Brusa BDC546 Technical Data And Start-Up Download Page 9

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Technical data

and start-up

BDC546

Safety and warning instructions

This chapter contains safety instructions applying to this device. These instructions refer to the assembly, start-up

and running operation in the vehicle. Always read and observe these instructions in order to protect people's safety

and lives and to avoid damage to the device!

3.1

Symbols and their meaning

Throughout this manual, a variety of symbols are used. For an overview of symbols as well as their meanings, refer

to the following table:

Prohibition symbols

SYMBOL

MEANING

SYMBOL

MEANING

General prohibition

Warning! High voltage!
Do not touch!

Do not switch!

Warning symbols

SYMBOL

MEANING

SYMBOL

MEANING

General hazard warning

Warning! Danger caused by 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 voltage

Disconnect device from mains

Wear protective glasses

Wear protective gloves

Information signs

SYMBOL

MEANING

SYMBOL

MEANING

Important information on avoiding possible
damage to property

Important information

Summary of Contents for BDC546

Page 1: ...BRUSA Elektronik AG Neudorf 14 CH 9466 Sennwald 41 81 758 19 00 info brusa biz www brusa biz DC DC converter BDC546 TECHNICAL DATA AND START UP Translation of the original German operating instructions ...

Page 2: ...elopment of our products we reserve the right to make changes to their designs Any changes will be disclosed in individual manuals by replacing relevant pages and or revising electronic data storage devices Writer Author Manuel Tschumper REVISIONS REVISION DATE NAME CHANGE 01 24 th Feb 2014 M Tschumper Document issued 02 24 th Feb 2014 M Tschumper List of parameters translation 03 25 th June 2014 ...

Page 3: ...ical data and start up BDC546 VALIDITY This manual is only valid for the devices listed in the following table BDC546 B04 BDC546 B05 OEM Version BDC546 B06 The breakdown of the device designation is as follows ...

Page 4: ...tems 13 3 4 Safety installations power limitations 14 3 4 1 Interlock 14 3 4 2 Pyrofuses 14 3 4 3 Over temperature protection derating 15 3 4 4 HV Automatic intermediate circuit discharge 15 3 5 Requirements regarding the start up personnel 16 4 General 17 4 1 Content and scope of this manual 17 4 2 Scope of the entire documentation 17 4 3 Scope of delivery 18 4 4 Applicable standards 19 4 5 Manuf...

Page 5: ...on 32 6 11 Type plate 33 7 Electrical interfaces 34 7 1 Control connector pin assignment device side 35 7 1 1 Pin 1 GND 36 7 1 2 Pin 2 AUX 37 7 1 3 Pin 6 TXD pin 7 RXD pin 8 P_GND 38 7 1 4 pin 9 CNL pin 10 CNH 39 7 1 5 Pin 11 PFO_VC pin 12 PFI_VC pin 14 PFO_VC pin 15 PFI_VC 40 7 1 6 Pin 13 PRO 41 7 1 7 Pin 16 EN 42 7 1 8 Pin 17 DO_MC 43 7 1 9 Pin 19 IL 44 7 2 Earthing grounding screw equipotential...

Page 6: ... 10 2 5 09 FW Gains Offset CRC 68 10 2 6 0A FPGA Gains Offsets and Settings CRC 68 10 2 7 10 Digital IO 69 10 2 8 11 Analog Input 69 10 2 9 12 Analog Values calculated and Offsets 70 10 2 10 13 PWM Input 70 10 2 11 20 Status 70 10 2 12 22 Temperatures 71 10 2 13 23 Stored App Data 71 10 2 14 23 Stored App Data 72 10 2 15 31 General Parameters 73 10 2 16 32 Revision Info 73 10 3 DC DC converter ope...

Page 7: ...7 Technical data and start up BDC546 14 Instructions for disposal 79 15 Index 80 16 Attachments 82 16 1 Cable fitting 82 16 2 Cable lugs 86 ...

