Related Manuals for Brusa BDC546
Summary of Contents for Brusa BDC546
- Page 1 TECHNICAL DATA AND START-UP DC/DC converter BDC546 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 - including extracts thereof. All technical information, drawings and photos used in this document are protected by copyright and any infringement...
- Page 3 ALIDITY This manual is only valid for the devices listed in the following table: BDC546-B04 BDC546-B05 (OEM Version) BDC546-B06 The breakdown of the device designation is as follows: Technical data and start-up BDC546...
-
Page 4: Table Of Contents
Proper use..........................20 Improper use / Limits of the product ..................20 About this device....................... 21 Technical data .......................... 21 Technical properties ......................... 23 BDC546 block diagram ......................23 Basic function / EMC concept ....................24 Technical data and start-up BDC546... - Page 5 Connections ........................48 Control connector ........................48 Highside cable .......................... 49 Lowside cable .......................... 50 Cooling water connections ....................... 51 Installation / initial start-up ....................52 Installation and connection of the DC/DC converter ..............52 Technical data and start-up BDC546...
- Page 6 [23] Stored App Data ..................... 72 10.2.15 [31] General Parameters ....................73 10.2.16 [32] Revision Info ......................73 10.3 DC/DC converter operation ...................... 74 10.4 Brusa CVI ..........................75 10.4.1 CVI software installation ....................75 10.4.2 CVI operation ........................76 Firmware update ......................77 11.1 FDT installation and firmware download instructions ..............
- Page 7 Instructions for disposal ....................79 Index ..........................80 Attachments ........................82 16.1 Cable fitting ..........................82 16.2 Cable lugs ..........................86 Technical data and start-up BDC546...
-
Page 8: Foreword
Foreword Dear customer, By purchasing the BRUSA BDC546, you have chosen an efficient and versatile product. As this device is a high- performance electronics product which uses dangerous levels of voltage and current, special expertise with respect to handling and operation is required! Before installing the device or carrying out any other work on it, this manual –... -
Page 9: Safety And Warning Instructions
Mandatory signs SYMBOL MEANING SYMBOL MEANING Disconnect device from voltage Disconnect device from mains Wear protective glasses Wear protective gloves Information signs SYMBOL MEANING SYMBOL MEANING Important information on avoiding possible Important information damage to property Technical data and start-up BDC546... -
Page 10: Safety Instructions And Danger Levels
Avoid these risks by observing this notice! NOTICE This notice is a warning against possible damage to property if the following instructions and work procedures are not observed. INFORMATION This type of notice discloses important information to the reader. Technical data and start-up BDC546... -
Page 11: Generally Applicable Safety Measures
Sparks forming at the device's connections can set them on fire and lead to explosions! CAUTION Hot surfaces! Burn hazard! The device produces high temperatures when in operation! Therefore, the device is to be handled with care and caution at all times! Technical data and start-up BDC546... -
Page 12: Safety Instructions For Handling And Operation
Prevent any fluid ingress into the device (e.g. during assembly work). Fluid ingress will lead to a short circuit and subsequently to damage to the device! In the case of any fluid ingress, do not start the device and immediately contact BRUSA Elektronik AG! ... -
Page 13: Safety Instructions For Electrical Systems
(if applicable) Ensure that the device is de-energised by means of a suitable voltage tester (note voltage range!) Earth and short-circuit the system. Cover or seal off adjacent live parts. Technical data and start-up BDC546... -
Page 14: Safety Installations / Power Limitations
To protect the fuel cell in case of an overvoltage on the lowside, a pyrofuse is provided to disconnect the connection between the fuel cell and the BDC546. For this, a fuse with a resistance of approx. 2 Ohm can be applied. -
