BDC546-B
Operating instructions
Version 1.1
Version
Date
Name
Comment
1.0
18.12.2012
M.Haller
Document released
1.1
05.01.2015
J. Pitschi
- Update of some descriptions of CAN-signals.
- Update of value for the current regulators based
on tolerances of the internal current measurement.
Document version
Inhalt
Version 1.1 ................................................................................................................................................ 1
Document version ............................................................................................................................................... 2
Introduction ......................................................................................................................................................... 4
List of abbreviations ........................................................................................................................................ 4
Valid regulator-values ..................................................................................................................................... 4
UHS-main-regulator ............................................................................................................................................ 5
Interpretation of the internal current measurement ............................................................................................ 5
Boostmode ..................................................................................................................................................... 5
Buckmode ....................................................................................................................................................... 5
Limit regulators ............................................................................................................................................... 5
Regulator priorities ......................................................................................................................................... 6
Recommended current settings for BDC operation ........................................................................................... 6
Recommended BDC-settings for a test assembly ............................................................................................. 7
Recommended BDC-settings for operation “fuel cell to battery”: ................................................................... 7
Recommended BDC-settings for operation “battery to fuel cell”: ................................................................... 8
Examples of critical operating states .................................................................................................................. 9
Condition ULS > ULS_MAX ....................................................................................................................... 9
Condition ULS < ULS_MIN ........................................................................................................................ 9
Condition UHS_COM < UHS_MIN .......................................................................................................... 10
Condition UHS_COM > UHS_MAX ......................................................................................................... 10
Other important CAN-signals............................................................................................................................ 11
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Introduction
This document has to be read before startup the device first time. Otherwise damage on the device and
external connected devices can occur.
The signal names in squared brackets ([ ]) are the references to the CAN-matrix.
List of abbreviations
U: Voltage
I: Current
HS: High-Side
LS: Low-Side
LIM: Limit
MAX: Maximum
MIN: Minimum
REG: Regulator
COM: Commanded
Valid regulator-values
ULS_MIN: 0V (CAN-error is set, if the value is out of the range.)
ULS_MAX: 600V (CAN-error is set, if the value is out of the range.)
UHS_MIN: 0V (CAN-error is set, if the value is out of the range.)
UHS_MAX: 750V (CAN-error is set, if the value is out of the range.)
ILS_MIN: 0 to -400A (CAN-error is set, if the value is out of the range.)
ILS_MAX: 0 to 400A (CAN-error is set, if the value is out of the range.)
IHS_MIN: 0 to -400A (CAN-error is set, if the value is out of the range.)
IHS_MAX: 0 to 400A (CAN-error is set, if the value is out of the range.)
UHS_COM: 0 to 1024V (0 to -1024V) (The device doesn’t check this value. If the UHS_COM
value is higher than UHS_MAX or lower than UHS_MIN, the device
is going to regulate on the limiting-values.)
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UHS-main-regulator
The main-regulator regulates the high-side-voltage. For a functional operation, the following CAN-messages
have to be set correctly:
[SG_Sollwert]: Value of the commanded high-side voltage.
(Sollwert engl.: desired value)
[SG_HR_Mode_Check]: 0x1
Interpretation of the internal current measurement
Boostmode
Direction of current from LS to HS.
Current measurements have a positive value.
[BDC_ILS_act] & [BDC_IHS_act] > 0
Responsible current-limit-regulators:
IHS_MAX [SG_IHS_max] > 0
ILS_MAX [SG_ILS_max] > 0
Buckmode
Direction of current from HS to LS.
Current measurements have a negative value.
[BDC_ILS_act] & [BDC_IHS_act] < 0
Responsible current-limit-regulators:
IHS_MIN [SG_IHS_min] < 0
ILS_MIN [SG_ILS_min] < 0
With the current-limit-regulators, the user can avoid an unexpected change of the mode. (Boostmode to
buckmode or buckmode to boostmode.)
Limit regulators
On reaching one or more set limit-values, the device will regulate on this values under compliance of the
regulator-priority. The device won’t switch off.
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U
HS_Reg
U
LS_Lim
-Min
U
HS_Lim.