Page 8: ... Safety and warning instructions is to be read thoroughly 2 List of abbreviations Throughout this manual some specific technical abbreviations are used You will find an overview of these abbreviations as well as their meanings in the following table ABBR MEANING ABBR MEANING BDC Bidirectional High Power DC DC Converter FC Fuel Cell CAN Controller Area Network VC Traction intermediate circuit HV Hi...

Page 9: ...he following table Prohibition symbols SYMBOL MEANING SYMBOL MEANING General prohibition Warning High voltage Do not touch Do not switch Warning symbols SYMBOL MEANING SYMBOL MEANING General hazard warning Warning Danger caused by suspended loads Warning Explosive environment Warning Danger caused by batteries Warning Hot surface Warning High voltage Warning High pressure fluid ejection Warning Fi...

Page 10: ... WARNING This notice is a warning against serious but reversible risks of injury Avoid these risks by observing this notice CAUTION This notice is a warning against a minor risk of injury Avoid these risks by observing this notice NOTICE This notice is a warning against possible damage to property if the following instructions and work procedures are not observed INFORMATION This type of notice di...

Page 11: ...ons 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 of death Do not store any highly flammable substances or combustible fluids in the...

Page 12: ...mage 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 BRUSA Elektronik AG Always use an isolation monitoring unit to con...

Page 13: ... working on an HV grid the following 5 safety rules must generally 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 acc...

Page 14: ...etween the fuel cell and the BDC546 For this a fuse with a resistance of approx 2 Ohm can be applied The BDC546 offers a digital input output each for both connection wires from the DC DC converter to the fuel cell It can be connected with one pyrofuse each The outputs are permanently supplied by the plus wiring system terminal 30 For a permissible LS voltage the input has almost the same potentia...

Page 15: ...by 20 A for every degree temperature increase If a temperature sensor is defective derating is activated at temperatures 80 C for safety reasons and correspondingly the lowside current is reduced to 0 A at a temperature of 100 C 3 4 4 HV Automatic intermediate circuit discharge The BDC546 is equipped with an active as well as passive feature for discharging the HV circuit This includes the highsid...

Page 16: ...aff are defined as electricians who possess professional training knowledge and experience in the field of high voltage electronics electric mobility as well as knowledge of the relevant requirements and dangers which they can demonstrate in practice Furthermore they must be able to assess the work assigned to them independently identify possible dangers and establish necessary protection measures...

Page 17: ...entire set of documentation as well as diverse pieces of software are required The provision of the customer package ensures that the documentation and software are complete and up to date Specific documents are updated automatically and can be seen in the history The customer package includes the following indexes Manuals Contains all information fundamentally necessary for installation and opera...

Page 18: ...screw ground GND 1 6 M10 washer for M10 x 16 screws ground GND 1 7 M25 cable fittings Pflitsch prod no 22554e 1814 2 8 M32 cable fittings Pflitsch prod no 23255e 2520 2 9 crimp type cable lug flat HS 70 mm Ferratec AG Klauke 16578 2 10 crimp type cable lug flat LS 95 mm Ferratec AG Klauke 16588 2 11 23 pole control connector with crimp contacts AMPSEAL 770680 1 1 12 SN LP contacts AMPSEAL 770854 1...

Page 19: ...sideration of the EC guidelines national laws and harmonised standards EN valid at the time of production relevant to the product BDC546 4 5 Manufacturer contact information BRUSA Elektronik AG Neudorf 14 9466 Sennwald Switzerland Phone 41 81 758 19 00 Fax 41 81 758 19 99 Internet www brusa biz Email support brusa biz ...

Page 20: ...orm to the conditions and requirements stated in the technical documents and data sheets of the manufacturer are regarded as improper use Taking into consideration the proper use indicated in chapter 5 1 the following limit values have been stipulated for the operation of the product BDC546 The product may not be used outside these limit values Operation outside these limit values can lead to life...

