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Technical data

and startup

Safety and warning instructions

In this chapter you will find safety instructions which apply to this device. These refer to 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, some specific technical abbreviations are used. You will find an overview as well as their

meaning in the following table:

PROHIBITION SYMBOLS

SYMBOL

MEANING

SYMBOL

MEANING

General prohibition

Warning high voltage
Touching forbidden

Switching on forbidden

WARNING SYMBOLS

SYMBOL

MEANING

SYMBOL

MEANING

General hazard warning

Electromagnetic field warning

Potentially explosive warning

Battery hazard warning

Hot surface warning

High electrical voltage warning

High pressure warning / fluid spurting out

Fire hazard warning

MANDATORY SIGNS

SYMBOL

MEANING

SYMBOL

MEANING

Disconnect device from voltage

Disconnect device from mains

INFORMATION SIGNS

SYMBOL

MEANING

SYMBOL

MEANING

Important information on avoiding possible
damage to property

Important information

Summary of Contents for DMC514

Page 1: ...ktronik AG Neudorf 14 CH 9466 Sennwald 41 81 758 19 00 info brusa biz www brusa biz TECHNICAL DATA AND STARTUP Translation of the original German operating instructions DMC514 ISU DMC524 ISU DMC534 IS...

Page 2: ...in the relevant manuals through the replacement of the relevant pages and or a revision of the electronic data storage device Writer Author Holger Schmidt REVISIONS REVISION DATE NAME CHANGE rev11 04...

Page 3: ...3 Technical data and startup VALIDITY This manual is valid only for the following devices TYPE DMC514 ISU Ser No 1000 DMC524 ISU Ser No 1000 DMC534 ISU Ser No 1000 DMC544 Ser No 1000...

Page 4: ...s 13 3 4 1 Interlock 13 3 4 2 Short circuit protection 13 3 4 3 Automatic discharge of DC link voltage 14 3 4 4 Monitoring of HV voltage 14 3 4 5 Overload protection derating 14 3 4 6 Inverter safety...

Page 5: ...18 04 at 400V first quadrant 36 7 2 DMC524 measured with HSM1 6 17 12 at 400V first quadrant 36 7 3 DMC534 measured with HSM1 10 18 13 at 400V first quadrant 37 7 4 DMC544 measured with HSM1 10 18 13...

Page 6: ...s for PARAM tool software 54 9 2 Ventilate and check cooling system 54 9 3 Load motor parameter table onto inverter 54 9 4 Build HV supply 55 10 Operation of the inverter through CVI 59 10 1 Build con...

Page 7: ...oughout this manual some specific technical abbreviations are used You will find an overview as well as their meaning in the following table ABBR MEANING ABBR MEANING AUX Wiring System Plus Terminal 3...

Page 8: ...heir meaning in the following table PROHIBITION SYMBOLS SYMBOL MEANING SYMBOL MEANING General prohibition Warning high voltage Touching forbidden Switching on forbidden WARNING SYMBOLS SYMBOL MEANING...

Page 9: ...ns against serious irreversible risks of injury Avoid these dangers by observing these instructions CAUTION This instruction warns against serious irreversible risks of injury Avoid these dangers by o...

Page 10: ...3 1 Safety instructions for cooling water systems WARNING Spurting cooling fluid Skin burning hazard Check the tightness of the cooling water system particularly the pipes screw joints and pressure ta...

Page 11: ...direct contact with water rain spurting water if possible Under no circumstances should you put a low resistance connection between the HV contacts the housing contacts and the LV contacts This will l...

Page 12: ...V supply is switched off a turning motor can still produce voltage INSTRUCTION Under no circumstances should the device be opened without authorisation The opening of the device housing sealed up lead...

Page 13: ...the operator from injuries from the HV connections The interlock switch 1 is automatically activated as soon as the service cap is opened 1 Interlock switch 3 4 2 Short circuit protection If a short...

Page 14: ...esponding error is detected over CAN The error must be confirmed before further operation 3 4 5 Overload protection derating INSTRUCTION Continuous operation at the temperature limit will inevitably l...

Page 15: ...rlock switch 1 is closed if the corresponding interlock condition of each device is met closed service cover plugged HV connections The interlock evaluation of the PDU switches the 12V supply voltage...

Page 16: ...staff is defined as electricians who dispose of professional training knowledge and experience in the field of electronics electric mobility as well as knowledge of relevant requirements and dangers...

Page 17: ...4 2 Scope of the entire documentation INFORMATION To start up the inverter successfully you will need the entire documentation as well as different software and firmware With the provision of the cust...

Page 18: ...k AG MEANING PIECES ILLUSTRATION 1 DMC5x4 inverter 1 2 M8 x 10 screws for the cable lugs 6 3 M8 serrated lock washer for M8 x 10 screws 6 4 Cable lugs compression cable lugs for HV and motor cables M8...

