dc/dc converter bsc624-12v-b - brusa · 9.1 producing the cable glands for the hv power connector...

BRUSA Elektronik AG

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

www.brusa.biz

DC/DC converter BSC624-12V-B

TECHNICAL INFORMATION AND START-UP

Translation of the original German operating instructions

Technical information

and start-up BSC624-12V-B 2

LEGAL NOTICE

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

Date of issue 06. Dezember 2012

Copyright © 2012 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. All technical information, drawings and photos used in this document are protected by copyright and any infringement constitutes a punishable offence!

Updates In light of the further technical development of our products, we reserve the right to make constructional 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.

Originator / author Holger Schmidt

REVISIONS

Revision Date Name Change 01 05.02.2013 HS Kleine Optimierungen ÜM 02 30.09.2013 MT 6.7 Grafik Sicherheitskonzept 03 28.04.2014 RB Optimierungen ÜM, Versionserhöhung 04 16.10.2014 JP Update of the interlock bridge and CVI installation 05 16.07.2016 AG 5. Information new 06 28.11.2016 AG 13. Warranty new

3 Technical information and start-up BSC624-12V-B

VALIDITY

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

BSC624-12V-B01 BSC624-12V-B02 BSC624-12V-B03 BSC624-12V-B04 BSC624-12V-B05 BSC624-12V-B06 BSC624-12V-B07

The decoding of the device designation is as follows:



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

3.3.1 Safety instructions for cooling water systems .................................................................... 10

3.3.2 Safety instructions for mechanical systems ....................................................................... 10

3.3.3 Safety instructions for handling and operation ................................................................... 11

3.3.4 Safety instructions for electrical systems ........................................................................... 12

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

3.4.1 Short-circuit protection ...................................................................................................... 13

3.4.2 Interlock ............................................................................................................................ 13

3.4.3 Overload protection – derating .......................................................................................... 14

3.4.4 HV – Overvoltage shut-down ............................................................................................. 15

3.4.5 LV – Overvoltage shut-down ............................................................................................. 16

3.4.6 HV – Undervoltage shut-down ........................................................................................... 16

3.4.7 LV – Undervoltage shut-down ........................................................................................... 16

3.4.8 HV – Automatic discharge ................................................................................................. 16

3.5 Requirements to the start-up personnel .................................................................................... 17

4 General ............................................................................................................................... 18

4.1 Content and scope of this manual ............................................................................................ 18

4.2 Scope of the entire documentation ........................................................................................... 18

4.3 Scope of delivery ...................................................................................................................... 19

4.4 Applicable standards ................................................................................................................ 20

4.5 Contact information of the manufacturer ................................................................................... 20

5 Use and limits of the product ........................................................................................... 21

5.1 Proper use................................................................................................................................ 21

5.2 Improper use / limits of the product .......................................................................................... 21

6 About this device............................................................................................................... 22

6.1 Technical data .......................................................................................................................... 22


6.2 Technical properties ................................................................................................................. 25

6.3 Block diagram BSC624-12V-B ................................................................................................. 25

6.4 Basic function / EMC concept ................................................................................................... 26

6.4.1 Topology benefits .............................................................................................................. 26

6.4.2 Internal current supplies .................................................................................................... 27

6.4.3 LV filter concept ................................................................................................................ 28

6.4.4 HV filter concept ................................................................................................................ 29

6.4.5 AUX filter concept ............................................................................................................. 30

6.5 Warnings on the device ............................................................................................................ 31

6.6 Vehicle installation basic principle ............................................................................................ 32

6.7 Safety concept vehicle installation ............................................................................................ 33

6.7.1 Principle of operation Interlock .......................................................................................... 33

6.8 Overview of the main structural components ............................................................................ 34

6.9 Dimensions and installation information ................................................................................... 35

6.9.1 Fixing points ...................................................................................................................... 35

6.9.2 Dimensions ....................................................................................................................... 36

6.9.3 Installation position ............................................................................................................ 36

7 Electrical interfaces ........................................................................................................... 38

7.1 Pin assignment of control connector (device side) .................................................................... 39

7.1.1 Pin 1 GND ......................................................................................................................... 40

7.1.2 Pin 2 AUX ......................................................................................................................... 41

7.1.3 Pin 3 EN ............................................................................................................................ 42

7.1.4 Pin 4 DO0 – pin 7 DO3 ...................................................................................................... 43

7.1.5 Pin 8 PG1, pin 14 PG2, pin 15 PG3 .................................................................................. 44

7.1.6 Pin 9 CNL, pin 10 CNH ..................................................................................................... 44

7.1.7 Pin 11 TXD, pin 12 RXD .................................................................................................... 45

7.1.8 Pin 13 PRO ....................................................................................................................... 46

7.1.9 Pin 16 DI0, pin 17 DI1, pin 18 DI2 ..................................................................................... 46

7.1.10 Pin 19 IL1, pin 20 IL2 ........................................................................................................ 47

7.1.11 Pin 21 AI1, pin 22 AI2, pin 23 AI3 ...................................................................................... 49

7.2 Pin assignment of HV power connector (device side) ............................................................... 50

7.3 Pin assignment of LV power connector (device side) ............................................................... 50

8 Connections ....................................................................................................................... 51



8.1 Control connector ..................................................................................................................... 51

8.2 HV power connector ................................................................................................................. 52

8.3 LV power connector ................................................................................................................. 53

8.4 LV- / PGND (power ground) ..................................................................................................... 54

8.5 Cooling system ......................................................................................................................... 55

9 Installation / initial start-up ............................................................................................... 56

9.1 Producing the cable glands for the HV power connector .......................................................... 59

9.2 Ventilating the cooling system .................................................................................................. 64

9.3 Voltage pre-charging ................................................................................................................ 65

10 Operation ........................................................................................................................ 67

10.1 Installation and operation of the PARAM software .................................................................... 67

10.2 CVI software installation ........................................................................................................... 67

10.3 Operation of the device ............................................................................................................ 68

10.4 Operation in the CAN-less mode (automatic mode) .................................................................. 69

11 Firmware update ............................................................................................................ 73

11.1 System requirements ............................................................................................................... 73

11.2 Installation Flash Development Toolkit ..................................................................................... 73

11.3 Preparing measures ................................................................................................................. 76

11.4 Executing the firmware update ................................................................................................. 77

12 Troubleshooting ............................................................................................................. 81

13 Warranty .......................................................................................................................... 81

14 Instructions regarding disposal .................................................................................... 82

15 Index ................................................................................................................................ 83


1 Foreword

Dear customer

With the BRUSA BSC624-12V-B, you have purchased a very high performance and versatile product. As the present device is a high-performance electronics product which uses dangerous voltages and currents, special expertise in handling and operation are required!

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

2 List of abbreviations

Throughout this manual, some specific technical abbreviations are used. The following table provides an overview of these abbreviations and their meaning:

Abbr. Meaning Abbr. Meaning BMS Battery Management System HW Hardware BSC Bi-directional Supply Converter LV Low Voltage CAN Controller Area Network PDU Power Distribution Unit EMC Electro-Magnetic Compatibility SMD Surface Mounted Device HF High Frequency SW Software HV High Voltage



3 Safety and warning instructions

In this chapter, you will find safety instructions applying to this device. These instructions refer to the assembly, start-up and the 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. The following table provides an overview of these symbols and their meaning:

Prohibition signs Symbol Meaning Symbol Meaning

General prohibition

Warning! High voltage! Do not touch

Do not switch

Warning signs Symbol Meaning Symbol Meaning

General warning of a dangerous area

Warning! Danger due to suspended loads!

Warning! Explosive environment!

Warning! Danger caused by batteries!

Warning! Hot surface!

Warning! High voltage!

Warning! High pressure / fluid ejection!

Warning! Fire hazard!

Mandatory signs Symbol Meaning Symbol Meaning

Disconnect device from power supply

Disconnect device from mains supply

Wear protective glasses

Wear protective gloves

Information signs Symbol Meaning Symbol Meaning

Important information on avoiding possible property damage

Important information


3.2 Safety instructions and danger levels

DANGER

This instruction warns about severe irreversible risks of personal injury with fatal consequences. Avoid this risk by adhering to this instruction!