Page 15: Over Temperature Protection (Derating)
HV - Automatic intermediate circuit discharge The BDC546 is equipped with an active as well as passive feature for discharging the HV circuit. This includes the highside as well as the lowside. Active intermediate circuit discharge is implemented inherently via an internal HV supply and cannot be controlled. -
Page 16: Requirements Regarding The Start-Up Personnel
as well as knowledge of the relevant requirements and dangers which they can demonstrate in practice. Furthermore, they must be able to assess the work assigned to them independently, identify possible dangers and establish necessary protection measures. Technical data and start-up BDC546... -
Page 17: General
Furthermore, it contains technical data, application information and a basic description of the device and its specific components. The operational and safety instructions given are to be adhered to in order to ensure ongoing optimum functioning of the device and to meet the warranty requirements of BRUSA Elektronik AG. Scope of the entire documentation INFORMATION To commission the device successfully, the entire set of documentation as well as diverse pieces of software are required. -
Page 18: Scope Of Delivery
Scope of delivery MEANING QUANTITY ILLUSTRATION 1. BDC546-B 2. Protective cap for cooling water connection pieces 3. M8 x 16 screws for the cable lugs 4. M8 washer for M8 x 16 screws 5. M10 x 16 hexagonal screw (ground GND) 6. -
Page 19: Applicable Standards
Applicable standards This manual has been produced under application and consideration of the EC guidelines, national laws and harmonised standards (EN) valid at the time of production relevant to the product BDC546. Manufacturer contact information BRUSA Elektronik AG Neudorf 14... -
Page 20: Use And Limits Of The Product
Taking into consideration the proper use indicated in chapter , the following limit values have been stipulated for the operation of the product BDC546. The product may not be used outside these limit values. Operation outside these limit values can lead to life-threatening situations. -
Page 21: About This Device
About this device Technical data HIGHSIDE BDC546-B UNIT Min. operating voltage (full performance, highside must not be below lowside) Max. operating voltage (full performance) Overvoltage, the switch-off threshold of the power stage can be set up to Max. voltage, no operation, max. 1 min... - Page 22 CONTROL CIRCUIT BDC546-B UNIT Min. voltage for signals at the control connector (AUX / Kl.30) Max. voltage for signals at the control connector (AUX / Kl.30) Lowside voltage measuring range 0 to 828 Lowside voltage signal accuracy (1 V at < 100 V, 1 % of the measuring value at > 100 V)
-
Page 23: Technical Properties
Tested according to ECE directives / Certified according to E13 Interlock function evaluation FGPA implemented, highly dynamic control circuit Patented Liquid Pin© cooling system SoftSwing® topology for minimum switching loss at above average EMC properties BDC546 block diagram Technical data and start-up BDC546... -
Page 24: Basic Function / Emc Concept
Specifically, the component can be used as connection between HV batteries and battery systems with other voltage levels. It is also possible to use the BDC546 as coupling between a HV battery and power electronic devices like frequency inverters, on-board converters, etc. Ideally, the component is used as interface between fuel cell systems and HV batteries. -
Page 25: Filter Concept For Highside And Lowside
) and the leakage inductance of the HV chokes (L ) form the push-pull filter. Due to the high clock frequencies, the capacitors may have very small dimensions. Thus, a rapid discharge of the intermediate circuit is possible. Technical data and start-up BDC546... -
Page 26: Warnings On The Device
In order to obtain an original label, please contact the BRUSA support at the manufacturer’s address provided in chapter Das Bild kann zurzeit nicht angezeigt werden. -
Page 27: Vehicle Installation Basic Principle
Vehicle installation basic principle Technical data and start-up BDC546... -
Page 28: Safety Concept For Vehicle Installation
Safety concept for vehicle installation INFORMATION This safety concept is a recommendation of BRUSA Elektronik AG and is a general requirement for the safe operation of electric vehicles! 6.7.1 General interlock function The interlock switches (1) are closed if the respective interlock conditions of the individual devices are met (closed service cap, HV connections plugged-in...). -