Page 21: ...s current at Tcoolant 60 C 300 A Lowside peak current 400 A Highside peak current 350 A Continuous output power in buck mode at ULS 600 V 180 kW Continuous output power in boost mode at ULS 600 V 180 kW Peak output line 220 kW Switching frequency 41 kHz DYNAMIC BEHAVIOUR BDC546 B UNIT Highside voltage step response in boost mode at UHS 200 V 400 V ILS 100 A ULS 150 V 3 ms Lowside voltage step resp...

Page 22: ...red highside voltage for valid T U and I measurements 150 VDC THERMAL COOLING SYSTEM BDC546 B UNIT Coolant water glycol mixing ratio 50 50 Amount of coolant in device 1100 ml Min coolant temperature at the input 40 C Max coolant temperature at the input 65 C Coolant pressure drop at 15 l min Tcoolant 25 C 0 25 bar Cooling water flow rate max 17 l min Cooling water flow rate min 15 l min Max coolin...

Page 23: ...tomotive applications High power density 6 4 kW kg Low ripple current due to high clock frequency Vibration resistant construction for mobile usage High efficiency up to 98 9 CAN interface integrated by default Tested according to ECE directives Certified according to E13 Interlock function evaluation FGPA implemented highly dynamic control circuit Patented Liquid Pin cooling system SoftSwing topo...

Page 24: ...tented switching strategy SoftSwing is applied It not only enables highly efficient operation of the component but also guarantees very low EMC emissions Additionally the low switching losses enable clocking at very high switching frequencies In combination with the high number of phase shifted clocking half bridges this makes it possible to achieve excellent ripple reduction 6 4 1 Topology benefi...

Page 25: ...ll interferences by means of the existing leakage inductance LS The wired Y capacitors Cy5 to Cy10 and the common mode choke Lh form the common mode filter The X capacitors Cb1 Cb2 Cb3 and the leakage inductance of the HV chokes LS form the push pull filter Due to the high clock frequencies the capacitors may have very small dimensions Thus a rapid discharge of the intermediate circuit is possible...

Page 26: ...µF Cb3 80 0 µF Lh 1 30 mH Ls 500 nH 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 replaced immediately In order to obtain an original label please contact the BRUSA support at the manufacturer s address provided in chapter 4 5 Das Bild ka...

Page 27: ...27 Technical data and start up BDC546 6 6 Vehicle installation basic principle ...

Page 28: ...f the respective interlock conditions of the individual devices are met closed service cap HV connections plugged in The interlock evaluation system of the PDU switches the 12 V supply voltage 2 of the HV contactors 4 in the battery if the interlock circuit is closed The emergency off switch 3 also disconnects the 12 V supply voltage of the HV contactors 4 The second interlock switch 5 of the insu...

Page 29: ...tangular signal frequency of 86 Hz f 90 Hz is regarded by the component as permissible The range of a valid duty cycle lies between 48 and 52 The signal is to be generated from AUX terminal30 logic HIGH and GND terminal31 logic LOW An invalid signal sequence is regarded as error state and potential operation of the component is prevented by deactivation of the power stages If it is required this f...

Page 30: ... Overview of the main structural components 1 Lowside cable fitting 2 Service cap 3 Housing cover 4 Housing 5 Water duct cover 6 Cooling water connections 7 Control connector 8 Grounding connection for grounding cable 9 Highside cable fitting ...

Page 31: ...ned in such a way that the device is installed in a secured position and with as few vibrations as possible The cable inlets and cooling water ducts should have enough space and must never touch components with sharp edges All cable connections must be secured with strain relief elements near the device not included in the scope of delivery 6 10 1 Fastening points NOTICE The housing has been desig...

Page 32: ... However the following installation positions are NOT advisable Connector side to the top This causes the danger of a 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 ...

