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HV Breakout Module – Mounting and installation

Installation Manual

Version 01.20 // 2021

4.3.3 Connecting the HV power cables

Most of the figures in this section display the mounting of HV power cables to an

HV BM 1.2

using ring terminals. The removal of the cables is done in reverse order.

The connecting procedure for

HV BM 1.1

and

HV BM 1.2

devices is almost identical, except

for the detail. HV BM 1.1, hardware revision A, is equipped with a green inner cover which

has to be removed or reinserted in an additional step. As of hardware revision E, this green

inner cover is integrated in the orange housing cover, which means that the additional step

is no longer required.

As for the

HV BM 3.1

, the HV power cables are connected by means of Phoenix terminals.

→ Please see chapter 7.1 "Cable preparation" for further information on the assembly of

HV power cables.

WARNING!

The improper opening of the housing during operation entails the risk of

life-threatening electrical shocks.

Make sure that the HV power cables have been disconnected before

opening the cover.

WARNING!

When using

HV power cables

made of aluminum

and ring terminals made

of an electrochemically nobler metal (copper), the contact resistance

between the two components increases.

This can lead to a massive increase in temperature and in the worst case

to the development of fire.

If ring terminals made of copper are used for connecting HV Breakout

Modules, make sure that only HV power cables made of copper are used.

HV power cables made of aluminum

require a specific connection technique.

Please contact our technical support for further information.

CAUTION!

The measurement module heats up considerably if it is operated in a cor-

responding working environment (e.g. engine compartment). The shunt also

heats up considerably during operation under high load. The surface and the

inside of the measurement module can therefore become extremely hot.

Let the measurement module cool down before touching and removing

the cover.

Always monitor the shunt temperature and the internal temperature

of the measurement module in order to make sure at any time that

they do not overheat.

→ See chapter 5.2.5 "Temperature monitoring".

Содержание HV BM 1.1

Страница 1: ...Innovative Measurement and Data Technology HV Breakout Module Type 1 1 1 2 3 1 Installation Manual Version 01 20 ...

Страница 2: ...nt will protect the environment and people from pos sible negative consequences Become familiar with local regulations for separate collection of electrical and electronic equipment Follow local regulations and do not dispose of old equipment with house hold waste Contact Information CSM offers support for its products during the entire product life cycle Updates for the individual components e g ...

Страница 3: ...tors 9 4 Mounting and installation 10 4 1 Before mounting 10 4 3 Connecting HV power cables to HV BM devices 12 4 3 1 HV BM 1 x Connection diagrams 13 4 3 2 Preparing the PG gland 14 4 3 3 Connecting the HV power cables 15 4 3 3 1 Opening the housing 16 4 3 3 2 Intermediate step Sliding pressure screws and springs on the HV power cable 16 4 3 3 3 HV BM 1 x Connecting the HV power cables 17 4 3 3 4...

Страница 4: ...re monitoring 33 5 2 6 Complete the configuration 33 5 2 6 1 Transferring configuration data to the measurement module 33 5 2 6 2 Saving a configuration 34 5 2 6 3 Documenting a configuration 34 6 Maintenance and Cleaning 35 6 1 Type label 35 6 2 Shunt label 36 6 3 Maintenance services 36 6 4 Cleaning instructions 36 7 Appendix 37 7 1 Cable preparation 37 7 1 2 Cable assembly for cross sections 35...

Страница 5: ... improper use of the product and or non observance of the product documentation in particular the safety instructions See chapter 2 Safety Instructions 1 2 Warranty and exclusion of warranty The warranty covers the safety and functionality of the product within the warranty period Excluded from the warranty are claims based on possible consequential damages caused by malfunction or non function of...

Страница 6: ...e tightness of the housing WARNING When using HV power cables made of aluminum and ring terminals made of an electrochemically nobler metal copper the contact resistance between the two components increases This can lead to a massive increase in temperature and in the worst case to the development of fire If ring terminals made of copper are used for connecting HV Breakout Modules make sure that o...