Page 29: Interlock Signal
Interlock signal The interlock signal is to be guided through all HV-carrying connectors in a HV system. The signal of the BDC546 can be evaluated via pin 19 of the control connector. A rectangular signal frequency of 86 Hz ≤ f ≤ 90 Hz is regarded by the component as permissible. -
Page 30: Overview Of The Main Structural Components
Overview of the main structural components Lowside cable fitting Service cap Housing cover Housing Water duct cover Cooling water connections Control connector Grounding connection for grounding cable Highside cable fitting Technical data and start-up BDC546... -
Page 31: Dimensions And Installation Information
The housing has been designed for a maximum admissible fastening screw torque of 8 Nm! For fastening the device at the fastening points, eight M6 screws are to be used and tightened with a tightening torque of 8 Nm. 8 screws with M6 thread, stud hole with 18 mm depth Technical data and start-up BDC546... -
Page 32: Dimensions
The water cooling circuit of the device has a U shape, which would now be upside down. In such case, the ventilation of the cooling circuit is difficult, and the device may be cooled insufficiently. Technical data and start-up BDC546... -
Page 33: Type Plate
Product number (specified by the customer) Supplier number (specified by the customer) Highside voltage range for operation Efficiency Max. admissible cooling water temperature at the input Lowside voltage range for operation Lowside peak current Peak power IP protection class Technical data and start-up BDC546... -
Page 34: Electrical Interfaces
Highside plus Highside minus Chapter 7.3 Highside and lowside power Chapter 7.3 Highside and lowside power connections connections Lowside plus Lowside minus Chapter 7.3 Highside and lowside power Chapter 7.3 Highside and lowside power connections connections Technical data and start-up BDC546... -
Page 35: Control Connector Pin Assignment (Device Side)
Enable (power ON, terminal 15) 17. DO_MC Digital main contactor output 18. NC Not connected 19. IL HV interlock input 20. NC Not connected 21. NC Not connected 22. NC Not connected 23. NC Not connected Technical data and start-up BDC546... -
Page 36: Pin 1 Gnd
Direct connection to the ground of the control unit. The signal earth is only capacitively connected to the housing. When wiring BDC546 control signals with other vehicle components (e.g. traction drive, vehicle battery, battery management (BMS), fuel cell), the vehicle ground is to be connected here. -
Page 37: Pin 2 Aux
Main contactor control Voltage Pin 16 EN RUN command HV voltage (V) Type. Current draw at Pin 2 AUX (V) (terminal 15) (sent via CAN) Pin 2 AUX (mA) 12.0 0.641 14.0 0.731 12.0 272.3 14.0 247.0 Technical data and start-up BDC546... -
Page 38: Pin 6 Txd, Pin 7 Rxd, Pin 8 P_Gnd
Should you have any questions regarding this subject, please refer to the BRUSA support at the manufacturer's address provided in chapter 4.5. -
Page 39: Pin 9 Cnl, Pin 10 Cnh
CAN 2.0 B (baud rate can be set, e.g. 250 k, 500 k, 1 Mbit) Termination of the CAN interface is not intended in the DC/DC converter (CAN terminating resistor) Via the CAN interface, messages can be transmitted in accordance with the CAN matrix provided by BRUSA as dbc file. -
Page 40: Pin 11 Pfo_Vc+, Pin 12 Pfi_Vc+, Pin 14 Pfo_Vc-, Pin 15 Pfi_Vc
GND and the pyrofuses are triggered. If no pyrofuses are applied, the respective function can be deactivated by means of the PARAM software. The pins 11, 12, 14 and 15 do not need to be connected in this case. Technical data and start-up BDC546... -
Page 41: Pin 13 Pro
NOTICE Programming an incorrect firmware may damage the device! Therefore, programming may only be carried out after consultation with BRUSA Elektronik AG! INFORMATION This pin is only activated for programming of a new firmware (pin 13 PRO = high). For this purpose, pin 16 EN does not need to be high. -
Page 42: Pin 16 En
If voltage is applied at pin 2 AUX and if pin 16 is EN = high, the device is put into the operational mode. Most appropriately, this is implemented by connecting pin 16 EN to the Plus wiring system via a switch. Technical data and start-up BDC546... -
Page 43: Pin 17 Do_Mc
