Brusa BSC623-12V-B Series Technical Information And Start-Up Download Page 9

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Technical information

and start-up

BSC624-12V-B

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.

Summary of Contents for BSC623-12V-B Series

Page 1: ...lektronik AG Neudorf 14 CH 9466 Sennwald 41 81 758 19 00 info brusa biz www brusa biz DC DC converter BSC624 12V B TECHNICAL INFORMATION AND START UP Translation of the original German operating instr...

Page 2: ...ight 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...

Page 3: ...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 deco...

Page 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...

Page 5: ...uctural 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...

Page 6: ...he 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 Operati...

Page 7: ...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 abbreviation...

Page 8: ...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 warnin...

Page 9: ...ING 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...

Page 10: ...fety 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 ta...

Page 11: ...ossible 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 w...

Page 12: ...ts 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 t...

Page 13: ...ding 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...

Page 14: ...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 si...

Page 15: ...rmer 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...

Page 16: ...L 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...

Page 17: ...alist 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 requirement...

Page 18: ...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...

Page 19: ...housing HAN Modular Compact Carrier housing HAN Modular Compact Socket insert HAN CC 4 mm 2 crimp contact socket 4 pieces Cable gland HSK M EMV M25 x 1 5 for cable diameters 9 16 mm 6 cm x 4 mm 2 cabl...

Page 20: ...eration 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 Elektr...

Page 21: ...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 st...

Page 22: ...ay 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 90 6 3...

Page 23: ...ent 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 m...

Page 24: ...hanical 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...

Page 25: ...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 transform...

Page 26: ...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 con...

Page 27: ...nction 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 acti...

Page 28: ...es 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 c...

Page 29: ...e 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 wi...

Page 30: ...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 inte...

Page 31: ...led 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 o...

Page 32: ...Technical information and start up BSC624 12V B 32 6 6 Vehicle installation basic principle...

Page 33: ...k 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 o...

Page 34: ...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...

Page 35: ...d 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 t...

Page 36: ...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 c...

Page 37: ...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...

Page 38: ...rol 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 grou...

Page 39: ...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...

Page 40: ...ring 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 gro...

Page 41: ...xclusive supply from the wiring system control connector CAN communication sending and receiving Communication via RS232 monitoring Microprocessor programming firmware Voltage current and temperature...

Page 42: ...3 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...

Page 43: ...s 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 uni...

Page 44: ...f the 120 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...

Page 45: ...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 voltag...

Page 46: ...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...

Page 47: ...r 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 respec...

Page 48: ...vel in the beginning and in the end of the interlock loop R4 may be optionally equipped with a 0 resistor in order to avoid any undesired voltage drop Please note that in such case the external interl...

Page 49: ...ividually 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 p...

Page 50: ...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...

Page 51: ...he 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...

Page 52: ...ay 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 cri...

Page 53: ...a 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 proces...

Page 54: ...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...

Page 55: ...ling system may lead to an overheating of the device 1 Connection of cooling water input external 16 mm 2 Connection of cooling water output external 16 mm The cooling water hoses are to be implemente...

Page 56: ...ain 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 connectio...

Page 57: ...tions 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...

Page 58: ...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 th...

Page 59: ...ch 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 connec...

Page 60: ...ough 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...

Page 61: ...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 bot...

Page 62: ...ower 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 assign...

Page 63: ...l information and start up BSC624 12V B 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 c...

Page 64: ...ficient 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 d...

Page 65: ...vation 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 p...

Page 66: ...m 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 c...

Page 67: ...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 isol...

Page 68: ...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 w...

Page 69: ...erating 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 imp...

Page 70: ...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 read...

Page 71: ...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...

Page 72: ...st 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 se...

Page 73: ...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 ot...

Page 74: ...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...

Page 75: ...owing 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...

Page 76: ...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...

Page 77: ...kit 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...

Page 78: ...LUSTRATION 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...

Page 79: ...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 P...

Page 80: ...t 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...

Page 81: ...P 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 e...

Page 82: ...ectric 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 b...

Page 83: ...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...

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