Table of Contents
Summary of Contents for Brusa DMC514
- Page 1 TECHNICAL DATA AND STARTUP DMC514 (ISU) DMC524 (ISU) DMC534 (ISU) DMC544 Translation of the original German operating instructions. BRUSA Elektronik AG Neudorf 14 CH-9466 Sennwald +41 81 758 19 00 www.brusa.biz info@brusa.biz...
- Page 2 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!
- Page 3 ALIDITY This manual is valid only for the following devices: TYPE DMC514 (ISU) - Ser.No. > 1000 DMC524 (ISU) - Ser.No. > 1000 DMC534 (ISU) - Ser.No. > 1000 DMC544 - Ser.No. > 1000 Technical data and startup...
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Page 4: Table Of Contents
Table of contents Foreword ..........................7 List of abbreviations ......................7 Safety and warning instructions ..................8 Symbols and their meaning ......................8 Safety instructions and danger levels ..................9 Generally applicable safety measures ..................10 3.3.1 Safety instructions for cooling water systems ..............10 3.3.2 Safety instructions for mechanical systems ............... - Page 5 Warning message definition ....................35 Level of inverter efficiency ....................36 DMC514 measured with HSM1-10.18.04 at 400V (first quadrant) ..........36 DMC524 measured with HSM1-6.17.12 at 400V (first quadrant) ..........36 DMC534 measured with HSM1-10.18.13 at 400V (first quadrant) ..........37 DMC544 measured with HSM1-10.18.13-W7 at 400V (first quadrant) ........
- Page 6 LV current consumption......................47 8.4.1 ............................. 48 8.4.2 ....................49 Ext AW1 Ext AW2 Grounding screw ........................50 Cooling water connections ....................... 51 Cooling circuit Information and Warnings ................. 52 8.7.1 Cooling water filter......................52 Start-up ..........................53 System requirements for PARAM-tool software ................ 54 Ventilate and check cooling system ..................
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Page 7: Foreword
Dear customer! With the BRUSA inverter DMC5x4 you have received 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... -
Page 8: Safety And Warning Instructions
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! Symbols and their meaning Throughout this manual, some specific technical abbreviations are used. -
Page 9: Safety Instructions And Danger Levels
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! Avoid these dangers by observing these instructions! CAUTION This instruction warns against serious, irreversible risks of injury! Avoid these dangers by observing these instructions! -
Page 10: Generally Applicable Safety Measures
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! The present safety instructions from the system integrator and/or distributor must therefore be supplemented by specific country and local guidelines. -
Page 11: Safety Instructions For Handling And Operation
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! Technical data and startup... -
Page 12: Safety Instructions For Electrical Systems
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... -
Page 13: Safety Installations / Power Limitations
Safety installations / power limitations 3.4.1 Interlock INFORMATION The pins IL1 and IL2 on the control connector must be connected and evaluated by the customer for this. The interlock switch (1) protects the operator from injuries from the HV connections. The interlock switch (1) is automatically activated as soon as the service cap is opened. -
Page 14: Automatic Discharge Of Dc-Link Voltage
ISO26262 and can meet the criteria of ASIL-C. The ISU is not a standard protective function and can be applied by BRUSA optionally. You can find detailed information on the ISU on the attached sheet DMC_ISU.pdf... -
Page 15: Safety Measures For Vehicle Installation
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! 3.5.1 Principle of operation Interlock The interlock switch (1) is closed if the corresponding interlock condition of each device is met (closed service cover, plugged HV connections ...). -
Page 16: Requirements For The Start-Up Personnel
Requirements for the start-up personnel All courses of action described in this manual may only be carried out by a qualified electrician! Specialist staff is 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. -
Page 17: General
The operation and safety instructions given in the previous chapters must be strictly adhered to ensure the ongoing optimum functioning of the inverter and to meet the guarantee requirements of BRUSA Elektronik AG. All work sequences and illustrations are based on the DMC524 model and are applicable to all model versions mentioned in this handbook. -
Page 18: Delivered Mechanical Components