Page 33: ...duction 4 Product number specified by the customer 5 Supplier number specified by the customer 6 Highside voltage range for operation 7 Efficiency 8 Max admissible cooling water temperature at the input 9 Lowside voltage range for operation 10 Lowside peak current 11 Peak power 12 IP protection class ...

Page 34: ... 2 Grounding connection Chapter 7 2 Earthing grounding screw equipotential bonding 3 Highside plus Chapter 7 3 Highside and lowside power connections 4 Highside minus Chapter 7 3 Highside and lowside power connections 5 Lowside plus Chapter 7 3 Highside and lowside power connections 6 Lowside minus Chapter 7 3 Highside and lowside power connections ...

Page 35: ... Not connected 5 NC Not connected 6 TXD RS232 Transmit 9 pole D Sub pin 2 7 RXD RS232 Receive 9 pole D Sub pin 3 8 P_GND RS232 ground 9 pole D Sub pin 5 9 CNL CAN low 10 CNH CAN high 11 PFO_VC Pyrofuse output VC 12 V 12 PFI_VC Pyrofuse input VC open drain 13 PRO Enable firmware download 14 PFO_VC Pyrofuse output VC 12 V 15 PFI_VC Pyrofuse input VC open drain 16 EN Enable power ON terminal 15 17 DO...

Page 36: ...icle s ground is to be connected at this pin Internal wiring Direct connection to the ground of the control unit The signal earth is only capacitively connected to the housing When wiring BDC546 control signals with other vehicle components e g traction drive vehicle battery battery management BMS fuel cell the vehicle ground is to be connected here ...

Page 37: ...he internal 15 V supply is activated and takes over the supply This relieves the wiring system The pins 11 PFO_VC and 14 PFO_VC are always supplied via pin 2 AUX 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 Pyrofuse control M...

Page 38: ...ction is highly recommended 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 For wiring of the RS232 ground an additional grounding connection P_GND is provided It is connected with the GND supply ground via one PTC fuse The microprocessor ...

Page 39: ...Mbit Termination of the CAN interface is not intended in the DC DC converter CAN terminating resistor Via the CAN interface messages can be transmitted in accordance with the CAN matrix provided by BRUSA as dbc file The following parameters of the CAN messages can be modified via the PARAM software Identifier Baud rate Bit timing ...

Page 40: ...yrofuses can be connected directly to these pins If an overvoltage is detected the pyrofuses are triggered The pins 11 PFO_VC and 14 PFO_VC are internally always connected to pin 2 AUX via a fuse The pins 12 PFI_VC and 15 PFI_VC are open drain connections If an overvoltage is detected the two pins are drawn to GND and the pyrofuses are triggered If no pyrofuses are applied the respective function ...

Page 41: ... This pin is only activated for programming of a new firmware pin 13 PRO high For this purpose pin 16 EN does not need to be high Internal wiring It is highly recommended to disconnect the device from the HV supply prior to programming The device has to be supplied via the AUX wiring system and pin 13 PRO high 7 16 V when it is set to programming mode Afterwards programming can be carried out via ...

Page 42: ...oltage of 1 V is required Internal wiring To programme a new firmware pin 13 must be PRO high For this purpose pin 16 EN high is not necessary If voltage is applied at pin 2 AUX and if pin 16 is EN high the device is put into the operational mode Most appropriately this is implemented by connecting pin 16 EN to the Plus wiring system via a switch ...

Page 43: ...ng Pin 17 DO_MC is a digital output switching between signal ground GND and wiring system Plus AUX and designed for a peak current of 4 A for 120 ms and 200 mA continuous current This way two main contactors between the HV battery and the BDC546 can be directly controller ...

Page 44: ... be disconnected by the interlock loop However it can detect errors that are caused by external devices in the interlock loop In case of an invalid signal sequence or missing interlock signal the signal Interlock_In is set and the error DC_Err_Interlock is returned via CAN Detection of the interlock error leads to an immediate shut down of the device If no interlock monitoring system is applied th...