WARNING

This instruction warns about the risk of severe but reversible injury! Avoid this risk by adhering to this instruction!

CAUTION

This instruction warns about a minor risk of injury! Avoid this risk by adhering to this instruction!

INSTRUCTION

This instruction warns about possible property damage if the following instructions and work procedures are not adhered to.

INFORMATION

This type of instruction discloses important information for the reader.



3.3 Generally applicable safety measures The following safety measures have been developed based on the knowledge of the manufacturer. They are incomplete as 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

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

pressure tanks.

Rectify any identifiable leaks immediately!

3.3.2 Safety instructions for mechanical systems

DANGER

Explosive environment! Danger to life! Do not store any highly flammable substances or combustible fluids in the direct surroundings of

the device! Sparks forming 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! Therefore, the device is to be

handled with care and caution at all times!


3.3.3 Safety instructions for handling and operation

INSTRUCTION

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

converter are identical.

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

ensure that the device is continuously cooled sufficiently! Do not place the device in direct sunlight and in direct proximity to heat sources!

Even though the device has a high IP protection class, direct contact with water (rain, splashing water) is to be avoided if possible!

Never damage existing galvanic isolations (e.g. by connecting HV contacts with the device casing) in the vehicle.

Prevent any fluid ingress into the device (e.g. during assembly work). Fluid ingress will lead to a short circuit and subsequently to damage to the device!

In the case of any fluid ingress, do not start the device and immediately contact the company BRUSA Elektronik AG.

Always use an insulation monitoring unit to continuously monitor the galvanic isolation between the HV and LV circuit!

Never connect or disconnect the HV connectors without ensuring the absence of voltage beforehand!

Before connecting a voltage supply to the HV side of the DC converter (e.g.: HV battery), the voltage must be pre-charged via a suitable pre-charging device, see chapter 9.3 Voltage pre-charging.

INFORMATION

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



3.3.4 Safety instructions for electrical systems

DANGER

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

beforehand!

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

have life threatening consequences!

INSTRUCTION

Never open the device without authorisation! The opening of the device (sealed housing) directly leads to the forfeiture of any guarantee and warranty rights!

INFORMATION

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

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

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

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


3.4 Safety installations / power limitations

3.4.1 Short-circuit protection

Since, due to its resonant clock topology, the transformer stage has a certain internal resistance, the device is generally short-circuit proof. In the case of an external short-circuit (caused by the operator), this means that the voltage breaks down while the signal E_LV_UNDERVOL is emitted.

In the buck mode, undervoltage is identified on the LV side in the case of a short-circuit.

In the boost mode, undervoltage is identified on the HV side in the case of a short-circuit.

Independent of the operating mode, undervoltage is also identified at the respective power input.

3.4.2 Interlock

INSTRUCTION

In order to guarantee the function of the interlock, for the cable bridge (1) in the HV power connector it is not allowed to use another cable then the delivered. The cable has to prepare according the manual chapter 9.1 Producing the cable glands for the HV power connector.

With this safety installation, the proper connection of the connectors on the device is monitored. The device comprises an internal as well as an external interlock identification, which function independently of each other. An interruption of the interlock circuit causes an immediate shut-down of the device. In order to use the external interlock identification, the respective interlock pins must be connected at the control connector and the error detection must be activated (for details, please refer to the PARAM manual). With a shut-down of the device, the signal CRE_INTERLOCK is emitted.

The internal interlock identification monitors the HV power connector exclusively and is always active. The optional external interlock identification is an interlock loop, which is ideally looped through all HV components in the vehicle. The interlock signal must be generated and analysed respectively via an upstream control unit (e.g. BRUSA PDU254).

Further information on the interlock can be found in chapter 7.1.10 Pin 19 IL1, pin 20 IL2



3.4.3 Overload protection – derating

This safety installation is a self-protection feature of the DC/DC converter. If the device reaches a defined temperature threshold, this reduces the power rating (derating) to protect the device from damage caused by overheating. Consequently, the maximum possible current is reduced proportionally to the temperature increase in order to avoid a further rise in the temperature.

Via the CAN interface, the currently transferable current LVCUR_AVL is reported back. Here, it can be identified whether or not the device is in the derating mode.

A total of 8 temperature sensors are installed to measure the temperature. These sensors are divided into 4 measuring groups:

Installation position / measuring point Number of temp. sensors Active regulation max. current Switches buck / boost converter 2 no Switches HV side transformer stage 2 yes Switches LV side transformer stage 2 yes Winding HF power transformer 1 + 2 1 each yes

Switches buck / boost converter

Since very low losses occur at the switches of the buck / boost converter and an extremely efficient cooling predominates, these measuring values only show slightly increased values regarding the cooling liquid temperature. For this reason, these measuring values provide information on the actual ambient temperature in the device. Generally, the device shuts down when the temperature of the switches of the buck / boost converter is >/= 81°C. If this temperature falls to </= 80°C, the device is 100% operable again. Here, no derating occurs but a direct shut-down of the device. With a shut-down of the device, the signal E_OVERTEMP is emitted.


Windings of the HF power transformers

If the temperature at the windings of the HF power transformers reaches >/= 106°C, the current is reduced

successively to a temperature value of < 131°C. At >/= 131°C, the device shuts down.

If the temperature falls to </= 129°C, the device is operable again with reduced power according to the derating diagram.

With a shut-down of the device, the signal E_OVERTEMP is emitted.

Transformer stage switches

If the temperature at the transformer stage switches reaches >/= 95°C, the current is reduced successively to

a temperature value of >/= 120°C .

At >/= 120°C, the device shuts down.

If the temperature falls to < 120°C, the device is operable again with reduced power according to the derating diagram.

With a shut-down of the device, the signal E_OVERTEMP is emitted.

3.4.4 HV – Overvoltage shut-down

The device provides the following possibilities for identifying an overvoltage at the HV side:

Rapid HW overvoltage identification (immediate shut-down of the device if voltage > 470 V) Slow SW overvoltage identification (shut-down of the device if voltage > 456 V; automatic reactivation if

voltage < 454 V) With a shut-down of the device, the signal E_HV_OVERVOL is emitted.



3.4.5 LV – Overvoltage shut-down

The device provides the following possibilities for identifying an overvoltage at the LV side:

Rapid HW overvoltage identification (immediate shut-down of the device if voltage > 20 V)

Slow SW overvoltage identification (shut-down of the device if voltage > 16.4 V; automatic reactivation if voltage < 16.2 V)

With a shut-down of the device, the signal E_LV_OVERVOL is emitted.

3.4.6 HV – Undervoltage shut-down

The device provides the following possibilities for identifying undervoltages at the HV side:

Immediate shut-down of the device if HV voltage < 215 V

This error identification is deactivated for 3 s when starting the device in the boost mode. With a shut-down of the device, the signal E_HV_UNDERVOL is emitted.

3.4.7 LV – Undervoltage shut-down

The device provides the following possibilities for identifying undervoltages at the LV side:

Immediate shut-down of the device if LV voltage < 7 V

This error identification is deactivated for 5 s when starting the device in the buck mode. With a shut-down of the device, the signal E_LV_UNDERVOL is emitted.

3.4.8 HV – Automatic discharge

The device has an active as well as a passive intermediate circuit discharge. The active intermediate circuit discharge is implemented inherently via the internal HV supply and thus cannot be controlled. The passive intermediate circuit discharge is implemented via a resistor string:

Active intermediate circuit discharge: As soon as the device is separated from the HV supply, the internal HV circuits discharge to a value of < 50 V within 350 ms.

Passive intermediate circuit discharge: As soon as the device is separated from the HV, the internal HV circuits discharge to a value of < 50 V within 120 s.


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

professional training,

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

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



4 General

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

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

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

4.2 Scope of the entire documentation

INFORMATION

To commission the device successfully, the entire documentation as well as diverse software are required. With the provision of the customer package, it is ensured that the documentation and software are complete and up-to-date. The updating of specific documents is carried out automatically and can be seen in the history.