Pin 17 DO_MC is a digital output switching between signal ground GND and wiring system Plus AUX and designed for a peak current of 4 A for 120 ms and 200 mA continuous current. This way, two main contactors between the HV battery and the BDC546 can be directly controller. Technical data and start-up... -
Page 44: Pin 19 Il
Internal wiring Via pin 19 IL, the signal of an external interlock loop can be recorded and evaluated. As the BDC546 itself is not part of the loop, it cannot be disconnected by the interlock loop. However, it can detect errors that are caused by external devices in the interlock loop. -
Page 45: Earthing / Grounding Screw (Equipotential Bonding)
The grounding screw (1) must be connected with the ground of the vehicle and/or test bench. A washer (2) is to be positioned between the grounding screw (1) and the cable lug. Grounding screw (1) torque = 28 Nm Technical data and start-up BDC546... -
Page 46: Highside And Lowside Power Connections
Before crimping the cable lugs to the power cables, the cable fittings have to be guided over the power cables. Do not install the cable fittings at the device housing yet Highside cable fittings Lowside cable fittings Highside plus screw Highside minus screw Lowside plus screw Lowside minus screw Technical data and start-up BDC546... - Page 47 Lowside tightening torque: M32 x 1.5 with 45 Nm Highside tightening torque: M25 x 1.5 with 35 Nm Use the union nut to mount the cables in the cable fitting. For the tightening torque, refer to the cable specifications. Technical data and start-up BDC546...
-
Page 48: Connections
13. PRO ** Enable firmware download 14. PFO_VC- 15. PFI_VC- 16. EN * Enable (power ON, terminal 15) 17. DO_MC 18. NC 19. IL ** 20. NC HV interlock input 21. NC 22. NC 23. NC Technical data and start-up BDC546... -
Page 49: Highside Cable
The cable lugs included in the scope of delivery are to be assembled with cables in accordance with the following specifications. On request, this process may also be carried out by BRUSA. For installation of a shielded cable with connection to the shielding braid, refer to chapter 9.2 Building the HV wiring... -
Page 50: Lowside Cable
The cable lugs included in the scope of delivery are to be assembled with cables in accordance with the following specifications. On request, this process may also be carried out by BRUSA. For installation of a shielded cable with connection to the shielding braid, refer to chapter 9.2 Building the HV wiring... -
Page 51: Cooling Water Connections
(1, 2) in order to guarantee a water tight connection. Ensure that the cooling water hoses are properly mounted on the connection pieces in order to avoid leaks. Fitting is realized with hose clamps. Technical data and start-up BDC546... -
Page 52: Installation / Initial Start-Up
Prior to installation, visually check the packing material and particularly the device itself for damage. Each device undergoes a strict quality and function test at BRUSA before distribution. However, we do not have any influence on the shipping routes, some lengthy, or loading of our products. - Page 53 7.3 Highside and lowside power connections Use the union nut to mount the cables in the cable fittings (3). 6. Close the service cap (2). Attach the cap with the countersunk screws (1). Tightening torque: 3 Nm Technical data and start-up BDC546...
- Page 54 The device is now completely installed and can be commissioned. The device can be set by means of customer-specific CAN tools or using the BRUSA-specific PARAM software. This software is ideally suited for the device and can be purchased optionally. For further information, please contact the manufacturer under the address provided in chapter 4.5 Manufacturer contact...
-
Page 55: Building The Hv Wiring
1. Strip the HV cable coating (1) to a length of 60 mm. Ensure that the shielding braid (2) underneath is not damaged! 2. Shorten the shielding braid (1) by 50 mm. The shielding braid (1) on the cable side requires a length of approx. 10 mm. Technical data and start-up BDC546... - Page 56 (2) over the HV cable (3). Guide the cone of the grounding insert under the shielding braid (4). 5. Slide the connection thread (1) over the HV cable (2) up to the cone of the grounding insert. Technical data and start-up BDC546...
- Page 57 7. Manually check the tight fit of the cable lug. 8. Attach a shrinking tube (1) over the cable lug (2). The shrinking tube (1) must be attached to prevent contact with the housing after installation. Technical data and start-up BDC546...