Page 45: ...ng circuit is connected correctly A loose grounding circuit can lead to sparking and subsequent fires 1 M10 x 16mm grounding screw 2 M10 washer The grounding screw 1 must be connected with the ground of the vehicle and or test bench A washer 2 is to be positioned between the grounding screw 1 and the cable lug Grounding screw 1 torque 28 Nm ...

Page 46: ...ed if the device has been de energised NOTICE Ensure proper connection of the highside and lowside Observe the polarity INFORMATION Before crimping the cable lugs to the power cables the cable fittings have to be guided over the power cables Do not install the cable fittings at the device housing yet 1 Highside cable fittings 2 Lowside cable fittings 3 Highside plus screw 4 Highside minus screw 5 ...

Page 47: ...tion 70 mm Required lowside cable cross section 95 mm Tightening torque of the screws for the cable lugs 3 4 5 6 13 Nm Mount the cable fittings 1 2 at the housing Lowside tightening torque M32 x 1 5 with 45 Nm Highside tightening torque M25 x 1 5 with 35 Nm Use the union nut to mount the cables in the cable fitting For the tightening torque refer to the cable specifications ...

Page 48: ... the respective requirements EMC environmental impacts etc Here only the actually used pins are to be wired mandatory or highly recommended Pin 16 EN is to be connected to pin 2 AUX via a switch e g in the vehicle by means of the ignition key with the Plus wiring system 1 GND Signal ground Minus wiring system terminal 31 2 AUX 12 V Plus wiring system terminal 30 3 NC 4 NC 5 NC 6 TXD RS232 Transmit...

Page 49: ...g In case of longer cable lengths then 1 5 m consult the manufacturer BRUSA Chapter 4 5 Manufacturer contact information 1 M25 cable fittings HS 2 Cable lug flat HS 70 mm In order to guarantee reliable operation of all controllers in particular of the HV voltage controller in boost mode the following instructions are to be strictly adhered to Required cable cross section 70 mm Max cable length bet...

Page 50: ...cable with connection to the shielding braid refer to chapter 9 2 Building the HV wiring In case of longer cable lengths than 1 5 m consult the manufacturer BRUSA Chapter 4 5 Manufacturer contact information 1 M32 cable fittings LS 2 Cable lug flat LS 95 mm Required cable cross section 95 mm Max cable length between device and connected load source 1 5 m Guide the cable fitting 1 over the power ca...

Page 51: ...ctively to overheating of the device 1 Cooling water inlet connection 18 mm external Ø 2 Cooling water outlet connection 18 mm external Ø The cooling water hoses 18 mm internal hose diameter are to be implemented in accordance with the cooling water connection pieces 1 2 in order to guarantee a water tight connection Ensure that the cooling water hoses are properly mounted on the connection pieces...

Page 52: ...ttery used is equipped with a pre charging unit Any connection without pre charging unit may lead to sparks voltage peaks and damage to the device INFORMATION Prior to installation visually check the packing material and particularly the device itself for damage Each device undergoes a strict quality and function test at BRUSA before distribution However we do not have any influence on the shippin...

Page 53: ...d however they are already over the power cables For information on assembling the power cables refer to chapter 9 2 Building the HV wiring Ensure proper connection of lowside minus 1 lowside plus 2 and highside minus 3 highside plus 4 Observe the polarity Refer to chapter 7 3 Highside and lowside power connections 5 Mount the cable fittings at the housing For the tightening torques of the connect...

Page 54: ...e against vibration and consequential damage 10 Ventilate the cooling system Ensure that no air is trapped in the cooling system Refer to chapter 9 3 Ventilating the cooling system 11 Ensure that the converter is connected to the power source via a suitable pre charging unit Refer to chapter 9 4 Voltage pre charging Any connection without pre charging contactor may lead to voltage peaks and damage...