The customer package includes the following indexes:

Manuals: Contains all information fundamentally necessary for installation and operation. Firmware / CAN: Contains all necessary CAN data as well as current firmware. PC software: Contains additional tools for the operation, parameter setting and maintenance as well as the required driver files. CAD data: Contains various CAD data in 2D and 3D. Measurements / tests: Contains different test results of validating measurements as well as qualifying tests, if applicable. History: List of all updates within the customer package, indicating the affected documents or software / firmware etc.


4.3 Scope of delivery

Meaning Pieces Illustration 1. DC/DC converter BSC624-12V-B 1

2. 23 pole control connector with crimp contacts *

AMPSEAL 770680-1 1

3. SN/LP contacts

AMPSEAL 770854-1 for wire diameter: 0.5 mm2

25

4. Harting high voltage connector set HAN-Modular Compact: * Straight connector housing HAN-Modular Compact

Carrier housing HAN-Modular Compact

Socket insert HAN CC

4 mm2 crimp contact socket (4 pieces) Cable gland HSK-M-EMV M25 x 1.5 for cable diameters 9 - 16 mm

6 cm x 4 mm2 cable (interlock bridge)

1

5. Low voltage connector set: * Positive pole connector housing for 50 mm2 cable MC contact SP10AR-N/50

O-ring M3 x 5 threaded pin

M8 / 50 mm2 straight cable lug for 12 V ground connection

M8 / 50 mm2 angled cable lug for 12 V ground connection

1

6. Protective cap for cooling water connection pieces 2

* customer side connector



4.4 Applicable standards This manual has been produced under application and consideration of the EC guidelines, national laws and harmonised standards (EN) valid at the time of production and relevant to the product BSC624-12V-B.

4.5 Contact information of the manufacturer

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


5 Use and limits of the product

5.1 Proper use The product BSC624-12V-B has been designed to supply the 12 V wiring system in the applications listed below, taking into consideration the limits indicated in chapter 5.2 :

Integration in hybrid vehicles

Integration in electric vehicles

Integration in fuel cell vehicles

Use in the high-performance area (racing)

Integration in electric motorcycles

Integration in utility vehicles (electric and hybrid)

Integration in electric boats

Test bench applications

INFORMATION

These equipment are custom built evaluation kits destined for professionals to be used solely at research and development facilities for such purposes.

5.2 Improper use / limits of the product Improper use is any use carried out under conditions which deviate from those indicated by the manufacturer in their technical documents and data sheets. Taking into consideration the proper use indicated in chapter 5.1 , the following limits have been stipulated for the operation of the device BSC624-12V-B. The device may not be used/operated outside of these limits. Any operation outside of these limits may lead to damage to the device or even to life-threatening situations.

BSC624-12V-B Unit HV side overvoltage, deactivation of the power stage > 470 V

Max. HV side voltage, no operation, max. 1 min 600 V

LV side overvoltage, deactivation of the power stage > 20.0 V

Max. LV side voltage, no operation, max. 1 min 25.0 V

Max. voltage for signals at the control connector (AUX) 32.0 V

Min. coolant temperature at the input - 40 °C

Max. coolant temperature at the input 65 °C

Cooling water flow rate min. 4 l/min

Cooling water flow rate max. 10 l/min

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

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

Max. static pressure 2.0 bar



6 About this device

6.1 Technical data

High voltage side Remarks BSC624-12V-B Unit Min. voltage, limited power ULVmax = 14 V 220 V

Min. voltage, full power - 240 V

Max. voltage, full power - 450 V

Overvoltage, deactivation of the power stage - > 470 V

Max. voltage, no operation, max. 1 min Device may be damaged 600 V

With reverse polarity Fuse triggers - -

Low voltage side Remarks BSC624-12V-B Unit Nominal voltage +/-0.1 V 14.0 V

Min. voltage, full power - 8.0 V

Max. voltage, full power - 16.0 V

Overvoltage, deactivation of the power stage - > 20.0 V

Max. voltage, no operation, max. 1 min Device may be damaged 25.0 V

With reverse polarity Fuse triggers - -

Power data Remarks BSC624-12V-B Unit LV continuous current - 200 A

LV peak current - 250 A

HV continuous current, boost mode @ UHV = 400V, ULV = 14V, η = 90% 6.3 A

HV peak current, boost mode @ UHV = 400V, ULV = 14V, η = 90% 7.9 A

Continuous power, buck mode @ nominal voltage 2.8 kW

Peak power, buck mode @ nominal voltage 3.5 kW

Dynamic behaviour Remarks BSC624-12V-B Unit LV step response UHV = 360V, ULV_com = 13.0V → 14.0V,

ILV = 150A, buck mode < 500 us

HV voltage step response ULV = 12.6V, UHV_com = 350V → 360V; ILV = 156A, boost mode

< 500 us

Regular limit frequency PWM variable limited to 1 kHz 1 kHz

Standby mode Remarks BSC624-12V-B Unit Typ. current draw at AUX (control connector) @ UHV = 0 V, ULV = UAUX = 14 V,

enable = low 58.0 µA

@ UHV = 0V, ULV = UAUX = 14V, enable = high

220.2 mA

@ UHV = 330V, ULV = UAUX = 14V, enable = high

14.2 mA


Galvanic isolation Remarks BSC624-12V-B Unit Withstand voltage between HV and LV Test voltage 2’700 VDC

Galvanic isolation between signal and power ground Test voltage 10 VDC

Isolation resistance HV-side against chassis/GND - > 5 MΩ

Control circuit Remarks BSC624-12V-B Unit Min. voltage for signals at the control connector (AUX)

- 7 V

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

- 32 V

Buck mode: LV control with HV undervoltage limitation and current limits

- -

Boost mode: HV control with LV undervoltage limitation and current limits

- -

LV voltage measuring range - 0 to 20.0 V

LV voltage signal accuracy Referring to scale end +/-1 %

HV voltage measuring range Limited by value range in CAN matrix 0 to 480.0 V

HV voltage signal accuracy Referring to scale end +/-1 %

HV (Low Side) current measuring range Limited by value range in CAN matrix +/-25.0 A

HV (Low Side) current signal accuracy LEM +/-3.5 %

Clock frequencies Remarks BSC624-12V-B Unit Transformer stage - 197 kHz

Buck / Boost converter min. @ UHV = 220V, ULV = 14.0V, ILV = 250A 40 kHz

Buck / Boost converter max. @ UHV = 450V, ULV = 16.0V, ILV = 0A 150 kHz

Crystal oscillator - 6 MHz

Microcontroller Hitachi HD64F7045FI28 4 x fcrystal 24 MHz

Supply HV 12.4VDC @ UHV = 85V 88 kHz




Supply 12.4VDC 5VDC - 260 kHz

Supply AUX 11.7VDC - 260 kHz

Supply CAN - 230 kHz

Thermal / cooling system Remarks BSC624-12V-B Unit Coolant (water / glycol mixing ratio) - 50 / 50 -

Amount of coolant in device including junction 225 ml

Min. coolant temperature - - 40 °C

Max. coolant temperature - 65 °C

Cooling water flow rate min. - 4 l/min

Cooling water flow rate max. - 10 l/min

Drop in pressure @ 4 l/min < 0.1 bar

Max. static pressure - 2 bar

Ambient temperature range (storage) - - 40 to + 105 °C

Ambient temperature range (operation) - - 40 to + 85 °C



Level of efficiency Remarks BSC624-12V-B Unit Typical @ UHV = 330V, ULV = 14.0V, ILV = 150A 94.4 %

Basic mechanical data Remarks BSC624-12V-B Unit Housing material Corrosion-tight aluminium AlMgSi1 -

Length - 300 mm

Width - 150 mm

Height - 70 mm

Housing volume Without connector 3.15 l

Weight (without cooling water) +/- 0.05kg 4.8 kg

IP protection - IP65 -

External diameter of cooling water connection pieces - 16.0 mm

Water-tight pressure compensation membrane Integrated - -


6.2 Technical properties Compact and light-weight construction

Vibration-resistant construction for mobile usage

Coverage of a large HV range (220 – 450 VDC) Bi-directional functioning

All connections are pluggable (excluding LV negative pole)

Excellent EMC properties

Very high power and efficiency levels Resonant topology of the transformer stage

Galvanic isolation between HV and LV side by means of integrated HF power transformer

High IP protection class

CAN interface integrated by default

6.3 Block diagram BSC624-12V-B



6.4 Basic function / EMC concept The BSC624-12V is a bi-directional DC/DC converter with galvanic isolation between the high voltage and the low voltage circuit. The device is based on a transformer stage working in a serial-resonant manner, by means of which the galvanic isolation is realised. Furthermore, by means of two buck / boost converters working in a geared mode for the purpose of ripple reduction, the desired voltage can be set in the respective operating mode. With the resonant topology of the transformer stage and the auto-commutation of the buck / boost converter, losses can be limited to a minimum and excellent EMC properties can be achieved.