4.6. INFORMATION For the DMC544, you can use the same cable lugs as for the DMC534. The diameter of 70mm cables fits without problems into 50mm cable lugs and is qualified by BRUSA Elektronik AG. MEANING PIECES ILLUSTRATION DMC5x4 inverter... - Page 19 MEANING PIECES ILLUSTRATION 23 pole control connector with crimp terminals AMPSEAL 770680-1 SN/LP contacts AMPSEAL 770854-1 for wire diameter: 0.5 mm We recommend the use of the following crimping tool: Tyco 58440-1 Normaquick cooling water connection pieces 0° Norma PS3 Software package (For a listing see chapter 4.2 Scope of the entire documentation)
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Page 20: Optional Delivery Contents
Optional delivery contents INFORMATION These accessories can be obtained optionally from BRUSA Elektronik AG. MEANING TYPE ILLUSTRATION Special key for HV cable fitting RAAA041 Normaquick cooling water connection pieces 90° Norma PS3 MHAA776 M18x1.5 D16 cooling water connection MAAA366 Rubber seal for M18x1.5 D16 cooling water connection MAAA365 Protective cap for M18x1.5 D16 cooling water connection... -
Page 21: Eu-Guidelines
This manual has been produced under the application and in respect of Inverter DMC5x4 EG guidelines, national regulations and harmonised standards (EN) which were valid at the time of production. Contact information of the manufacturer BRUSA Elektronik AG Neudorf 14 9466 Sennwald... -
Page 22: Intended Use Of The Device
Intended use of the device Proper use The BRUSA DMC5x4 inverter has been designed for the following uses. In the case of planned operations in other sections, please contact the company BRUSA Elektronik AG beforehand at the manufacturers address as given in chapter 4.6. -
Page 23: Improper Use / Limits Of The Product
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 DMC5x4 inverter. Operation out with the defined limits can also lead to life-threatening situations! The following limit values are set for the DMC5x4 inverter by the manufacturer and must be adhered to in all cases: ... -
Page 24: About This Device
About this device Technical data HV AND LV POWER SUPPLY DMC514 DMC524 DMC534 DMC544 UNIT Min. Input voltage at terminal 15 (connect inverter) Min. Input voltage at terminal 15 (automatic disconnection of the inverter) Min. HV input voltage for operation (Software disconnection) Min. - Page 25 THERMAL DMC514 DMC524 DMC534 DMC544 UNIT Amount of coolant in device Flow rate 6-10 6-10 6-10 6-10 l/min External diameter of cooling water connection pieces Minimum coolant temperature at inlet - 40 - 40 - 40 - 40 °C Maximum coolant temperature at inlet...
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Page 26: Type Plate
Type plate The type plate is on the back of the device and contains the following information: Classification Operating voltage (section) Maximum input current Maximum coolant temperature at inlet Serial number IP protection category Max. power Maximum phase currents (U, V, W) Level of efficiency Date of manufacture Technical data... -
Page 27: Device Warnings
The power output stage of the DMC5x4 is based on the most capable, resonant SoftSwing® topology which was developed and patented by BRUSA Elektronik AG. SoftSwing® topology achieves minimal switching losses and excellent EMC features which are above average. Through this, the use of applications with motor frequencies of up to 2 kHz is possible. -
Page 28: Covers
Covers INFORMATION Only the covers mentioned in this chapter may be removed by the customer! Torque for M4 x 08 screws: 2.5 Nm Service lid M4 x 08 screws (8 pieces) Technical data and startup... -
Page 29: Assembly Information
Assembly information 6.6.1 Installation position Even if the device has high IP protection, install it well above the fording depth of the vehicle. Ensure for the installation positioning that the connection side is tilted downwards. This prevents water accumulation on the cable sealing which could result in water leaking into the housing. -
Page 30: Example Of Use
Example of use Technical data and startup... -
Page 31: Input And Output Values
Input and output values TRQrq, Requested and current torque Iz min, Iz Min. and max. high voltage current (DC) TRQact SPDrq, Requested and current speed Uz act Current high voltage SPDact Uz min, Uz Min. and max. high voltage (DC) IAC act, Iz High voltage actual current phases and actual current... -
Page 32: Block Diagram Output Stage / Power Print
Block diagram output stage / power print Technical data and startup... -
Page 33: Operating Modes Of The Inverter
6.10 Operating modes of the inverter Start / Power up: This mode can be viewed as standby state. The requirements for this are: Terminal 30 connected (12 V is engaged) Connect terminal 15 (activation of the ignition key) Standby: The activation of this mode takes place automatically after the start-up process (after activation of Start mode / Power up). -
Page 34: Regulatory Approach And Limitations
Speed mode: In this mode, the main controller is the speed regulator. The entry of the speed takes place over CAN. The negative or positive torque can be reduced at the same time. The inverter continuously attempts to follow the given speed (in respect of the limited torque value). -
Page 35: Error Definition