Page 55: ... e g by Huber Suhner A cable lug refer to chapter 4 3 Scope of delivery To assemble the cable lugs an appropriate crimping tool must be used NOTICE Ensure that no individual strands of the braid step 4 are protruding Once installed this will damage the sealing lip and subsequently cause an ingress of water into the housing For this reason all protruding strands have to be shortened to the admissib...

Page 56: ...able 1 to a length of 20 mm For the lowside 95 mm cross section 22 mm are required Ensure that the copper strands 2 underneath are not damaged 4 Guide the pressure screw 1 and the sealing insert 2 over the HV cable 3 Guide the cone of the grounding insert under the shielding braid 4 5 Slide the connection thread 1 over the HV cable 2 up to the cone of the grounding insert ...

Page 57: ...y protrude at the sides To assemble the cable lugs an appropriate crimping tool must be used We recommend the following crimping tool Klauke ultra EK 120 UNV L 7 Manually check the tight fit of the cable lug 8 Attach a shrinking tube 1 over the cable lug 2 The shrinking tube 1 must be attached to prevent contact with the housing after installation ...

Page 58: ...o be carried out by means of pressure or vacuum filling Ensure that the admissible maximum system pressure is not exceeded 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 proper fit Always check for correct connection of the cooling water inlet 1 and cooling water outlet 2 2 Swit...

Page 59: ...a a pre charging resistor When using a PTC as pre charging resistor it is heated by means of multiple subsequent pre charging processes If the PTC overheats another pre charging process is temporarily impossible In this case the pre charging resistor has to be cooled down for a certain period of time If the system is only connected to one power source at the highside the pre charging unit on the h...

Page 60: ...tor 1 must be able to interrupt the pre charging current in case of an error 2 The main contactor 3 closes Monitor the pre charging time and open the pre charging contactor 1 again if the voltage of the power source is not achieved at the converter after a specific maximum time 3 The main contactor 2 closes The main contactor 2 may only close if the converter is successfully pre charged to the vol...

Page 61: ...n The PARAM software provided by BRUSA is used for parameterization and configuration of BRUSA devices PARAM provides access to the various parameters and functions of the BDC546 via CAN interface This provides the possibility of individually adjusting parameters e g activation of interlock signal evaluation or overvoltage shut down functions at a specific voltage Parameters and functions or their...

Page 62: ...llation of the required PCAN USB OEM and PEAK drivers as well as of the PARAM tool Additionally the user interface and the operating functions of the PARAM tool are generally described 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 the visually separated USB adapter with suitable 120 OHM terminating r...

Page 63: ... 32 Bit 2147483648 2 147 483 647 UINT_DEZ 4 Byte 32 Bit 0 4294967295 UINT_HEX 4 Byte 32 Bit 0x0000 0000 0xFFFF FFFF FLOAT 4 Byte 32 Bit 3 4028235E 38 3 4028235E 38 CONV_FLOAT 4 Byte 32 Bit 3 4028235E 38 3 4028235E 38 Default value Default value for parameters prior to initial start up factory settings Unit The physical unit R W user Read and write permissions for the values R Values can be read R ...

Page 64: ...nfiguration by BRUSA content not relevant for the customer 07 FPGA HR NVM data CRC Configuration by BRUSA content not relevant for the customer 08 FPGA BR NVM data CRC Configuration by BRUSA content not relevant for the customer 09 FW gains offset CRC Configuration by BRUSA content not relevant for the customer 0A FPGA gains offsets and settings CRC Configuration by BRUSA content not relevant for ...

Page 65: ...ustomer 42 FPGA Voltage and IB measuring value block Configuration by BRUSA content not relevant for the customer 43 FPGA Filter block Configuration by BRUSA content not relevant for the customer 44 FPGA PWM and PI current controller Configuration by BRUSA content not relevant for the customer 45 FPGA Main controller block Configuration by BRUSA content not relevant for the customer 46 FPGA Debug ...