Страница 7: ...st not exceed 120 C As soon as that value is exceeded the module will send the error value 0x8001 instead of a measured value until the temperature value drops below 115 C again Exceeding the limit impairs the operational safety of the HV measurement module and entails the risk of life threatening electrical shocks Switch off the power supply or interrupt the current flow through the shunt to prev...

Страница 8: ...solation might be defective a test should be carried out immediately before putting the device in operation again Make sure that a high voltage isolation test according to EN 61010 1 2010 is carried out at least every 12 months If there is reason to assume that the isolation barrier is defective a HV isolation test needs to be carried out immediately H NOTE i The threaded mounting hole is designed...

Страница 9: ...ules were developed for measuring volta ges and currents and may only be used for this purpose f These measurement modules may only be used for the above mentioned purpose and under the operating conditions stated in the technical specifications See HV BM datasheets for further information f The operational safety can only be ensured if the device is used in accordance with its intended use f Comp...

Страница 10: ...T interface and at a data rate of up to 10 kHz via the additional CAN interface at the same time This allows fast data acquisition via Ethernet with simultaneous data recording via a CAN data logger The HV BM is integrated into the HV power cables by feeding the cables through PG glands into the inside of the module and connecting them there CSM provides shunt modules with different measurement ra...

Страница 11: ...view 1 PG glands 2 CAN sockets chapter 4 4 2 1 CAN sockets 3 EtherCAT IN socket chapter 4 4 2 2 EtherCAT IN socket 4 EtherCAT OUT socket chapter 4 4 2 3 EtherCAT OUT socket 5 EtherCAT bus status LED indicator chapter 3 3 1 Status LED indicator for EtherCAT bus 6 CAN bus LED indicator chapter 3 3 2 CAN bus LED indicator 7 LED indicators for EtherCAT bus chapter 3 3 3 EtherCAT bus LED indicators 8 L...

Страница 12: ...ckering Device is in status SAFE OPERATIONAL green continuously lit Device is in status OPERATIONAL red flashing Configuration error red continuously lit Measurement module is switched on or the power supply connection has been established but there is no Ethernet communication green red flashing Flashing new firmware Tab 3 2 Status LED 3 3 2 CAN bus LED indicator The LED indicator Fig 3 1 between...

Страница 13: ...the start up process of the module Once the module has initialized itself and no errors were detected the LED indicators will fade out After self initialization the device checks the connected shunt module Meanwhile the measurement channel LED indicators of the current channels Current are lit red If the shunt module is correctly detected the measurement channel LED fades out again The measurement...

Страница 14: ... installation NOTE i Trouble free operation and electrical safety can only be ensured if the measurement module is correctly installed Ensure correct installation Operate the measurement module exclusively within the specified operating environment See HV BM datasheets for further information 4 2 Mounting HV Breakout Module CAUTION HV Breakout Modules can heat up very considerably when current flo...

Страница 15: ...ct the cables without kinking or clamping them f Avoid mounting positions in which the modules are subjected to continuous strong vibra tions and or shocks Parts material required f four M4 screws 3 f a suitable screwdriver or wrench Mounting the measurement module Fasten the measurement module at the mounting position i Please contact our support for the appropriate drill hole diagrams NOTE i Mak...

Страница 16: ...bles to the measurement module WARNING HV BM 1 x devices are supplied with suitable ring terminals Only use adequate ring terminals when mounting the HV power cables If you want to use ring terminals other than those included in the scope of delivery make sure that f sufficient space is provided in the housing so that there is ade quate clearance between the ring terminals and the housing as well ...

Страница 17: ...n the right The current is measured in the minus path in order to minimize disturbances of the current measurement The voltage is measured on the consumer side between plus and minus path Ⓐ HV BM Shunt Ⓥ Source Consumer I U Fig 4 2 HV BM 1 x connection diagram for voltage and current measurement Exclusive current measurement in the minus path Fig 4 3 shows the appropriate diagram if only current i...

Страница 18: ...ealing insert has a specific sealing area cable diameter with and without inlet This is marked accordingly in Fig 4 5 25 20 mm and 20 15 mm Remove the sealing insert and cut out the inlet if required The following PG gland types are available CSM type 9 14 11 20 15 25 CSM article number ART1520202 ART1520201 ART1520200 Pflitsch designation bg 220ms tri sc bg 225ms tri sc bg 232ms tri sc Sealing ra...