-
Page 58: Ventilating The Cooling System
Always check for correct connection of the cooling water inlet (1) and cooling water outlet (2)! 2. Switch on the cooling circuit. 3. Leave the cooling circuit turned on for around 30 s. 4. Switch off the cooling circuit. Technical data and start-up BDC546... -
Page 59: Voltage Pre-Charging
In this case, the pre-charging resistor has to be cooled down for a certain period of time. If the system is only connected to one power source at the highside, the pre-charging unit on the highside is sufficient. Technical data and start-up BDC546... - Page 60 The main contactor + (2) closes. The main contactor (2) may only close if the converter is successfully pre-charged to the voltage of the power source. The pre-charging contactor (1) opens. The HV connection to the device is now established. Technical data and start-up BDC546...
-
Page 61: Parameterization And Operation
XML file! With the password monitor, the customer can log into PARAM or the BDC546. Changes can be applied to the non-volatile memory of the BDC546 by pressing Update & Reset Target. PARAM... -
Page 62: Installation And Operation Of The Param Software
PEAK System (www.peak-system.com). For CAN communication, it is recommended to use the visually separated USB adapter with suitable 120 OHM terminating resistor: IPEH-002022 (PCAN USB adapter) IPEK-003003 (PCAN terminating resistor) Technical data and start-up BDC546... -
Page 63: Parameters
Default value: Default value for parameters prior to initial start-up, factory settings. Unit: The physical unit. R/W user. Read and write permissions for the values “R” - Values can be read “R/W” - Values can be read and written Technical data and start-up BDC546... -
Page 64: Parameter Groups
These parameters are set by BRUSA and cannot be changed by the customer. In this category, users can define the thresholds of the limiting voltage and current controller. - Page 65 Event log Content not relevant for the customer FPGA: General functions Configuration by BRUSA, content not relevant for the customer FPGA: Choke current Configuration by BRUSA, content not relevant for the customer measuring value block FPGA: Voltage and IB...
-
Page 66: [01] Can Configuration - Crc
Defines which Dbg Msgs will be sent (hex value). UINT_HEX DBG_CAN_Rate Interval of the Dbg Msgs in [ms]. UINT_DEZ DBG_CAN_Base ID Base ID for DbgCAN-Messages UINT_HEX Defines which Dbg Msgs will be sent slow (hex DBG_CAN_EnableSlowMask value). UINT_HEX Technical data and start-up BDC546... -
Page 67: [02] Device Configuration - Crc
[02] Device Configuration – CRC NAME BEZEICHNUNG / EINHEIT / DEFAULTWERT DATENTYP Die Konfiguration vom Hauptregler kann nur von BRUSA eingestellt werden. FPGA HR Device Configuration 1= ILS; 2=ULS; 3=UHS; 4=IHS UINT_DEZ Mit einem Wert >0 wird der Interlock nicht mehr Interlock Disable ausgewertet. -
Page 68: 09] Fw Gains, Offset - Crc
INT_DEZ U15V Gain 1/2048Lsb per bit INT_DEZ U15V Offset 1/1Lsb per bit INT_DEZ Ib Gain 1/2048Lsb per bit INT_DEZ Ib Offset FLOAT SS Delay OU INT_DEZ SS Com Time INT_DEZ SS Max Demag Delay INT_DEZ Technical data and start-up BDC546... -
Page 69: 10] Digital Io
Messwert Pyrofuse - 0 ... 5V (ADC9, Pin87 SHC) FLOAT Versorgung 3.3V 0 ... 5V (ADC13, Pin83 SHC) FLOAT Versorgung 1.2V 0 ... 5V (ADC14, Pin82 SHC) FLOAT Referenz 2.5V 0 ... 5V (ADC15, Pin81 SHC) FLOAT Technical data and start-up BDC546... -
Page 70: [12] Analog Values Calculated And Offsets
IntStat Fehlers) UINT_HEX hex (gespeicherter Wert beim Auftreten des IntHist Fehlers) UINT_HEX lFpgaIsrTick INT_DEZ BDC State UINT_DEZ BDC Supply State dez (State der Supply Statemachine) UINT_DEZ Supply 3.3V FLOAT Supply 1.2V FLOAT Ref 2.5V FLOAT Technical data and start-up BDC546... -
Page 71: 10.2.12 [22] Temperatures