6.12.1 Error definition Errors invariably lead to shut down the inverter (Error mode). The resuming of operation is not taken place here automatically. Errors must always be cleared with the command DMC_ClrError. This can take place alternatively through a hardware reset. You will find further information in the manual DMC5_ControlConcept.pdf. -
Page 36: Level Of Inverter Efficiency
Level of inverter efficiency DMC514 measured with HSM1-10.18.04 at 400V (first quadrant) DMC514 Torque [Nm] 110 120 130 140 150 1000 77.39 79.95 84.24 86.43 87.75 88.65 89.30 89.78 90.13 90.35 2000 80.93 87.80 90.47 91.90 92.79 93.38 93.88 94.15 94.11 94.21 3000 90.18 93.43 94.56 95.12 95.40 95.53 95.57 95.54 95.48 95.38... -
Page 37: Dmc534 Measured With Hsm1-10.18.13 At 400V (First Quadrant)
DMC534 measured with HSM1-10.18.13 at 400V (first quadrant) DMC534 Torque [Nm] 1000 78.57 84.89 87.29 88.49 89.13 89.48 89.64 89.68 89.64 89.53 89.38 89.17 88.91 88.64 88.35 2000 86.66 90.93 92.46 93.23 93.62 93.82 93.90 93.90 93.84 93.72 93.57 93.38 93.15 92.90 92.71 3000 90.18 93.43 94.56 95.12 95.40 95.53 95.57 95.54 95.48 95.38 95.27 95.10 94.90 94.68 94.47 4000... -
Page 38: Connections
Connections Circuit connections INFORMATION For connections 1 - 5 the following specifications are recommended: Shielded, insulated automotive cable (e.g. Huber & Suhner). Cable lug without insulation for each M8 cross section (e.g. Vogt AG). Torque for cable lug (M8 x 10): 15 Nm. High voltage- (HV-) High voltage+ (HV+) Motor phase U... -
Page 39: Pin Assignment Motor Sensor Connection (Device Side)
Pin assignment motor sensor connection (device side) INFORMATION The pin assignment of the motor sensor connection is BRUSA specific and deviates from the standard pin assignment standards of the cable manufacturer! 1. POS3 6 bit absolute position bit 3 2. POS4 6 bit absolute position bit 4 3. -
Page 40: Pin Assignment Of Control Connector (Device Side)
Pin assignment of control connector (device side) GND* Ground (Minus wiring system, 2. AUX* +12 V (Plus wiring system, terminal 31, input range 6 – 32V) terminal 30, input range 6 – 32V) Enable (Power ON, terminal 15, input 4. DO0 Reserve range 6 –... -
Page 41: Pin 1 Gnd (Ground Terminal 31)
8.3.1 Pin 1 GND (ground terminal 31) INFORMATION If DMC5x4 control signals are connected with other vehicle components, then the connection to the vehicle's ground must take place at this pin. Internal wiring Pin 1 GND Housing Direct ground connection of the inverter's control electronics. The signal ground is connected with the inverter housing through a few components. -
Page 42: Pin 3 En (Enable, Power On)
If HV voltage > 100 V, the wiring system is loaded with </= 30 mA. 8.3.3 Pin 3 EN (Enable, Power ON) INFORMATION To program new firmware, pin 3 must be high! Internal wiring KL30 Pin 3 4,7K KL15 If voltage is applied at pin 2 and pin 3 = high, this effects the start-up of the controller. Communication with the inverter is thereby enabled. -
Page 43: Pin 11 Txd, Pin 12 Rxd (Rs232 Interface)
SW-FW-SHC3_Firmware_download.pdf In this document you will find all information regarding programming and the settings necessary for it. The firmware for the microprocessor can be downloaded over this interface (provided by BRUSA). Pin 13 PRO must be high for this. Technical data... -
Page 44: Pin 13 Pro (Enable Firmware Programming)
INSTRUCTION The programming of the wrong firmware can lead to the damage of the inverter! The programming may only be carried out after consultation with the company BRUSA Elektronik INFORMATION This pin is only activated for the programming of a new firmware (Pin PRO = high). Pin 3 EN must also be high for this. -
Page 45: Pin 17 Ext Aw1, Pin 18 Ext Aw2 (External Shut Down Path 1 + 2)
8.3.7 Pin 17 EXT AW1, Pin 18 EXT AW2 (External shut down path 1 + 2) INFORMATION These pins must be active for the basic functioning of the inverter. This function is also intended as an additional safety installation. The shutdown takes place redundantly through this at the output stage drivers (see illustration). -
Page 46: Pin 19 Il1, Pin 20 Il2 (Interlock 1 + 2)
8.3.8 Pin 19 IL1, Pin 20 IL2 (Interlock 1 + 2) DANGER High voltage! Danger to life! The bypassing or short-circuiting of safety installations can result in fatal dangers through high voltage! The interlock is a security installation and under no circumstances can it be disabled or bypassed! INFORMATION This function must be implemented by the customer by connecting and assessing both pins (pin 19 IL1 and Pin 20 IL2)! -
Page 47: Lv Current Consumption
LV current consumption In the following tables you can see the LV current consumption of the control connector. The currents were measured as follows: Test setup HV-Supply DMC5x4 Ext AW1 Ext AW2 Technical data and startup... -
Page 48: I Aux
8.4.1 [µA] without HV I_Aux [uA] Spannung [V] [µA] @ 300V I_Aux [uA] Spannung [V] [µA] @ 400V I_Aux [uA] Spannung [V] Technical data and startup... -
Page 49: I Aux + I En + I Ext Aw1 + I Ext Aw2
8.4.2 Ext AW1 Ext AW2 without HV Ext AW1 Ext AW2 I_Aux [mA] I_En [mA] I_Ext AW1 [mA] I_Ext AW2 [mA] Total Current [mA] Voltage [V] @ 300V Ext AW1 Ext AW2 I_Aux [mA] I_En [mA] I_Ext AW1 [mA] I_Ext AW2 [mA] Total Current [mA] Voltage [V] @ 400V... -