Page 19: ...MPSEAL 770854 1 for wire diameter 0 5 mm 2 We recommend the use of the following crimping tool Tyco 58440 1 25 8 Normaquick cooling water connection pieces 0 Norma PS3 2 9 Software package For a listi...

Page 20: ...water connection MAAA366 1 Rubber seal for M18x1 5 D16 cooling water connection MAAA365 2 Protective cap for M18x1 5 D16 cooling water connection MHAA682 3 Cable glands for 13 mm 18 mm cable diameter...

Page 21: ...of Inverter DMC5x4 EG guidelines national regulations and harmonised standards EN which were valid at the time of production 4 6 Contact information of the manufacturer BRUSA Elektronik AG Neudorf 14...

Page 22: ...ASM Permanently Excited Synchronous Motor PSM Hybrid synchronous motor HSM Internal Permanently Excited Synchronous Motor IPM The BRUSA DMC5x4 inverter has generally been designed for integration into...

Page 23: ...the defined limits can also lead to life threatening situations The following limit values are set for the DMC5x4 inverter by the manufacturer and must be adhered to in all cases Max HV input voltage...

Page 24: ...from Bussmann THREE PHASE OUTPUT U V W R S T DMC514 DMC524 DMC534 DMC544 UNIT RMS current duration IACcont 112 225 337 450 A Periodic cycle with max current 30 sec 100 90 sec 50 150 300 450 600 A Cont...

Page 25: ...nt 25 C with a water to glycol mixture ratio of 50 50 70 120 150 180 mbar Maximum pressure of the coolant 1 1 1 1 bar Maximum particle size in the coolant 0 2 0 2 0 2 0 2 mm Ambient temperature range...

Page 26: ...device and contains the following information 1 Classification 2 Operating voltage section 3 Maximum input current 4 Maximum coolant temperature at inlet 5 Serial number 6 IP protection category 7 Max...

Page 27: ...different three phase motors The power output stage of the DMC5x4 is based on the most capable resonant SoftSwing topology which was developed and patented by BRUSA Elektronik AG SoftSwing topology a...

Page 28: ...Technical data and startup 28 6 5 Covers INFORMATION Only the covers mentioned in this chapter may be removed by the customer Torque for M4 x 08 screws 2 5 Nm 1 Service lid 2 M4 x 08 screws 8 pieces...

Page 29: ...the installation positioning that the connection side is tilted downwards This prevents water accumulation on the cable sealing which could result in water leaking into the housing 6 6 2 Fixing as in...

Page 30: ...Technical data and startup 30 6 7 Example of use...

Page 31: ...RQact Requested and current torque Iz min Iz max Min and max high voltage current DC SPDrq SPDact Requested and current speed Uz act Current high voltage Uz min Uz max Min and max high voltage DC IAC...

Page 32: ...Technical data and startup 32 6 9 Block diagram output stage power print...

Page 33: ...place automatically after the start up process after activation of Start mode Power up For detailed information see also the descriptions of Pin 2 and Pin 3 see chapter 8 3 2 Pin 2 AUX Wiring system t...

Page 34: ...o high too low DC voltage DC and AC Current Power INFORMATION If no limitation is active the motor will attempt to reach the entered value immediately If there is no load on the drive side the motor a...

Page 35: ...You will find further information in the manual DMC5_ControlConcept pdf You will find a list of possible error and warning messages along with their description in the manual errors_and_warnings pdf...

Page 36: ...first quadrant DMC524 Torque Nm Speed rpm 10 20 30 40 50 60 70 80 100 120 140 160 180 200 220 1000 74 32 82 62 86 02 87 79 88 80 89 47 89 93 90 25 90 65 90 81 90 83 90 80 90 62 90 40 90 14 2000 84 56...

Page 37: ...97 19 The efficiency map is only valid for the inverter 7 4 DMC544 measured with HSM1 10 18 13 W7 at 400V first quadrant DMC544 Torque Nm Speed rpm 0 20 40 60 80 100 120 140 160 180 200 220 240 260 2...

Page 38: ...ogt AG Torque for cable lug M8 x 10 15 Nm 1 High voltage HV 2 High voltage HV 3 Motor phase U 4 Motor phase V 5 Motor phase W 6 Control connector Chapter 8 3 Pin assignment of control connector 7 Moto...

Page 39: ...absolute position bit 3 2 POS4 6 bit absolute position bit 4 3 POS5 6 bit absolute position bit 6 4 GND NTC Ground NTC PTC 5 NTC Motor temperature sensor 6 PTC Motor overheat switch off 7 VCC GEB Moto...

Page 40: ...igh 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 Reserve 17 Ext...

Page 41: ...V inputs this 12 V inlet is also necessary for the functioning of the inverter The inverter is generally ready for operation when the following requirements are met Voltage is applied at the HV inlet...

Page 42: ...e is applied this effects the activation of Ready mode The internal device logic is only fed if pin 3 high This is also the case if HV and HV are already applied in high voltage Pin 3 has the function...