With the BSC624-12V, a compact, vibration-resistant and light-weight construction was prioritised in order to enable the usage in almost all applications and installation locations.

6.4.1 Topology benefits

The power component of the transformer stage is based on a resonant switching topology which is used for switching in the current zero-crossing. The buck / boost converter required for the voltage adaptation uses the auto-commutation principle, which leads to a soft commuting of the bridge point. Due to the significantly slower changes of current and voltage, EMC faults can be significantly reduced in comparison to hard-switching topologies.


6.4.2 Internal current supplies

Generally, the device can be supplied by HV as well as via pin 2 AUX. For the full operational availability,

however, the 12.5 V / 2.5 A supply must be active. This supply starts automatically at a HV voltage of > 75 V. Due to the greater output voltage, the 11.3 V / 1 A supply of pin 2 AUX is deactivated automatically in order to reduce the current consumption from the wiring system.

The 5V supply is guaranteed as soon as either pin 3 EN or pin 13 PRO are connected with pin 2 AUX. For safety reasons, the hardware-side self-retaining function (uC via Enable1) is deactivated at the software-side.

In order to guarantee an optional autarkic operation of the device, a 10.7 V / 0.1 A supply is implemented. Thus, for instance, pin 3 EN can be activated via a connection with pin 2 AUX in the customer side connector, by which means the device remains switched on at all times.

The 12.5V / 2.5A supply is also realised with the auto-commutation topology (analogous buck / boost converter). This supply is galvanically isolated from the high voltage circuit and furthermore functions without optocoupler.

In the boost mode, the drivers are initially supplied during the start-up by pin 2 AUX.

All supply circuits are short-circuit proof. The signal ground pin 1 GND is galvanically isolated from the power ground PGND. Thereby, stray voltage

and/or ground loops are avoided.



6.4.3 LV filter concept

Component Value Unit

ELV1 680.0 µF

CLV1 40.0 µF

Ls 364.0 nH

CLV2 130.0 µF

ELV2 816.0 µF

CX 17.6 µF

Ctotal 1‘683.6 µF

The capacitors ELV1 and ELV2 are implemented as SMD tantalum capacitors in order to achieve the respective capacity values required.

The capacitors CLV1 and CLV2 are implemented as SMD ceramic capacitors; thereby, a connection with extremely low impedance is achieved.

The capacitor CX is situated directly at the LV power connector. Since, in the case of a defect of these filter capacitors (e.g. short-circuit caused by a breakage of the component), the LV fuse does not provide any protection for the device, special and extremely reliable types are used which offer a very high degree of robustness with respect to mechanical forces.


6.4.4 HV filter concept

Component Value Unit

Cy1 6.6 nF

Lh 2314.0 µH

Ls 5.8 µH

Cy2 15.0 nF

Cb 16.2 µF

The HV choke located at the input is generally of the common-mode choke type (Lh). However, it also helps to filter the differential mode interferences by means of the existing leakage inductance (Ls).

The wired Y capacitors (Cy2) together with the common-mode choke (Lh) form the common-mode filter.

In order to filter particular high-frequency common-mode interferences, Y capacitors (Cy1) with very low impedance are directly connected at the input.

The intermediate circuit capacitor (Cb) together with the leakage inductance of the HV choke (Ls) forms the differential mode filter. Due to the high clock frequencies, the capacitor may have very small dimensions. Thus, a rapid discharge of the intermediate circuit is possible.



6.4.5 AUX filter concept

In order to achieve an ideal cushioning of the line-bound interferences, all pins of the control connector are filtered to GND by means of SMD capacitors. GND, on the other hand, is connected to the housing with very low impedance. Thereby, a cross-talk of common-mode interferences from one pin to others can be largely suppressed.

Pin 2 AUX is additionally equipped with an X filter. Furthermore, pin 2 AUX is protected against surge and burst faults by means of a fast PTC fuse as well as a 36 V suppressor diode. The CAN interface is filtered against common-mode interferences by means of a special choke. All pins of the control connector are protected against air- or contact-discharged ESD faults. In the case of a CAN and RS232 interface, this is implemented by using special ESD diodes.

For suppressing high-frequency common-mode interferences, all pins are led through a ferrite core. For details on the wiring of individual pins, please refer to chapter 7.1 Pin assignment of control connector (device side)


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



6.6 Vehicle installation basic principle


6.7 Safety concept 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 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.



6.8 Overview of the main structural components

1. HV warning sign 2. Control connector 3. Housing cover 4. Housing 5. Water duct cover 6. LV negative pole 7. Pressure compensation membrane 8. LV positive pole 9. Cooling water connections 10. HV power connector


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

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

The device may not be installed in the direct vicinity of heat sources (e.g. combustion motor).

The mechanical fixture is to be directed in a way that the device is installed in a fixed position and with as little vibrations as possible.

The cable inlets and cooling water ducts should have enough space and must never touch components with sharp edges.

All electrical connections are to be fixed within a distance of < 30 cm from the device with a strain relief in order to protect the cable and/or the cable harness at the control connector against vibration.

6.9.1 Fixing points

INSTRUCTION

The housing has been designed for a maximum admissible torque of the fixing screws of 5 Nm! For fixing the device, we recommend screws of the strength category 8.8, which are tightened with a torque of 5 Nm.

1. 2 pcs. thread M5, stud hole with depth: = 15 mm 2. 4 pcs. thread M5, stud hole with depth: = 11 mm



6.9.2 Dimensions

6.9.3 Installation position

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

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

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


6.10 Type plate

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

input 9. LV voltage range for operation 10. LV peak current 11. Peak power, buck mode 12. IP protection class



7 Electrical interfaces

1. Control connector Chap.7.1 Pin assignment of control connector (device side)

2. LV power connector Chap. 7.3 Pin assignment of LV power connector (device side)

3. LV- / PGND (power ground) Chap. 8.4 LV- / PGND (power ground)

4. HV power connector Chap. 7.2 Pin assignment of HV power connector (device side)


7.1 Pin assignment of control connector (device side)

INSTRUCTION

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

1. GND Signal ground

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

(Plus wiring system, terminal 30) 3. EN Enable (power ON, terminal 15) 4. DO0 Digital output 1 (programmable) 5. DO1 Digital output 2 (programmable) 6. DO2 Digital output 3 (programmable) 7. DO3 Digital output 4 (programmable) 8. PG1 Analogue ground (for pins 21 – 23) 9. CNL CAN low 10. CNH CAN high 11. TXD RS232 Transmit (9 pole D-Sub: pin 2) 12. RXD RS232 Receive (9 pole D-Sub: pin 3) 13. PRO Enable firmware download 14. PG2 Ground reserve 15. PG3 RS232 ground (9 pole D-Sub: pin 5) 16. DI0 Digital input 1 17. DI1 Digital input 2 18. DI2 Digital input 3 19. IL1 HV interlock loops input 20. IL2 HV interlock loop output 21. AI1 Analogue input 1 (programmable) 22. AI2 Analogue input 2 (programmable) 23. AI3 Analogue input 3 (programmable)



7.1.1 Pin 1 GND

INFORMATION

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

Internal wiring

Direct connection to the ground of the control unit.

