BRUSA Elektronik AG can accept no

liability! If anything is unclear regarding the operation of this product, we would ask you to sort this out with our

support team BEFORE you start the installation!

Technical data

and Start-up


13 Index

B

Block Diagram

Controller Structure .............................................................. 32

Installation into the Vehicle .................................................. 24

Temperature Measurement ................................................. 33

C

Cable connections

Instructions and Cross-sections ............................................ 19

Cooling System

Connections .......................................................................... 34

Specification .......................................................................... 20

Cooling Water Connection

Fall in Pressure ................................................................ 15, 16

G

Gear Box

Oil Quantity ........................................................................... 31

Oil Specification .................................................................... 31

Power Transmission .............................................................. 22

Specification .......................................................................... 20

Guarantee

Instruction ............................................................................. 12

H

High voltage

The 5 Safety Rules ................................................................. 12

HSM-10.18.13

Induced Motor Voltage ......................................................... 51

Level of Efficiency ................................................................. 51

Power .................................................................................... 50

Short Circuit Torque .............................................................. 52

HSM-10.18.13-Co


Level of Efficiency ................................................................. 53

Power .................................................................................... 53


HSM-6.17.12


Level of Efficiency ........................................................... 43, 44

Power .................................................................................... 42

S1 Torque .............................................................................. 45


Thermal Behaviour 25° ......................................................... 47

Thermal Behaviour 65° ................................................... 46, 48

HV supply ................................................................................... 59

I

Installation / start-up ................................................................. 56

Installation Tolerance ................................................................ 29

Interlock

Principle of operation............................................................ 25

K

Kühlwasserstutzen ..................................................................... 35

M

Motor

Connection ............................................................................ 38

Emergency Shut Down .......................................................... 13

Limit Values ........................................................................... 18

Product-Lifespan Guidelines ................................................. 11

Specification .......................................................................... 19

Motor Table ............................................................................... 14

N

NTC ................................................................................ 13, 22, 33

P

Parking Lock ................................................................... 22, 36, 39

Pictograms ............................................................................. 8, 23

PTC ................................................................................. 13, 22, 33

Q

Quick-lock coupling .................................................................... 35

R

Rotor Offset

Instructions ........................................................................... 26

Labelling ................................................................................ 26

S

Safety

Important Instructions .......................................................... 10

Warning Signs ....................................................................... 23

T

Temperature Measurement ...................................................... 13

Temperature Sensor ............................................................ 31, 69

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