Страница 19: ... that the HV power cables have been disconnected before opening the cover WARNING When using HV power cables made of aluminum and ring terminals made of an electrochemically nobler metal copper the contact resistance between the two components increases This can lead to a massive increase in temperature and in the worst case to the development of fire If ring terminals made of copper are used for ...

Страница 20: ...le If not already done loosen and remove the pressure screws of the PG glands Fig 4 8 PG gland front view pressure screw and spring Loosen and remove the pressure screw and remove the spring from the PG gland Fig 4 9 Sliding pressure screws and springs onto the HV power cable Slide the pressure screw and the spring onto the HV power cable Feed the HV power cable s through the PG gland s into the h...

Страница 21: ... the four M3 threaded holes in the HV BM module housing Fig 4 10 Fig 4 10 HV BM 1 2 housing opened M3 threaded holes marked 4 3 3 3 HV BM 1 x Connecting the HV power cables The scope of delivery of an HV BM 1 x includes four nuts for mounting the HV power cables on the threaded bolts Prepare the nuts for mounting Fig 4 11 HV BM 1 2 housing opened If the nuts are already mounted Loosen the four nut...

Страница 22: ...ten them applying the torque specified in Tab 4 2 Module type Screw type Tightening torque HV BM 1 1 hardware rev A Brass screw 5 Nm M6 and 15 Nm M8 HV BM 1 2 Brass screw 15 Nm M8 HV BM 1 2 Steel screw 30 Nm M8 10 Tab 4 2 Tightening torques for the mounting of ring terminals 4 3 3 4 Exceptional case Mounting ring terminals for cable cross section 35 mm The following section describes the mounting ...

Страница 23: ... not be damaged Fig 4 16 HV BM 1 2 remove the spacers from the threaded bolts Remove the spacers from the threaded bolts Fig 4 17 HV BM 1 2 place the shunt module and the ring terminals on the threaded bolts Put the shunt module back on the threaded bolts Place the ring terminals upside down on the threaded bolts Make sure that the surface of the ring terminal rests plane on the mounting surface s...

Страница 24: ...sed WARNING The ring terminals must not touch each other or the housing during ope ration otherwise there is a risk of life threatening electric shocks and short circuits Also the contact resistance between the nuts and the ring terminators needs to be minimized Tighten the nuts applying the above mentioned torque so that the terminals are securely fixed during operation and the contact resistance...

Страница 25: ...note below that table HV BM 1 1 Reinsert the green inner cover 11 Fig 4 21 HV BM 1 2 housing closed and HV cable mounted Place the cover on the housing NOTE i To avoid water ingress condensation etc special care must be taken to ensure the tightness of the housing CSM provides a sealing cord as spare part This should be changed e g if it is brittle or fragile or has been pinched Make sure that cov...

Страница 26: ... work is only carried out by qualified and trained personnel Observe safety instructions See chapter 4 4 2 4 Ground connection WARNING The behavior of the CAN bus can be influenced by connecting a CAN bus measurement module to an existing CAN bus system Improper use of a CAN bus system may cause life threatening situations and material damage Always connect CAN bus measurement modules to a separat...

Страница 27: ... can be provided either via CAN or EtherCAT socket The supply lines of the two CAN sockets are connec ted to each other The same applies to the two EtherCAT sockets The CAN and EtherCAT interfaces are nevertheless separated from each other This means that the supply voltage fed to CAN is not provided at the EtherCAT sockets and vice versa Banana plugs which are not in use do not need to be isolate...

Страница 28: ...alified and trained personnel i The LEMO 0B socket is CSM s standard version To equip the measurement module with other sockets please contact the sales department 4 4 2 2 EtherCAT IN socket The measurement module is connected to the XCP Gateway alternatively to an EtherCAT master or to an upstream EtherCAT measurement module via the IN socket EtherCAT measurement modules receive their power suppl...