The signal ground is only capacitively connected to the housing and is thus galvanically isolated from the power ground. This helps to avoid ground loops.

When wiring BSC624-12V-B-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.

1MΩ

23,5μF

Pin 1 GND

housing


7.1.2 Pin 2 AUX

Internal wiring

If no voltage is present at the HV power connector, the device is supplied via this pin by the 12 V wiring

system. It is then possible to communicate with the device by means of Pin 3 EN = high, via CAN or RS232. The following functions are ensured in the case of exclusive supply from the wiring system (control connector):

CAN communication (sending and receiving)

Communication via RS232 (monitoring)

Microprocessor programming (firmware)

Voltage, current and temperature measurement

Voltage Pin 2 AUX (V)

Pin 3 EN (terminal 15)

RUN command (sent via CAN)

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

12.0 0 0 0 0.0559 14.0 0 0 0 0.0578 12.0 1 0 0 250.8000 14.0 1 0 0 220.2000 12.0 1 0 330 10.7200 14.0 1 0 330 14.1800

1.76

uF

Pin 2 AUX 100uH 1.5A

5V

36V

5V Supply

12.5V

14.1

uF

12.5V-Supply

HV

11.3V Supply

10.7V Supply



7.1.3 Pin 3 EN

INFORMATION

The admissible voltage range for pin 3 EN = high is 7 - 32 V. For a pin 3 EN = low, a voltage of < 1 V is required.

Internal wiring

To programme a new firmware, pin 13 must be PRO = high.

For this purpose, it is not necessary that pin 3 is EN = high. If voltage is applied to pin 2 AUX and if pin 3 is EN = high, the device is put into the operational mode. Most

appropriately, this is implemented by means of a connection of pin 3 EN with the Plus wiring system via a switch.

Even if high voltage is applied to the HV connector, the device-internal logic is only supplied if pin 3 is EN = high (or pin 13 PROG = high).


7.1.4 Pin 4 DO0 – pin 7 DO3

INFORMATION

These digital outputs all have the following characteristics: RDSON = 1.7 Ω at Ta = 25°C VOUTmax = 32 V

VCLAMP ≥ 45 V (voltage resistance for inductive loads)

Short-circuit resistance (Imax = 700 mA)

Deactivation in the case of excessive temperatures due to overload

Internal wiring

With these programmable, digital outputs, low-frequency applications can be optionally realised, such as e.g.

controlling external LEDs for various status functions or controlling other external components, such as e.g. PWM for display instruments, relays or small fan units.

If an error occurs at one output, the other outputs remain functional. One exception are cases in which the error triggers a deactivation of the device due to an excessive temperature (overload).

The outputs can be operated with frequencies of up to 10 kHz. In order to enable correct signal sequences even with these frequencies, each output is connected with a 500 Ω / 2 W pull-up resistor.

10nF

Pin 4 DO0 -

Pin 7 DO3

AUX 5

00Ω

33

V



7.1.5 Pin 8 PG1, pin 14 PG2, pin 15 PG3

Internal wiring

For simplifying the external wiring, three additional ground connections are available. They are connected with the GND supply ground via one PTC fuse each. The following assignment is recommended: pin 8 PG1 = analogue ground (for pin 21 AI1, pin 22 AI2, pin 23 AI3) pin 14 PG2 = reserve ground

pin 15 PG3 = RS232 ground (9 pole D-Sub: pin 5)

7.1.6 Pin 9 CNL, pin 10 CNH

INFORMATION

The termination of the CAN lines (optional positioning of the 120 Ω terminating resistor) may be executed by BRUSA. This is to be indicated by the customer when making the order.

Internal wiring

CAN 2.0 B (baud rate can be parameterised, e.g. 125k, 250k, 500k, 1Mbit) Both pins are isolated from the GND ground and the remaining control signals (avoiding disturbances caused

by stray voltage). Via the CAN interface, messages can be transmitted in accordance with the CAN matrix provided by BRUSA

as .dbc-file.

The following parameters of the CAN messages can be modified via the PARAM software:

identifier

baud rate

scanning spot

4.7μ

F

Pin 8 PG1 Pin 14 PG2 Pin 15 PG3

300m

A

47pF

Pin 9 CNL

33V

51uH

47pF

Pin 10 CNH

120Ω

33V

51uH

Termination resistor is optional

CAN-Transceiver and galvanic

isolation


7.1.7 Pin 11 TXD, pin 12 RXD

INFORMATION

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

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

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

Internal wiring

The firmware for the microprocessor can be downloaded via this interface (provided by BRUSA). Pin 13 PRO

must be high for this.

CAN parameters and current operating data, such as voltages, currents and temperatures of the device, can be read out and displayed via this interface. The Hyperterminal software required for this purpose is usually included in the standard installation of Windows. Please note that this functionality is more convenient covered by the PARAM software running via CAN. Further information in this respect can be found in the PARAM manual.

Pin assignment of the 9 pole D-Sub cable bushing

470p

F

Pin 12 RXD

10V

470p

F

Pin 11 TXD

15V

RS232-Transeiver

200Ω

200Ω 47

0pF

470p

F

100Ω

100Ω

33V

33V

RXD (12)

TXD (11)

9-polige D-Sub Kabelbuchse

PG3 (15) 5

2 3



7.1.8 Pin 13 PRO

INSTRUCTION

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

INFORMATION

This pin is only activated for the programming of a new firmware (pin 13 PRO = high). For this purpose, pin 3 EN must not be high.

Internal wiring

Both with the supply via high voltage as well from the wiring system, pin 13 PRO = high triggers the following

processes:

The device is stopped (reset) if it is in operation.

The device is ready-to-receive and the programming can now be implemented via the serial interface.

7.1.9 Pin 16 DI0, pin 17 DI1, pin 18 DI2

Internal wiring

Via the digital inputs, various functions can be realised optionally, such as:

DI0: Enable of automatic mode

DI1: Activation of current limits

DI2: Voltage or current regulation mode

47nF

Pin 13 PRO

5V

2.7kΩ

220p

F

1,0V

3,3V

Schmitt Trigger 12

0kΩ

5V Supply Enable

23.5

kΩ

2.7kΩ

5V Supply

11.3V Supply

100n

F

100n

F

11.3V Supply Enable

22kΩ

33V

10nF

Pin 16 DI0 Pin 17 DI1 Pin 18 DI2

5V

220p

F

1,0V

3,3V

Schmitt Trigger

22kΩ

23.5

kΩ

uC

33V


7.1.10 Pin 19 IL1, pin 20 IL2

INSTRUCTION

In order to guarantee the functioning of the interlock, the signal of the internal interlock identification in the HV connector may not be modified or distorted!

INFORMATION

The interlock is a safety-relevant function, which is processed internally but can also be analysed via an upstream system (e.g.: vehicle system). The interlock connection is looped via the HV connector (bridge in the HV customer side connector) and thus enables to check whether or not this connector is properly connected. The device has two independent interlock monitoring circuits: internal interlock identification

external interlock identification

Internal wiring

The internal interlock identification works independently from the usage of the external interlock identification

and it exclusively monitors whether or not the HV connector is properly connected. In the case of an error, the signal INTL_OC_int* is set and the error CRE_INTERLOCK is emitted via CAN. For safety reasons, the internal interlock identification cannot be deactivated.

By using the external interlock identification, not only the HV connector of the respective device but also those of additional devices can be checked.

For this purpose, the customer must feed in the interlock signal in the form of a DC current of at least 20 mA at pin 19 and / or pin 20. Here, the polarity is not relevant. To avoid damaging the internal resistor and optocoupler, the DC current must be limited to a maximum of 40 mA.

By means of the PARAM software, it is to be checked whether or not the external interlock identification has been activated and corrected if applicable.

If one of the monitored connectors is not contacted correctly, the loop is open and the input current can no longer flow. If a threshold of approx. 15 mA is undercut, the signal INTL_OC_ext* is set, while the error CRE_INTERLOCK is emitted via CAN.

The identification of the internal and external interlock error – provided that the latter is activated – leads to an immediate shut-down of the device.