Page 66: ... CAN Msg Send3 ID Default 0x12 0x00 deaktiviert UINT_HEX RW CAN Msg Send3 Rate Default 200ms UINT_DEZ RW CAN Msg Recv1 ID Default 0x01 0x00 deaktiviert UINT_HEX RW CAN Msg Recv1 Timeout Default 100ms 10 x SendTime UINT_DEZ RW CAN Msg Recv2 ID Default 0x02 0x00 deaktiviert UINT_HEX RW CAN Msg Recv2 Timeout Default 100ms 10 x SendTime UINT_DEZ RW CAN Msg Recv3 ID Default 0x03 0x00 deaktiviert UINT_H...

Page 67: ... das Gerät auch bei Low Pegel von Klemme 15 aktiviert 1 Bei Low Pegel von Klemme 15 schaltet das Gerät immer komplett ab UINT_HEX RW Pyrofuse Configuration 0 Aus 1 Überwacht ULS 2 Überwacht UHS UINT_HEX RW Pyrofuse Voltage Auslösespannung Pyrofuse in V CONV_FLOAT RW HR Sollwert Steuerung 0x00 direkt 0x01 Rampe 0x02 Filter UINT_HEX RW HR Sollwert Rampe Steilheit in A V pro Sek Minimum 32 CONV_FLOAT...

Page 68: ... FLOAT R Pyro VC Offset Ohm FLOAT R 10 2 6 0A FPGA Gains Offsets and Settings CRC Kapitel nicht Kundenrelevant NAME BEZEICHNUNG EINHEIT DEFAULTWERT DATENTYP R W IL Gain 1 8192Lsb per bit INT_DEZ R Automatischer Offsetabgleich starten 1 Start UINT_DEZ R IL Offset 0 A FLOAT R IL Offset 1 A FLOAT R IL Offset 2 A FLOAT R IL Offset 3 A FLOAT R IL Offset 4 A FLOAT R IL Offset 5 A FLOAT R IL Offset 6 A F...

Page 69: ... Power Supply 1 0 PE8 Pin 27 SHC UINT_DEZ R HV Supply abschalten 1 0 PE9 Pin 28 SHC UINT_DEZ R Beide Pyrofuse zünden 1 0 PE11 Pin 29 SHC UINT_DEZ R SH_ENA_POWERSTAGE 1 0 PB5 UINT_DEZ R 10 2 8 11 Analog Input Kapitel nicht Kundenrelevant NAME BEZEICHNUNG EINHEIT DEFAULTWERT DATENTYP R W Spannung low side 0 5V ADC0 Pin96 SHC FLOAT R Spannung high side 0 5V ADC1 Pin95 SHC FLOAT R Temp der Hauptdrosse...

Page 70: ...k DutyCycle Gemessener DutyCycle vom Interlock 0 0 100 0 CONV_FLOAT R Interlock Frequenz Gemessene Frequenz in Hz vom Interlock CONV_FLOAT R 10 2 11 20 Status NAME BEZEICHNUNG EINHEIT DEFAULTWERT DATENTYP R W CAN1 MsgLostBitmap hex UINT_HEX R Feature Bitmap hex UINT_HEX R Error Bitmap hex UINT_HEX R Temp Error Bitmap hex UINT_HEX R Warning Bitmap hex UINT_HEX R IntStat hex gespeicherter Wert beim ...

Page 71: ...Minimale T des Moduls CONV_FLOAT R Max Temperatur Modul 1y Maximale T des Moduls CONV_FLOAT R Min Temperatur Modul 2x Minimale T des Moduls CONV_FLOAT R Max Temperatur Modul 2x Maximale T des Moduls CONV_FLOAT R Min Temperatur Modul 2y Minimale T des Moduls CONV_FLOAT R Max Temperatur Modul 2y Maximale T des Moduls CONV_FLOAT R Min Temperatur Modul 3x Minimale T des Moduls CONV_FLOAT R Max Tempera...