-Min
I
HS_Lim
-Min
I
LS_Lim
U
HS_com
I
LS_com
High
Low
[SG_Sollwert]
[SG_ULS_max]
[SG_ULS_min]
[SG_UHS_max]
[SG_UHS_min]
[SG_IHS_max]
[SG_IHS_min]
[SG_ILS_max]
[SG_ILS_min]
Regulator priorities
The main-regulator is the high-side voltage regulator (U
The high-side-voltage-limit-regulators (U
(U
). This can result in an operation mode where ULS is getting higher than the set ULS_MAX (or lower
LS_LIM
than ULS_MIN).
-Max
) have a higher priority than the low-voltage-limit-regulators
HS_LIM
-Max
). This regulator has the lowest priority.
HS_REG
-Max
-Max
-Min
UHS_COM: The commanded voltage of the high-side-regulator.
UHS_REG: HS -voltage-regulator main regulator
ULS_LIM: LS-over- and undervoltage-regulators. If ULS reaches this value, the device tries to
regulate to this value and to keep the operation.
UHS_LIM: HS-over- and undervoltage-regulators. If ULS reaches this value, the device tries to
regulate to this value and to keep the operation.
IHS_LIM: HS-current-regulator for buck- and boostmode where IHS_MAX is set for boostmode and
IHS_MIN is set for buckmode.
ILS_LIM: LS-current-regulator for buck- and boostmode where ILS_MAX is set for boostmode and
ILS_MIN is set for buckmode.
ILS_COM: The LS-current generated by the regulators. (This value is not set by CAN. It is an
internal generated value.)
Recommended current settings for BDC operation
Due to measurement tolerances a parametrization of the current regulators to zero in order to avoid a
change of operating direction may cause problems (especially at no load conditions). Therefore BRUSA
recommends to set the current regulators to MIN_CURRENT_LIM, whereby |MIN_CURRENT_LIM| ≥ 2A.
Recommended current setting
Boostmode: IHS_MIN = ILS_MIN = -2 (to avoid Buckmode)
Buckmode: IHS_MAX = ILS_MAX = 2 (to avoid Boostmode)
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BDC546
ILS_MIN active
BDC546
Fuel Cell
Battery
ULS1
Recommended BDC-settings for a test assembly
BDC_1
UHS_COM active
Low-Side (LS)
ULS_MAX [SG_ULS_max]
ILS_MAX [SG_ILS_max]
ILS_MIN [SG_ILS_min]
ULS_MIN
High-Side (HS)
UHS_MAX [SG_UHS_max]
IHS_MAX [SG_IHS_max]
IHS_MIN [SG_IHS_min]
UHS_MIN [SG_UHS_min]
Recommended BDC-settings for operation “fuel cell to battery”:
BDC_1:
UHS_COM_1 > 170V
ILS_MAX_1 > |ILS_MIN_2|
ILS_MIN_1 = -2 (prevention of buckmode)
IHS_MAX_1 > |IHS_MIN_2| (Recommendation: IHS_MAX_1 > ILS_MAX_1)
IHS_MIN_1 = -2 (prevention of buckmode)
UHS
BDC_2
High-Side (HS)
UHS_MAX [SG_UHS_max]
IHS_MAX
UHS_COM [SG_Sollwert] UHS_COM [SG_Sollwert]
IHS_MIN [SG_IHS_min]
UHS_MIN [SG_UHS_min]
Low-Side (LS)
ULS_MAX [SG_ULS_max]
ILS_MAX [SG_ILS_max]
ILS_MIN [SG_ILS_min]
ULS_MIN [SG_ULS_min]
ULS2
BDC_2:
UHS_COM_2 < UHS_COM_1
|ILS_MIN_2| < ILS_MAX1
ILS_MAX_2 = 2 (prevention of boostmode)
|IHS_MIN_2| < IHS_MAX_1 (Recommendation: |IHS_MIN_2| > |ILS_MIN_2|)
IHS_MAX_2 = 2 (prevention of boostmode)
HS- and LS-voltage limit regulators have to be set according to the fuel cell and battery specifications.
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Recommended BDC-settings for operation “battery to fuel cell”:
BDC_2:
UHS_COM_2 > 170V
ILS_MAX_2 > |ILS_MIN_1|
ILS_MIN_2 = -2 (prevention of boostmode)
IHS_MAX_2 > |IHS_MIN_1| (Recommendation: IHS_MAX_2 > ILS_MAX_2)
IHS_MIN_2 = -2 (prevention of boostmode)
BDC_1:
UHS_COM_1 < UHS_COM_2
|ILS_MIN_1| < ILS_MAX_2
ILS_MAX_1 = 2 (prevention of buckmode)
|IHS_MIN_1| < IHS_MAX_2 (Recommendation: |IHS_MIN_1| > |ILS_MIN_1|)
IHS_MAX_1 = 2 (prevention of buckmode)
HS- and LS-voltage limit regulators have to be set according to the fuel cell and battery specifications.