By means of the PARAM software, it can be determined whether an existing interlock error has been detected



by the internal or external identification.

The LV connector is not integrated into the interlock circuit. For the wire bridge in the HV customer side connector the delivered wire has to be installed. The installed wire

bridge may not be removed or modified (e.g. extended)! For customers using an alternative interlock concept (e.g. feeding of a square wave signal, comparison of the

voltage level in the beginning and in the end of the interlock loop), R4 may be optionally equipped with a 0 Ω resistor in order to avoid any undesired voltage drop.

Please note that, in such case, the external interlock identification of the device no longer functions and that, therefore, it must be deactivated in the PARAM software.

When placing the order, it is to be ensured that a device version which is suitable for the interlock concept to be used is selected:

BSC624-12V-B01: R4 = 62R (this is a customer-specific version)

BSC624-12V-B02: R4 = 62R

BSC624-12V-B03: R4 = 0R

BSC624-12V-B04: R4 = 62R

BSC624-12V-B05: R4 = 0R

BSC624-12V-B06: R4 = 62R

BSC624-12V-B07: R4 = 0R


7.1.11 Pin 21 AI1, pin 22 AI2, pin 23 AI3

INFORMATION

Via these three analogue inputs, two different functions each can be realised optionally: 1 mA – current supply for external 5 kΩ potentiometer 33 kΩ pull-up resistor for external 33 kΩ NTC temperature sensor.

Internal wiring

Each of the three analogue inputs can be individually programmed. When setting all three inputs as current

supply, it is possible to implement the following functions for instance:

pin 21 AI1: LV voltage control

pin 22 AI2: Buck mode current limit

pin 23 AI3: Boost mode current limit

During the set-up for the temperature measurement (Tmin = 25°C) of external components, for instance, the following configuration is possible:

pin 21 AI1: Battery temperature

pin 22 AI2: Cooling water temperature

pin 23 AI3: Reserve

10nF

Pin 21 AI1 Pin 22 AI2 Pin 23 AI3

5V

Analog Multiplexer

22kΩ

150Ω

33kΩ

10

nF

I = 1

mA

5V

Ana

log

Mul

tiple

xer

uC



7.2 Pin assignment of HV power connector (device side)

1. HV interlock loop input 2. HV interlock loop output 3. HV+ (high voltage Plus) 4. HV- (high voltage Minus)

Information on the interlock function can be found in chap. 3.4.2 Interlock

7.3 Pin assignment of LV power connector (device side)

1. LV+ wiring system Plus 2. LV- / PGND wiring system power ground / vehicle ground


8 Connections

8.1 Control connector

INSTRUCTION

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

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

INFORMATION

Control connector included in the scope of delivery has to be assembled in accordance with the respective requirements (EMC, environmental impacts etc.). Here, only the actually used pins are to be wired (mandatory* and/or urgently recommended**). Pin 3 EN is to be connected to pin 2 AUX via a switch (e.g.: in the vehicle via the ignition key with the wiring system Plus).

1. GND * Signal ground

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

(Plus wiring system, terminal 30) 3. EN * Enable (power ON, terminal 15) 4. DO0 5. DO1 6. DO2 7. DO3 8. PG1 9. CNL * CAN low 10. CNH * CAN high 11. TXD ** RS232 Transmit (9 pole D-Sub: pin 2) 12. RXD ** RS232 Receive (9 pole D-Sub: pin 3) 13. PRO ** Enable firmware download 14. PG2 15. PG3 ** RS232 ground (9 pole D-Sub: 5 pin) 16. DI0 17. DI1 18. DI2 19. IL1 ** HV interlock loop input 20. IL2 ** HV interlock loop output 21. AI1 22. AI2 23. AI3



8.2 HV power connector

DANGER

High voltage! Danger to life! Before starting the assembly process, ensure that the HV cables are de-energised. Generate the interlock loop in the HV connector insert according chapter 9.1 Producing the cable

glands for the HV power connector. Use exclusively the delivered wire.

Any circumvention of safety installations may have life threatening consequences!

INSTRUCTION

The HV power connector has been designed for a maximum number of 500 cycles of connector operation! The manufacturer guarantees the full functioning (conductance, tightness) up to this quantity.

INFORMATION

The HV power connector included in the scope of delivery is to be assembled with a cable in accordance with the following specifications. On request, this process may also be carried out by BRUSA. For proper assembly, the following tools are required: Buchanan four-indent crimping tool: 09 99 000 0001 (recommended) Locator Han C: 09 99 000 0308 (recommended) Multiple crimping depth adjustment mandrel: 09 99 000 0379 (recommended) Harting crimping tool 4.0 - 6.0 mm2: 09 99 000 0110 (optional) or Harting crimping tool 1.5 - 4.0 mm2: 09 99 000 0303 (optional) Dismounting tools for crimp contacts 1.5 - 6.0 mm2: 09 99 000 0305 (optional)

1. Socket insert 2. Straight carrier housing 3. Carrier housing 4. Gasket 5. Housing screws (4 pieces) 6. 4 mm2 crimp contact socket 7. Cable wire for the interlock bridge

In order to guarantee a reliable operation of all controllers - in particular of the HV voltage controller in the boost mode - the following instructions are to be strictly adhered to:

Max. cable length between the device and the HV battery = 5 m Required cable diameter = 2 x 4 mm² (screened two-core cable)

Admissible cladding diameter = 9 - 16 mm

Screen connection to both sides (recommended for reasons of EMC)


8.3 LV power connector

INSTRUCTION

The LV power connector is a push-pull connector. In order to separate the connector, the latter is to be pushed in the plugging direction (unlocked) and then be pulled out in the pulling direction. The LV power connector has been designed for a maximum number of 1000 cycles of connector operation. The manufacturer guarantees the full functioning (conductance, tightness) up to this quantity. In order to guarantee this number of cycles of connector operation, a lubricating film is to be applied to the positive pole connector housing. The following lubricants are suitable for this purpose according to the connector manufacturer Multicontact. Metalon HAT-1.5 - 50 ml (73.1052) Kontasynth BA100 SPRAY (73.1051) Barrierta I EL-102 Barrierta I S-402 Barrierta I MI-202

INFORMATION

The LV power connector included in the scope of delivery is to be assembled with a cable in accordance with the following specifications. On request, this process may also be carried out by BRUSA. For proper assembly, the following tools are recommended:

Crimping tool Elpress M-PZ-T2600: 18.3710

Crimping insert TB11-14,5 (KRF): 18.3713

1. MC contact (12 V+) 2. Positive pole connector housing (push-pull) 3. Cable lug M8 / 50 mm2 – flat

For information on assembly please refer to chap. 8.4 LV- / PGND (power ground)

4. Cable lug M8 / 50 mm2 - 90° For information on assembly please refer to chap. 8.4 LV- / PGND (power ground)

In order to guarantee a reliable operation of all controllers - in particular of the HV voltage controller in the boost mode - the following instructions are to be strictly adhered to:

Max. cable length between the device and the 12 V LV battery = 2 m.

Required cable diameter = 50 mm2 (unscreened single core cable). Select the cladding diameter in accordance with the connector housing.



For the assembly of the LV-connector a hexagonal crimping of the 50mm2 contact element is prescribed. It is recommended to make two to three crimpings next to each other in order to ensure a reliable contact.

The contact element and the connector housing are to be aligned in a way that the threaded pin can be screwed in entirely.

8.4 LV- / PGND (power ground)

WARNING

Fire hazard! Severe burns! With a loose or non-existing ground connection, the current of the wiring system may return via

the screen of the HV cable and thus cause a cable fire or, consequently, a vehicle fire!

You have to ensure in any case that the ground connection is properly connected! Always adhere to the prescribed torque!

INFORMATION

The cable lug included in the scope of delivery (flat or 90° - see chapter 8.3 LV power connector) is to be assembled with a cable in accordance with the following specifications. On request, this process may also be carried out by BRUSA.

The mounting of a washer (2) between ground screw (1) and cable lug is mandatory!

Hexagonal crimping of the cable lug (check tight fit!). We recommend to execute up to three crimpings in a row in order to guarantee a safe connection.

