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Summary of Contents for Thunderstruck Ground Fault Monitor V2
- Page 1 Ground Fault Monitor V2 Manual v1.0 1 February, 2024 © 2024 Thunderstruck Motors...
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Page 2: Table Of Contents
GFMv2 Manual v1.0 February, 2024 Table of Contents OVERVIEW ........................... - 3 - Features ........................... - 3 - Applications ..........................- 3 - SPECIFICATIONS ........................... - 4 - INSTALLATION AND WIRING ......................- 7 - Included Components ......................- 7 - Hardware and Dimensions ...................... - Page 3 GFMv2 Manual v1.0 February, 2024 Table of Figures Figure 1 – General Specifications ....................- 4 - Figure 2 – Low Voltage Specifications ..................- 4 - Figure 3 – High Voltage Specifications ..................- 5 - Figure 4 – High Voltage Measurement Specifications ..............- 6 - Figure 5 –...
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Page 4: Overview
February, 2024 OVERVIEW The Thunderstruck Motors GFM (Ground Fault Monitor) measures the isolation between an electrical system ground and a separate High Voltage (HV) isolated system. It is designed for use in a wide range of Electric Vehicle (EV) systems and is highly configurable. -
Page 5: Specifications
GFMv2 Manual v1.0 February, 2024 SPECIFICATIONS General Parameter Units Comments Without connectors or Weight harnesses. Environment °C Temperature Overall dimensions 117x59x15 (LxWxH) Protects against small IP30 Ingress Protection (IP) tools and wires, no equivalent water protection. Figure 1 – General Specifications Electrical –... -
Page 6: Figure 3 - High Voltage Specifications
GFMv2 Manual v1.0 February, 2024 Electrical – High Voltage Parameter Units Comments HV operational sense Outside of this range voltage measurement will be degraded and an condition will isofault be pushed. HV absolute voltage HV circuit isolation integrity not guaranteed outside of range. -
Page 7: Figure 4 - High Voltage Measurement Specifications
GFMv2 Manual v1.0 February, 2024 Isolation measurement Includes GFM internal range Ω/V 65535 measurement resistance. Isolation measurement Configurable using Seconds period parameter. isorate Isolation measurement Configurable using Seconds initialization time parameter. intimin Fault reaction time Seconds Note 1: can increase if is set higher than 0 isorate Figure 4 –... -
Page 8: Installation And Wiring
GFMv2 Manual v1.0 February, 2024 INSTALLATION AND WIRING The GFM is a high voltage device and is designed to be installed inside of a protected and high voltage safe enclosure. For example, in a typical EV it is recommended to install the GFM inside of a high voltage battery box or inside of a high voltage contactor box. -
Page 9: Connectors
GFMv2 Manual v1.0 February, 2024 Connectors The GFM has three connectors; the Low Voltage (LV), Serial Port, and High Voltage (HV) connector. LV Connector HV Connector LV-1 HV-6 LV-2 HV-5 LV-3 HV-4 LV-4 HV-3 LV-5 HV-2 LV-6 HV-1 Figure 6 – Connector Illustrations Connector Details Connector Name Manufacturer... -
Page 10: Figure 7 - Connector Specification And Pinout
GFMv2 Manual v1.0 February, 2024 LV-4 CANH CAN bus high LV-5 OUT1 Configurable grounding output. LV-6 OUT2 Configurable grounding output. HV-1 Connects to HV pack positive. Wire must be properly rated and protected- the shorter the length the better. HV-2 Circuit left empty for isolation purposes. -
Page 11: Typical Circuit Design
GFMv2 Manual v1.0 February, 2024 Typical Circuit Design The circuit diagram below illustrates a recommended option for high voltage design, as well as showing the typical wiring that could be used to create an interlock circuit as well as a warning indicator (see the OPERATION section). -
Page 12: Configuration
GFMv2 Manual v1.0 February, 2024 CONFIGURATION The default configuration of the GFM is designed to be suitable for most isolation monitoring applications. To be flexible to a wide group of end users, the GFM has many configurable parameters that change its behavior. If the default configuration is deemed appropriate for the end user, it is recommended to at least review and configure the parameter. -
Page 13: Figure 9 - Configuration Parameters
GFMv2 Manual v1.0 February, 2024 Low Pack Voltage - threshold for Volts 20.0 a low pack fault. lpvdelay Seconds Time hysteresis for High Pack Voltage – threshold for Volts a high pack fault. hpvdelay Seconds Time Hysteresis for Isolation Parameters Threshold for an isolation isowarn Ω/V... -
Page 14: Operation