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BDC546
UHS_COM active
Battery 1
Battery 2
ULS
UHS
Examples of critical operating states
The following examples shows critical operating states who can occur due to regulator priorities. The
examples refer to schematic diagram below.
Low-Side (LS) High-Side (HS)
ULS_MAX [SG_ULS_max]
ILS_MAX [SG_ILS_max]
UHS_MAX [SG_UHS_max]
IHS_MAX [SG_IHS_max]
UHS_COM [SG_Sollwert]
ILS_MIN [SG_ILS_min]
Operating mode of the devices:
BDC: Boostmode, UHS_COM active [SG_Sollwert]
IHS_MIN [SG_IHS_min]
UHS_MIN [SG_UHS_min] ULS_MIN [SG_ULS_min]
Condition ULS > ULS_MAX
BDC regulates ULS_MAX by converting energy from LS to HS.
ILS_MAX or IHS_MAX is active.
UHS rises till UHS = UHS_MAX.
UHS_MAX is active, because of the higher priority of the HS-limit-regulators.
BDC changes the operating mode to buckmode by converting energy from HS to LS.
ILS_MIN or IHS_MIN is active.
UHS falls till UHS < UHS_MAX or ULS overvoltage detection (ULS > 600V) is active.
Inadvertent operating-mode-changes from boost- to buckmode can be avoided by setting ILS_MIN
and/or IHS_MIN to zero. (See chapter “Recommended BDC operating settings”)
Condition ULS < ULS_MIN
BDC regulates ULS_MIN by converting energy from HS to LS.
BDC changes the operating mode to buckmode.
ILS_MIN or IHS_MIN is active.
UHS falls.
ULS rises till ULS > ULS_MIN or UHS < UHS_MIN.
Inadvertent operating-mode-changes from boost- to buckmode can be avoided by setting ILS_MIN
and/or IHS_MIN to zero. (See chapter “Recommended BDC operating settings”)
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Condition UHS_COM < UHS_MIN
Device in boostmode: BDC regulates UHS_MIN.
Device in buckmode: BDC regulates UHS_COM till UHS < UHS_MIN. Then the BDC regulates on
UHS_MIN as well.
Condition UHS_COM > UHS_MAX
Device in buckmode: BDC regulates UHS_MAX.
Device in boostmode: BDC regulates UHS_COM till UHS > UHS_MAX. Then the BDC regulates on
UHS_MAX as well.
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Other important CAN-signals
[SG_DigOut_Activate]:
Activ high sets AMP_PIN17 to LV_BUS+ (+12V)
I
= 4A (120ms)
peak
I
= 200mA
cont.
[SG_Activate]:
Activ high, device starts to work (if there is no error).
[BDC_Ready]:
Information if the device is ready or not.
[BDC_Running]:
Information if the device is running or not.
[BDC_Warning] & [BDC_Error]:
Information if the device has been set a warning or an error or not.
[BDC_UHS_min_Lim]:
Information if the UHS_MIN-regulator is active.
[BDC_UHS_max_LIM]:
Information if the UHS_MAX-regulator is active
[BDC_IHS_min_Lim]:
Information if the IHS_MIN-regulator is active.
[BDC_IHS_max_Lim]:
Information if the IHS_MAX-regulator is active.
[BDC_ULS_min_Lim]:
Information if the ULS_MIN-regulator is active.
[BDC_ULS_max_Lim]:
Information if the ULS_MAX-regulator is active.
[BDC_ILS_min_Lim]:
Information if the ILS_MIN-regulator is active.
[BDC_ILS_max_Lim]:
Information if the ILS_MAX-regulator is active.
[BDC_ILS_act]:
Information about the actual low side current value.
[BDC_IHS_act]:
Information about the actual high side current value.
[BDC_ULS_act]:
Information about the actual low side voltage value.
[BDC_UHS_act]:
Information about the actual high side voltage value.
[BDC_ILS_available]:
Derating current.
[BDC_T_max]:
Maximum measured transformer or choke temperature.
[BDC_ULS_act_red] & [BDC_UHS_act_red]:
Redundant low-side- and high-side-voltage measurement.
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