Max. cable length between the device and the 12 V LV battery = 2 m.

Required cable diameter = 50 mm2 (unscreened single core cable). When installing the cables (LV+ and LV-) in the vehicle, ensure that the spanned area remains as small as

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

1. Ground screw M8 x 16 mm

Torque = 16 Nm 2. Washer


8.5 Cooling system

INSTRUCTION

Ensure that no trapped air is present in the cooling system! The venting may also be implemented via pressure or vacuum filling. Here, ensure that the admissible maximum system pressure is not exceeded! Trapped air in the cooling system may lead to an overheating of the device!

1. Connection of cooling water input (external Ø 16 mm)

2. Connection of cooling water output (external Ø 16 mm)

The cooling water hoses are to be implemented in accordance with the cooling water connection pieces

(external diameter 16 mm) in order to guarantee a water tight connection.

Ensure that the cooling water hoses are properly mounted onto the connection pieces in order to avoid leaks.

Please also ensure that the specified flow direction is adhered to.



9 Installation / initial start-up

DANGER

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

beforehand!

The device may only be connected by a qualified electrician!

Safety installations must never be by-passed or circumvented! Any resulting malfunctions could have life threatening consequences!

INSTRUCTION

All electrical connections are to be fixed within a distance of < 30 cm from the device with a strain relief in order to protect the cable and/or the cable tree at the control connector against vibration and consequential damage.

Ensure that the HV battery used has a pre-charging unit. Any connection without pre-charging unit may cause the formation of sparks / voltage peaks and thus damage to the device!

Procedure step Illustration / other information 1. Mechanically install the device in its specified

position.

Please refer to the installation instructions See chap. 6.9 Dimensions and installation information

---

2. Connect the cooling water hoses (1).

See chap. 8.5 Cooling system

3. Ventilate the cooling system.

Ensure that no trapped air is present in the cooling system!

See chap. 9.2 Ventilating the cooling system

---


Procedure step Illustration / other information 4. Produce a ground connection (1) (LV).

See chap. 8.4 LV- / PGND (power ground)

Maximum cable length 2m!

5. Produce the cable connections of the control

connector.

See chap. 8.1 Control connector

---

6. Connect the control connector (1) with the device.

Ensure that the control connector (1) fully engages and is tightly fit.

7. Implement the LV power connector in accordance

with the manufacturer's specifications.

See chap. 8.3 LV power connector ---

8. Connect the LV power connector (1) with the device (push-pull connector).

Das Bild kann zurzeit nicht angezeigt werden.



Procedure step Illustration / other information 9. Implement the HV lines and the HV power

connector.

See chap. 8.2 HV power connector See chap. 9.1 Producing the cable glands for the HV power connector

---

10. Connect the HV power connector (1) with the device.

11. Connect the battery cable to the HV battery.

See chap. 9.3 Voltage pre-charging ---

12. Manually check that all cable and hose connections are tightly fit.

All electrical connections are to be fixed within a distance of < 30 cm from the device with a strain relief in order to protect the cable and/or the cable harness at the control connector against vibration.

---

INFORMATION

The installation of the device is now complete. You can commission the device. The operation of the device may be implemented by means of customer-specific CAN tools or via the BRUSA-specific PARAM software. This software is ideally aligned to the device and can be purchased optionally. To do this, please contact the manufacturer under the address provided in chapter 4.5 .


9.1 Producing the cable glands for the HV power connector The HV wiring is to be implemented in accordance with the following instructions. Here, it is important to ensure that no strands are damaged. For this reason, check the correct mounting of the screw connection of each complete cable as well as the tight fit of the crimp contact sockets (pull test).

For the HV connections we recommend:

Screened, isolated automotive cable (e.g. by Huber & Suhner). Harting high voltage connector set HAN-Modular Compact, see chapter 4.3 Scope of delivery

When assembling the cable lugs, using the appropriate crimping tool is absolutely necessary!

PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 1. Strip the HV cable (1) to a length of 40 mm.

Ensure that the braid underneath is not damaged!

2. Shorten the braid (1) to 15 mm.



PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 3. Strip both strand ends (1) to a length of 9 mm.

Mount the crimp contact sockets (2) included in the scope of delivery onto the strand ends (1).

Further information can be found in chap. 8.2 HV power connector

4. Lead the HV cable through the union nut (1).

Lead the HV cable through the terminal insert (2).

5. Put the braid (1) over the terminal insert (2). Here,

the braid (1) may protrude from the O-ring (3) by a maximum of 2 mm. Fix the terminal insert (2) in its position at the HV cable, e.g. with insulating tape (4).

Ensure that no individual strands of the braid (1) protrude beyond the O-ring (3)! Once installed, this will damage the sealing lip and subsequently cause an ingress of water into the housing! Therefore, cut all protruding strands to the admissible length.




PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 6. Put the gland base (1) over the terminal insert (2).

Remove the insulating tape. Screw together the gland base (1) with the union nut (3).

At this stage, only attach the union nut manually.

7. Put the carrier housing (1) onto the gland base (2)

and tighten it.

Tighten the gland base (2) at the carrier housing (1) with a torque of 15 Nm.

8. Strip both strand ends (1) of the delivered interlock

bridge to a length of 9 mm. Mount the crimp contact sockets (2) included in the scope of delivery onto the strand ends (1).

Further information can be found in chap. 8.2 HV power connector



PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 9. Insert the crimp contact socket of the interlock loop

(1) into the socket insert.

For the pin assignment, please refer to chapter 7.2 Pin assignment of HV power connector (device side)

10. Insert the crimp contact socket into the socket insert

(1). Pull the socket insert (1) into the carrier housing (2).

For the pin assignment, please refer to chapter 7.2 Pin assignment of HV power connector (device side)

11. Put the gasket (1) onto the carrier housing (2).

Put on the straight carrier housing (3). Screw together the carrier housing (2) with the straight carrier housing (3).

Before tightening, check the tight fit of the gasket (1).


PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 12. Tighten the union nut (1).

Tighten the union nut (1) with a torque of 12 Nm.

13. Manually check the tight fit of the cable gland. ---



9.2 Ventilating the cooling system

INSTRUCTION

Trapped air in the cooling duct along with a generally insufficient cooling of the device lead to increased wear and tear! Ensure that the cooling circuit is fault-free.

Procedure step illustration / other information 1. Check the cooling water connections on the device

for water tightness and firm fit. ---

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


9.3 Voltage pre-charging

INSTRUCTION

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

When using a PTC as pre-charging resistor, the latter is heated by means of multiple subsequent pre-charging processes. If the PTC overheats, another pre-charging process is temporarily impossible. The pre-charging resistor must be cooled down for a certain period of time in such case.



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

1. The main contactor (3) closes. 2. The pre-charging contactor (1) closes.

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

Monitor the pre-charging time and open the pre-charging contactor (1) again if the condition U1 - U2 < 10 V is not fulfilled even after a specified maximum period.

3. The main contactor (2) closes.

The main contactor (2) may only close if the condition U1 - U2 < 10 V is fulfilled.

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

The HV connection to the device is now produced.


10 Operation

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

The BSC6_PARAM_Manual_xxxxxx describes the operating functions of the PARAM tool for the BSC6. The manual is field in the same folder of the customer package.

INFORMATION

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

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

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

If the PCAN USB adapter (dongle) is connected to the PC, the CVI and PARAM software can be started over the “StartBSC6xx.cmd”-File.

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



10.3 Operation of the device

INFORMATION

Optionally, the CAN user interface (CVI) may also be implemented by BRUSA if the device is not integrated into an existing CAN communication network. The following image shows an example of the user interface. Here, the start-up is implemented as described. The CVI software serves as user interface for internal laboratory applications for BRUSA Elektronik AG. The CVI is provided to customers as example for a custom user interface for first tests with no guarantee.

Connect pin 3 EN with pin 2 AUX (e.g. actuate ignition key, close switch etc.).

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

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

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

The device can be switched off in every operating mode by another actuation of the Run button and a deactivation of pin 3 EN. In the case of an emergency, an abrupt disconnection of the high voltage by opening the contactors is also admissible.