Страница 29: ...s Tab 4 5 Plug front view for OUT socket Pin assignment 4 4 2 4 Ground connection The HV BM has to be connected to ground in order to ensure user safety The cross section of a ground cable depends on the cross section of the HV power cable used WARNING To ensure user safety the measurement module must be connected to vehicle ground leakage monitor or protective ground PA PE If the ground connectio...

Страница 30: ... when choosing the ground cable cross section f M6 or M8 screw plus washer if required 15 f suitable tool wrench screwdriver socket wrench etc Connecting the ground cable To fix the ground cable to the housing insert the screw and tighten it carefully 15 The thread depth in the module housing is 6 mm for M6 and 8 mm for M8 The screw length must be chosen according to the thickness of the mounting ...

Страница 31: ...1 Measurement setup with an HV BM 1 1 connected to an XCP Gateway The installation consists of the following components f HV BM 1 1 measurement module f XCP Gateway pro protocol converter f Power supply See chapter 4 4 2 Connectors f Data acquisition PC with configuration software CSMconfig and DAQ software e g vMeasure CANape INCA etc f Interface cable with power supply connectors K420 xxxx f Con...

Страница 32: ...onfig menu via Help Help Topics NOTE i We recommend always using the latest version of CSMconfig Old versions may not support all module variants and functions The most current ver sion of CSMconfig can be found in the download area of the CSM website See https s csm de en cfg As of version 8 8 0 CSMconfig automatically checks upon each program start if a new version is available If a more up to d...

Страница 33: ...he measurement modules connected to the bus and to read out configurations stored in a device However an automatic channel configuration in its actual sense e g setting the measurement range is not performed A new configuration document is automatically created when executing the command Fig 5 2 Auto Configuration option Select Auto Configuration File Auto Configuration or Alt A The bus is checked...

Страница 34: ... voltage current f 1 or 3 channels U voltage f 1 or 3 channels I current This cannot be done directly on the CAN side Proceed as follows in order to measure just current on the CAN side as well Enable the option Per channel configuration in the CAN section see below Then enter the CAN ID 0 or 0x0000 for the U and P channels in the CAN ID field of the Channel Configuration Dialog The selection menu...

Страница 35: ...Message ID has to be assigned as well The corresponding field will be displayed instead of the Identifier base 5 2 4 Channel Configuration Dialog Fig 5 6 AutoConfig XCP Gateway window module connected via ECAT Double click on the selected channel entry with the mouse pointer The Channel configuration dialog opens Fig 5 7 Channel configuration dialog module connected via ECAT The most important par...

Страница 36: ...CSMconfig this error is displayed in the Device configuration dialog Ctrl R Operation mode row see Fig 5 8 Adjust the measurement range settings and write them to the module The red LEDs fade out and both sides of the module will be acti vated again Fig 5 8 Device Configuration Dialog display of divergent measurement ranges The channel dialog is identical on the CAN side The only exception If the ...

Страница 37: ...Configuration Dialog e g HVBM1EC_00042 If an XCP Gateway pro is applied the temperature signals are automatically displayed as additional measurement values in the DAQ software when using the ECAT side When accessing via the CAN side the temperature signals can be enabled as follows Open the Device configuration dialog as described above Enable the Info Message option The signals are displayed in ...

Страница 38: ... can be used to easily apply or restore already completed configurations to a module Fig 5 11 Save option Select File Save Ctrl S NOTE i The A2L and DBC file used in the measurement software must match the configuration stored in the module Otherwise incorrect measurement values or no values at all are received 5 2 6 3 Documenting a configuration In addition to saving the configuration files a fin...

Страница 39: ...CAN Device details f L1B 8p EtherCAT sockets LEMO 1B 8 pole f ECAT bus system f L0B 5p CAN sockets LEMO 0B 5 pole f CAN bus system ART1510110 Part number of the measurement module Power 7 30 V DC typ 2 2 W Power supply range typical power consumption Temp 40 C 120 C Operating temperature range Meas 100 V 1 kV Measurement range S N 1234 HEBM1 Measurement module serial number Rating IP67 Protection ...