GFMv2 Manual v1.0 February, 2024 OPERATION HV Isolation measurement Unless is disabled, the GFM will begin to make isolation measurements after being isometer powered on. The GFM does this by connecting a known resistance between HV+ and chassis, then HV- and chassis repetitively at a rate of 1-2Hz (by default). As a result, the measured voltage between chassis and either HV bus can oscillate at the frequency of the isolation measurement. -
Page 15: System Status And Conditions
GFMv2 Manual v1.0 February, 2024 System Status and Conditions There are six conditions that are evaluated by the GFM. All six conditions contribute to the “Warn” status, but only some of the conditions contribute to the “Fault” status. A “Fault” status always overrides any “Warn”... -
Page 16: Safety Interlock Via Can Bus
GFMv2 Manual v1.0 February, 2024 (Battery Management System), upon detecting a failed interlock signal should proceed to take steps to safely shut the system down and open the main contactors. Safety Interlock via CAN Bus The GFM can be configured to transmit data over CAN bus. This can come in a few different formats, including CANOpen (sID) and J1939 (eID). -
Page 17: Led
GFMv2 Manual v1.0 February, 2024 This configuration is suitable for controlling an isolation warning indicator. If there is currently an isolation warning (Isolation is less than ) then the condition is TRUE, and isowarn isowarn the output will be If required, an isolation warning indicator can be wired to be normally on. In this case, the isolation warning indicator will be ON when the GFM is OFF or if is TRUE. - Page 18 GFMv2 Manual v1.0 February, 2024 - 17 -...
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Page 19: Serial Interface
Terminal Installation A terminal application such as PuTTY (Windows) or Coolterm (Mac or Windows) is needed on the host computer. See the Serial Port Utilities document for installation and connection details: www.thunderstruck-ev.com/images/companies/1/DD_SerialPortUtilities_v1.3.pdf Baud rate: 115200 Primary Serial Commands The serial interface has several primary commands. All commands that can be entered into the GFM start with one of these primary commands. -
Page 20: Show
GFMv2 Manual v1.0 February, 2024 - high pack voltage hpvdelay - high pack voltage delay - low bus voltage lbvdelay - low bus voltage delay - high bus voltage hbvdelay - high bus voltage delay out<n> {isofault|isowarn|lpv|hpv|lbv|hbv| isofaultlatch|isowarnlatch|etc. isofaulthist|isowarnhist|etc. ENAble | DISable [ <> - 'enable' and 'disable' help zevccs - ZEVCCS control... -
Page 21: Enable/Disable
GFMv2 Manual v1.0 February, 2024 - time hysteresis for isofault isowarn - isolation fault threshold isowarndelay - time hysteresis for isofault canbr - can baud rate - low pack voltage lpvdelay - low pack voltage time hysteresis - high pack voltage hpvdelay - high pack voltage time hysteresis - low bus voltage... -
Page 22: Upgrade
GFMv2 Manual v1.0 February, 2024 upgrade GFM> upgrade Starting GFM Upgrade *** 1) Exit from the terminal application *** 2) Start the bootloader and download a new .hex file *** 3) Restart Output Mapping The outputs on the GFM may be configured to any of the conditions listed in the System Status and Conditions section. -
Page 23: Can Bus
GFMv2 Manual v1.0 February, 2024 CAN BUS CAN Bus is digital communication standard that provides a highly resilient interface between industrial, automotive, and marine devices. There are many standards that define the specific format of the data that devices send and receive on a CAN bus network. However, in general, devices are NOT compatible unless they are designed to be. -
Page 24: Firmware
Firmware Update The GFM uses the same 8-bit firmware update procedure as other TSM 8-bit products. The GFM serial baud rate is 115200. For more information, review the “Serial Port Utilities” document available at www.thunderstruck-ev.com Serial Port Utilities www.thunderstruck- ev.com/images/companies/1/DD_SerialPortUtilities_v1.3.pdf?1684256128393... -
Page 25: Warranty And Support
February, 2024 WARRANTY AND SUPPORT ThunderStruck Motors offers a high level of support and warranty consideration for anyone purchasing our products. The DIY industry invites participants of all skill levels, and our goal is to meet their needs with tolerance, understanding and flexibility as our way of contributing to success of the electric transportation movement. -
Page 26: Safety And Disclaimer
• When applicable, use a “Lockout Tagout” system. Disclaimer: The use of the GFM and these instructions is at your own risk. ThunderStruck Motors and Dilithium Design are not responsible for any damages or injury that occur during the use of GFM or these instructions. -
Page 27: Document History
GFMv2 Manual v1.0 February, 2024 DOCUMENT HISTORY Revision Number Date Description 1 February 2024 Initial release - 26 -...
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