Max Temperatur Modul 4x Maximale T des Moduls CONV_FLOAT Min Temperatur Modul 4y Minimale T des Moduls CONV_FLOAT Max Temperatur Modul 4y Minimale T des Moduls CONV_FLOAT Min Temperatur HL A Minimale T der Hauptdrossel CONV_FLOAT Technical data and start-up BDC546... -
Page 72: [23] Stored App Data
Max I in Modul 3x CONV_FLOAT Max IL3y Max I in Modul 3y CONV_FLOAT Max IL4x Max I in Modul 4x CONV_FLOAT Min IL4y Max I in Modul 4y CONV_FLOAT Reset AppData NVM Min I in Modul 1x CONV_FLOAT Technical data and start-up BDC546... -
Page 73: 10.2.15 [31] General Parameters
0 - Original, not 0 - FE'number' was done. FE_7 0 - Original, not 0 - FE'number' was done. FE_8 0 - Original, not 0 - FE'number' was done. FE_9 0 - Original, not 0 - FE'number' was done. Technical data and start-up BDC546... -
Page 74: Dc/Dc Converter Operation
As an alternative, the BDC546 can also be operated via a user-created CAN user interface on a computer. In this case, the CAN control commands have to be generated by the respective software. As an example for this type of user interface, the CVI software by BRUSA can be applied. -
Page 75: Brusa Cvi
The CVI is provided to customers as example for a custom user interface for first tests with no guarantee. If the BDC546 is operated via CVI, no superordinate control unit can be applied. (CAN collision) BRUSA Elektronik AG cannot assume any liability for damage to the BDC546 or other devices due to operation with the CVI software! ... -
Page 76: Cvi Operation
DC/DC converter. Voltages and temperatures measured by the BDC546 as well as error and warning messages are transmitted to the CVI and displayed. BRUSA CVI Please observe that the highside / lowside of the BDC546 has to be pre-charged by means of a pre- charging resistor as described in chapter 9.4 Voltage pre-charging. -
Page 77: Firmware Update
This manual describes the installation of the Flash Development Toolkit (FDT) required for programming as well as its system requirements. Additionally, the required procedures for downloading the new firmware to the BDC546 are described. 11.2 Additional information for firmware download ... -
Page 78: Troubleshooting
BDC546 Documentation of Errors and Warnings.pdf. Always try to clear all occurring errors with the help of this manual. If errors repeatedly occur, please refer to the BRUSA support under the manufacturer address indicated in chapter 4.5 Manufacturer contact information! -
Page 79: Instructions For Disposal
Disposal via a specialist service significantly helps to avoid dangers to people and the environment. For this reason, it is recommended to contact a recognised specialist disposal service for disposal of the device. Technical data and start-up BDC546... -
Page 80: Index
Index Block diagram GND / signal ground ..............34 BDC546 Block diagram ............22 Ground connection ..............35 Installation in the vehicle ............26 Guarantee .................. 12 Building the HV wiring ............... 54 Highside cable ................48 Cable manufacturing HV power connections ............... 45 Highside ................ - Page 81 Validity of the manual ..............3 Scope of delivery ............... 17 Voltage pre-charging ..............58 Serial number ................32 Start-up ..................51 Symbols ..................8 Warnings on the device ............. 25 Warranty ..................77 Technical properties ..............22 Technical data and start-up BDC546...
-
Page 82: Attachments
Attachments 16.1 Cable fitting Technical data and start-up BDC546... - Page 83 Technical data and start-up BDC546...
- Page 84 Technical data and start-up BDC546...
- Page 85 Technical data and start-up BDC546...
-
Page 86: Cable Lugs
16.2 Cable lugs Technical data and start-up BDC546... - Page 87 Technical data and start-up BDC546...