Page 72: ...ster kommandierter Sollwert CONV_FLOAT R Min kommandierter Sollwert Kleinster kommandierter Sollwert CONV_FLOAT R Max ULS Max U Low Side CONV_FLOAT R Min ULS Min U Low Side CONV_FLOAT R Max IHS Max I High Side CONV_FLOAT R Min IHS Min I High Side CONV_FLOAT R Max UHS Max U High Side CONV_FLOAT R Min UHS Min U High Side CONV_FLOAT R Max ILS Max I Low Side CONV_FLOAT R Min ILS Min I Low Side CONV_FL...

Page 73: ...LOAT R SwVer SW Version codiert als Hex Wert UINT_HEX R ProdDate Produktionsdatum codiert als Hex Wert UINT_HEX R 10 2 16 32 Revision Info NAME BEZEICHNUNG EINHEIT DEFAULTWERT DATENTYP R W FE_0 0 Original not 0 FE number was done R FE_1 0 Original not 0 FE number was done R FE_2 0 Original not 0 FE number was done R FE_3 0 Original not 0 FE number was done R FE_4 0 Original not 0 FE number was don...

Page 74: ...ent BDC546 B Operating instructions describes the process for setting the main controller set value and the limiting controllers limits Additionally the priorities of the individual controllers are provided As an alternative the BDC546 can also be operated via a user created CAN user interface on a computer In this case the CAN control commands have to be generated by the respective software As an...

Page 75: ... BRUSA Elektronik AG cannot assume any liability for damage to the BDC546 or other devices due to operation with the CVI software BRUSA Elektronik AG does not assume any liability for operation with the CVI software 10 4 1 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...

Page 76: ... 4 Voltage pre charging Connect pin 16 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 communication with the device Press the Run button in order to activate the power stage Communication with the device is ensured when the displays Tx and Rx are flashing To enable the main controller to fulfil its function it is ...

Page 77: ...n the manuals folder This manual describes the installation of the Flash Development Toolkit FDT required for programming as well as its system requirements Additionally the required procedures for downloading the new firmware to the BDC546 are described 11 2 Additional information for firmware download For programming the device has to be supplied via pin 2 AUX To set the device to programming mo...

Page 78: ... of all possible errors please refer to manual BDC546 Documentation of Errors and Warnings pdf Always try to clear all occurring errors with the help of this manual If errors repeatedly occur please refer to the BRUSA support under the manufacturer address indicated in chapter 4 5 Manufacturer contact information 13 Warranty The warranty corresponds to the regulations in our currently valid genera...

Page 79: ...ktroG in place since 24 March 2006 stipulates that electronic devices may no longer be disposed of along with ordinary household waste but must be separately collected and recorded by a specialist service Disposal via a specialist service significantly helps to avoid dangers to people and the environment For this reason it is recommended to contact a recognised specialist disposal service for disp...

Page 80: ...tation Further documents 16 E Earthing Grounding connection 44 Electrical interfaces 33 EMC concept 23 Error messages 77 F Filter concept 24 Firmware Important instructions 74 Update 76 G GND signal ground 34 Ground connection 35 Guarantee 12 H Highside cable 48 HV power connections 45 HV voltage pre charging 58 I Installation 51 Interlock 13 43 Function 27 Signal 28 L Limits of the product 19 Lis...

Page 81: ...tructions Danger levels 9 General 10 Handling and operation 11 Scope of delivery 17 Serial number 32 Start up 51 Symbols 8 T Technical properties 22 Topology 23 Type plate 32 V Validity of the manual 3 Voltage pre charging 58 W Warnings on the device 25 Warranty 77 ...

Page 82: ...Technical data and start up BDC546 82 16 Attachments 16 1 Cable fitting ...

Page 83: ...83 Technical data and start up BDC546 ...

Page 84: ...Technical data and start up BDC546 84 ...

Page 85: ...85 Technical data and start up BDC546 ...

Page 86: ...Technical data and start up BDC546 86 16 2 Cable lugs ...

Page 87: ...87 Technical data and start up BDC546 ...

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