Page 50: Grounding Screw
Grounding screw WARNING Sparking! Fire hazard! A loose ground circuit can lead to sparking and subsequent fires! Ensure that the ground connection is connected correctly! INFORMATION The grounding screw (1) must be connected with the ground of the vehicle and/or testing bay. We generally recommend a direct connection to the motor. -
Page 51: Cooling Water Connections
Cooling water connections INFORMATION The cooling water hose gets attached to the Normaquick terminals (1) and (2). Optionaly, you can order normal cooling water connections for hose clamps, see chapter 4.4 Optional delivery contents. The Normaquick connections have an inner diameter of 11 mm. Cooling water inlet (1) Cooling water outlet (2) Technical data... -
Page 52: Cooling Circuit Information And Warnings
Cooling circuit Information and Warnings INFORMATION For correct operation, the following points have to be considered: The mixing ratio of the coolant has to be at least 50% water and 50% glycol. Otherwise the inverter will be destroyed at low temperatures! ... -
Page 53: Start-Up
12. Parameters can now be set for the inverter with the see manual Param operation.pdf applied software (e.g. PARAM_Tool from BRUSA). 13. If it is not already done, load the motor parameter see chapter 9.3 Load motor parameter table onto table onto the inverter. -
Page 54: System Requirements For Param-Tool Software
These must be installed on the inverter using the PARAM-Tool software. If using other brands of motor, the corresponding tables must be invoiced for and developed by BRUSA Elektronik You will find instructions for installation and settings in the manual PARAM_Manual.pdf... -
Page 55: Build Hv Supply
Build HV supply INFORMATION Before the HV connections are switched via a contactor, a pre-loading of the high voltage must take place. The device specific X capacity values can be found in the technical data, see chapt. 6.1 Technical data Close the pre-charging contactor (1). - Page 56 Build HV-lines 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).
- Page 57 PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 3. Lead the HV cable (1) through the union nut (2). Lead the HV cable (1) through the terminal insert (3). 4. Place the terminal insert (1) with the front edge flush with the cable insulation (2). 5.
- Page 58 WARNING 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. Technical data and startup...
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Page 59: Operation Of The Inverter Through Cvi
Operation of the inverter through CVI INFORMATION The chapter is only relevant if you are working with the supplied CVI software CANAP_DMC5 ! Activation of the CAN communication Deactivation of the CAN communication Torque Speed (number of revolutions) Error messages Warning messages Limitations Stop button (deactivate motor) -
Page 60: Build Connection Between Cvi And The Inverter
10.1 Build connection between CVI and the inverter PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 1. Switch on the inverter. Activate terminal 15 in addition to terminal 30. The status Rx (9) will then flash. 2. Click the button GO (1). The CAN connection is activated. -
Page 61: Fix Cvi Problems
10.3 Fix CVI problems ERROR POSSIBLE CAUSES CORRECTION Error active, cannot be removed With an incompatible or faulty CAN matrix, it is Analyse and remove errors in the manual possible that the errors displayed in the section (5) DMC5_ErrorsAndWarnings.pdf. are incomplete! Limitation active The limitation value is set too high or too low. -
Page 62: Error Correction
If there is water in your device, take the device out of operation immediately! Disconnect the supply voltage and all other connections! Check the housing on damage and also the insulation of the HV-cables! Please refer to BRUSA support at the manufacturing address given in chapter 4.6. Technical data... -
Page 63: Instructions For Disposal
Instructions for disposal A basic requirement for the re-use and recycling of used electronic devices is the correct disposal. With the implementation of the electric and electronic device regulation (ElektroG) since the 24th of March 2006, electronic devices may no longer be disposed of along with ordinary household waste, rather they must be separately collected and recorded by a specialist services. -
Page 64: Warranty And Guarantee
Warranty and guarantee The warranty corresponds to the regulations in our currently valid general terms and conditions see under www.brusa.biz/en/support/terms-conditions.html. Technical data and startup... -
Page 65: Index
Index Start-up requirements ............41 ISU ....................45 ASIL .................... 14 Motor Cable connections Connection ................50 Cable recommendation ............38 Driving ................... 54 Activate / deactivate connection with PARAM_Tool .... 59 Controller ................... 42 output stage Cooling water release ................... 45 connections................