Page 43: ...rnal wiring 47pF Pin 12 RXD 33V 47pF Pin 11 TXD 33V RS232 Transceiver 200 200 470pF 470pF The RS232 port enables a direct serial connection between the inverter and a PC You will find the configuratio...

Page 44: ...e programming of a new firmware Pin PRO high Pin 3 EN must also be high for this In normal operation this pin may not be wired or it must be directly connected with terminal 31 An open circuit can lea...

Page 45: ...ot used both pins must be connected with terminal 30 Internal wiring 470pF Pin 17 EXT AW1 Pin 18 EXT AW2 20uF Schmitt Trigger 100k 5V Supply Enable 160k 1 0V 3 3V 48V 15k To enable the output stage pi...

Page 46: ...can it be disabled or bypassed INFORMATION This function must be implemented by the customer by connecting and assessing both pins pin 19 IL1 and Pin 20 IL2 The interlock switch is automatically activ...

Page 47: ...artup V A A A A IAux IEn IExt AW1 DMC5x4 HV Supply IExt AW2 8 4 LV current consumption In the following tables you can see the LV current consumption of the control connector The currents were measure...

Page 48: ...A 400V 0 10 20 30 40 50 60 6 8 10 12 14 16 18 20 22 24 26 28 30 32 Strom uA Spannung V I_Aux uA 0 10 20 30 40 50 60 6 8 10 12 14 16 18 20 22 24 26 28 30 32 Strom uA Spannung V I_Aux uA 0 10 20 30 40...

Page 49: ...12 14 16 18 20 22 24 26 28 30 32 Current mA Voltage V I_Aux mA I_En mA I_Ext AW1 mA I_Ext AW2 mA Total Current mA 0 10 20 30 40 50 60 70 6 8 10 12 14 16 18 20 22 24 26 28 30 32 Current mA Voltage V I_...

Page 50: ...Ensure that the ground connection is connected correctly INFORMATION The grounding screw 1 must be connected with the ground of the vehicle and or testing bay We generally recommend a direct connectio...

Page 51: ...g water hose gets attached to the Normaquick terminals 1 and 2 Optionaly you can order normal cooling water connections for hose clamps see chapter 4 4 Optional delivery contents The Normaquick connec...

Page 52: ...the liquid pins get clogged The water pump must be active even if the motor isn t running when the inverter PWM is active The reason is that the inverter also could clock when the vehicle is standing...

Page 53: ...Build the interlock circuit and check the functioning see chapt 8 3 8 Pin 19 IL1 Pin 20 IL2 Interlock 1 2 6 If it is not already done build all the connections at the inverter see chapter 8 Connection...

Page 54: ...the cooling circuit on for around 30 s To avoid the overheating of the device flow must be ensured as soon as the inverter is switched on via CAN enable 3 Switch off the cooling circuit 4 Check the co...

Page 55: ...a pre loading of the high voltage must take place The device specific X capacity values can be found in the technical data see chapt 6 1 Technical data 1 Close the pre charging contactor 1 2 Close th...

Page 56: ...chapter 4 3 Delivered mechanical components To assemble the cable lug using the appropriate crimping tool is absolutely necessary INSTRUCTION You must absolutely make sure that the individual strands...

Page 57: ...able 1 through the terminal insert 3 4 Place the terminal insert 1 with the front edge flush with the cable insulation 2 5 Put the shielding braid 1 over the terminal insert 2 During this the shieldin...

Page 58: ...the secure positioning of the cable lug manually 9 Assemble a shrinkage tube 1 on the cable lug 2 The assembly of a shrinkage tube 1 is absolutely necessary because otherwise contacting can result in...

Page 59: ...or DC current limitation value 11 Motor DC current limitation value 12 Generator DC voltage limitation value 13 Motor DC voltage limitation value 14 Display of different actual values 15 Command enabl...

Page 60: ...ired torque 19 INFORMATION If no limitation is active the motor will attempt to reach the entered value immediately If there is no load on the drive side the motor accelerates until it reached the max...

Page 61: ...e incomplete Analyse and remove errors in the manual DMC5_ErrorsAndWarnings pdf Limitation active The limitation value is set too high or too low Check limitation value Check default values see manual...

Page 62: ...errors reappear please refer to BRUSA support at the manufacturing address given in chapter 4 6 12 Flooding in the device DANGER If there is water in your device take the device out of operation imme...

Page 63: ...c device regulation ElektroG since the 24th of March 2006 electronic devices may no longer be disposed of along with ordinary household waste rather they must be separately collected and recorded by a...

Page 64: ...nical data and startup 64 14 Warranty and guarantee The warranty corresponds to the regulations in our currently valid general terms and conditions see under www brusa biz en support terms conditions...

Page 65: ...connection 41 I Interlock Function 13 Installation height 29 Pin assignment 46 Principle of operation 15 Inverter Connection to CVI 60 Programming 40 44 Reset 44 Start up requirements 41 ISU 45 M Mot...

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