10.4 Operation in the CAN-less mode (automatic mode)

INFORMATION

The BSC624-12V-B may be operated autonomously in the CAN-less mode via the buck mode. In this operating mode, the device is able to convert energy obtained from a HV circuit to a LV level without CAN connection. For the autonomous operation in the CAN-less mode, the following settings are to be implemented by means of the PARAM software.

Procedure step Illustration / other information 1. Open the PARAM software. --- 2. Change to the Parameter List tab (1)

3. In the drop-down menu, select [04] Control

configuration – CRC.



Procedure step Illustration / other information 4. In field (1), enter the value 2 (automatic mode).

For the autonomous operation without CAN connection, value = 2 must be set.

5. In field (1), enter the duration in seconds during

which a HV voltage must be present until the CAN-less mode is started (HV-ready time).

Requirement: The device is released via DI0.

6. In field (1), enter the LV which is applicable for

commanding the automatic mode (AUTO ULV com)


Procedure step Illustration / other information 7. In the fields (1-3), set the voltage and current limits

for the automatic mode (AUTO UHV lim, AUTO IHV lim, AUTO ILV lim)

8. In order to accept the modified data, click on the Set

key button (1).

9. Change over to the Main Parameter register (1).



Procedure step Illustration / other information 10. Click the Update & Reset Target button (1).

Requirements: The user must be logged in via the user password monitor (via Login button (2)).

INFORMATION

In order to activate the CAN-less mode, at the digital input DI0 (control connector pin 16), a High must be set. If the HV is set subsequently, the BSC starts the autonomous operating mode upon expiration of the previously defined HV-ready time. For this purpose, no CAN connection is necessary.


11 Firmware update

INSTRUCTION

The programming of an incorrect firmware may damage the device! Therefore, a firmware update may only be carried out after consultation with BRUSA Elektronik

AG! A firmware update may only be carried out at an error-free, functioning device!

11.1 System requirements

INFORMATION

The Flash development toolkit (Release 4.08) software functions with the following operating systems: Win2000 Win XP Win Vista Win 7

11.2 Installation Flash Development Toolkit

Procedure step Illustration / other information 1. Install the FDT Flash development toolkit software

as well as the FDT Protocol A plug-in while taking into consideration the settings listed below.

Download under: www.renesas.com

---

2. Start the installation of the FDT Flash development toolkit 4.08 software.

3. In the dialogue check FDT Application (1). If

required, uncheck other kernels. Click Next (2).



Procedure step Illustration / other information 4. In this dialogue, you can select and unselect the file

formats to be opened with FDT optionally. Click Next (1).

5. In this dialogue, you can change the installation path

if required. Click Next (1).

6. In this dialogue, you can check your settings again

and change them if required (Back button (1)) Click the Install button (2) in order to proceed.


Procedure step Illustration / other information 7. The installation process will be carried out.

8. After the installation has been successfully

completed, the following dialogue appears. Click the Finish button (1).

The installation of FDT is now completed. Now, follow the further instructions.

9. Upon completion of the installation, execute the file

fdt3_05_prota_A.EXE.

10. Select the installation directory.

The installation path is to be adapted in order to allow for the kernels to be installed in the FDT4.08 folder. Example: C:\Programme\Renessas\FDT4.08

Click the Next button (1).



11.3 Preparing measures

PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 1. At the control connector, connect pin 2 AUX with

pin 13 PRO.

See chap. 7.1 Pin assignment of control connector (device side)

---

2. Connect the device with your PC (RS232 interface).

See chap. 7.1.7 Pin 11 TXD, pin 12 RXD

Before executing this step, it is to be ensured that the RS232 interface is not already assigned!

---

3. Establish an HV or LV supply (AUX) to the device. ---


11.4 Executing the firmware update

INFORMATION

Depending on the software version and the operating system used, the graphical user interfaces may deviate.

PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 1. Start the Flash Development Toolkit 4.08 Basic

software. ---

2. Select the kernel SH/7045F in the list (1). Click the Next button (2) and skip the steps 3 and 4.

If the kernel SH/7045F is not included in the list, click the Other button (3).

3. Open the folder in which FDT Flash Development

Toolkit 4.08 and FDT 3.05 Protocol A Plugin are installed.

Follow the path: Renesas → FDT 4.08 → Kernels → ProtA → 7045 → Hitachi → 0_0_00.

---

4. Select the file 7045.fcf. Click the Open button (1).

The kernel SH/7045F is now included in the list. Return to step 2.



PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 5. Select the port to which the device is to be

connected (e.g.COM1) in field (1). Select Direct connection in field (2). Click the Next button (3).

6. Click the Next button (1).

7. Select BOOT Mode (1).

Uncheck field (2). Select 57600 (3). Click the Next button (4).


PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 8. Select Automatic (1).

Select Advanced (2). Click the Finish button (3).

You have now created the project and/or the device. The new firmware can be programmed as described below.

9. Check field (1).

Click the button (2) and select the new firmware file from the list which appears. Click the Program Flash button (3).

The firmware update is now executed. After the update has been completed successfully, the message Image successfully written to device appears in field (4).



PROCEDURE STEP ILLUSTRATION / OTHER INFORMATION 10. Click the Disconnect button (1) in order to securely

separate the connection to the device. Click the Exit button (2).

11. Separate the HV or LV supply to the device. --- 12. Disconnect the device from your PC (RS232

interface). ---

13. At the control connector, disconnect pin 2 AUX from pin 13 PRO.

See chap. 7.1 Pin assignment of control connector (device side)

---


12 Troubleshooting

The device differentiates between two error categories:

Critical errors (CRE): Normally, this type of error does not occur if the device is properly operated and installed. Except for the error message CRE_INTERLOCK, such error message probably indicates a defective component in the device.

Errors (E): This type of error normally occurs in the case of an error when operating the device. This does not include the errors E_TEMP and E_INT_SUPPLY.

As reference point as to when a device is to be sent in for the purpose of analysis and/or repair, BRUSA has defined the following maximum number of recurring error events: Critical errors (CRE): 10 Errors (E): 50

For a list of all possible errors, please refer to the manual BSC624-12V-B Documentation of Errors and Warnings.

Always try to clear all errors which occur with the help of this manual. Should errors reappear, please refer to the BRUSA support under the manufacturer address indicated in chapter 4.5 .

13 Warranty

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

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



14 Instructions regarding 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 24 March 2006, electronic devices may no longer be disposed of along with ordinary household waste but must be separately collected and recorded by a specialist services.

Disposal through a specialist service significantly helps to avoid dangers to people and nature. Therefore, in the case of disposal, we recommend contacting a recognised specialist disposal service.


15 Index

A Avoidance of damage to the device 73

B Block diagram

BSC624-12V-B basic concept 25 Installation into the vehicle 32

C Control connector Pin assignment on device side 39 Control connector Pin assignment, connector side 51 Controller 42 cooling system

Specification 24 Cooling system

Connections 38 Customer package 18

D Derating 14 Designation of the device

Decoding 3 Device limits 21 Device specification 24 Disposal 82

E EMC concept 26 Error messages 81

F firmware 42 Firmware 41, 45, 46, 76, 77

Important instructions 73

G Ground connection 40 Guarantee 82

Instructions 12

H HF power transformers 15 High voltage

The 5 safety rules 12

HV power connector

Mounting the cable glands 59 Pin assignment (device side) 50

I Interlock 13, 33, 47, 50

L LV power connector

Installation instructions 53 Pin assignment on device side 50

N Notes on life span 11

O operating ranges 21

P Pictograms 8 Prevention of damage to the device 64 programming 41, 42, 46 protective functions

LV side 16 Protective functions

general 13, 65 HV side 15, 16

S Safety

Important instructions 10 Serial number 37 Support contact 20 Switches buck / boost converter 14

T Temperature measurement 14 transformer stage switches 15

V Validity of the manual 3

W Warranty 82

dc/dc converter bsc624-12v-b - brusa · 9.1 producing the cable glands for the hv power connector...

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