Страница 40: ...test and a test protocol is issued for every HV Breakout Module This is documented by corresponding stickers attached to the top or the rear side of the device housing To ensure reliability and functionality a measurement module should be checked at least every 12 months CSM offers maintenance packages and a repair service for this purpose f High voltage isolation test functional testing included ...

Страница 41: ...er contact between the cable shield and the spring in the PG gland the cable must be carefully assembled Fig 7 1 PG gland longitudinal section NOTE Please note that the installation height of a PG gland changes if a reduction is used If a reduction for an M25 or M20 thread is used with an M32 PG gland the total height of the gland increases by approx 4 mm Fig 7 2 If a reduction is used when mounti...

Страница 42: ...e contact area for spring f without reduction M32 d 70 mm f with reduction M25 d 74 mm 7 1 2 Cable assembly for cross sections 35 mm to 95 mm NOTE i Observe the instructions for connecting HV power cables with a cable cross section of 35 mm to the shunt See chapter 4 3 3 4 Exceptional case Mounting ring terminals for cable cross section 35 mm The following section schematically illustrates and des...

Страница 43: ...m HV BM 1 2 ART1520200 PG cable gland set 15 25 HV BM Tab 7 1 Components for single wire HV power cables Fig 7 4 Step 1 Removing the outer sheath Remove the outer sheath to the required length 16 Make sure that the shielding mesh lying underneath will not be damaged Fig 7 5 Step 2 Removing the protective foil Remove the protective foil from the shielding mesh Fig 7 6 Step 3 Applying a mark on the ...

Страница 44: ... shrink sleeve over the cable Attach the ring terminal to the dismantled wire Use the crimping pliers to crimp the ring terminal at two points and then solder it Fig 7 11 Step 8 Placing and fixing the shrink sleeve Slide the shrink sleeve over the crimped end of the ring terminal so that about 15 mm of the shrink sleeve will cover the ring terminal Fix the shrink sleeve by applying heat For inform...

Страница 45: ...et 11 20 HV BM Fig 7 12 Step 1 Removing the outer sheath Remove the outer sheath over a length of 75 mm Make sure that the shielding mesh lying underneath will not be damaged Fig 7 13 Step 2 Removing the protective foil Remove the protective foil from the shielding mesh Fig 7 14 Step 3 Applying a mark on the shielding Mark a 20 mm wide segment on the shielding mesh Remove the remaining shielding m...

Страница 46: ...xing the ring terminal Slide 12 mm long pieces of shrink sleeve onto the red and the black wire Attach M8 ring terminals to the dismantled wires 18 Use the crimping pliers to crimp the ring terminals and then solder them Slide the shrink sleeves over the ring terminals so that they cover the crimped terminal ends and the red or black wire by 6 mm each Fix the shrink sleeve by applying heat For inf...

Страница 47: ...er side 19 Fig 4 15 HV BM 1 2 remove the shunt from the threaded bolts 19 Fig 4 16 HV BM 1 2 remove the spacers from the threaded bolts 19 Fig 4 17 HV BM 1 2 place the shunt and the ring terminals on the threaded bolts 19 Fig 4 18 HV BM 1 2 fasten the ring terminal with the nuts 19 Fig 4 19 HV BM 1 2 mounting the ring terminals on the copper bar side 20 Fig 4 20 HV BM 3 1 housing opened 20 Fig 4 2...

Страница 48: ...tective foil 41 Fig 7 14 Step 3 Applying a mark on the shielding 41 Fig 7 15 Step 4 Marking the inner sheath 41 Fig 7 16 Step 5 Attaching and fixing the shrink sleeve 42 Fig 7 17 Step 6 Dismantling the inner sheath 42 Fig 7 18 Step 7 Dismantling the red and black wire 42 Fig 7 19 Step 8 Attaching and fixing the ring terminal 42 7 3 List of tables Tab 2 1 Maximum internal temperature 3 Tab 3 1 HV B...

Страница 49: ...ners Specifications are subject to change without notice CANopen and CiA are registered community trade marks of CAN in Automation e V EtherCAT is registered trademark and patented technology licensed by Beckhoff Automation GmbH Germany Our company is certified ...

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