Brusa BSC624-12V-B06, BSC624-12V-B02, BSC624-12V-B01, BSC624-12V-B05, BSC624-12V-B07 Technical Information And Start-up
...
TECHNICAL INFORMATION
UP
AND START-
Translation of the original German operating instructions
www.brusa.biz
DC/DC converter
BSC624-12V-B
BRUSA Elektronik AG
Neudorf 14
CH–9466 Sennwald
+41 81 758 19 00
info@brusa.biz
BSC624-12V-B
2
L
EGAL NOTICE
Publisher
BRUSA
Neudorf 14
CH
T +41
F +41
www.brusa.biz
office@brusa.biz
Date of issue
06
Copyright
©
The content of this document may not be passed on to third parties without the written authorisation
of the company
not even in extracts. All technical information, drawings and
photos used in this document are protected by copyright 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 disclosed in the relevant manuals through the
replacemen
Originator / author
Holger Schmidt
Revision
Date
Name
Change
. Dezember 2012
2012
Elektronik AG
–9466 Sennwald
8175 809–00
8175 809–99
BRUSA Elektronik AG -
t of the relevant pages and/or a revision of the electronic data storage device.
REVISIONS
01 05.02.2013 HS Kleine Optimierungen ÜM
02 30.09.2013 MT 6.7 Grafik Sicherheitskonzept
03 28.04.2014 RB Optimierungen ÜM, Versionserhöhung
04 16.10.2014 JP Update of the interlock bridge and CVI installation
05 16.07.2016 AG 5. Information new
06 28.11.2016 AG 13. Warranty new
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BSC624-12V-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 decoding of the device designation is as follows:
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4
TABLE OF CONTENTS
1 Foreword .............................................................................................................................. 7
2 List of abbreviations ........................................................................................................... 7
3 Safety and warning instructions ........................................................................................ 8
3.1 Symbols and their meaning ........................................................................................................ 8
3.2 Safety instructions and danger levels ......................................................................................... 9
3.3 Generally applicable safety measures ...................................................................................... 10
3.3.1 Safety instructions for cooling water systems .................................................................... 10
3.3.2 Safety instructions for mechanical systems ....................................................................... 10
3.3.3 Safety instructions for handling and operation ................................................................... 11
3.3.4 Safety instructions for electrical systems ........................................................................... 12
3.4 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
3.4.6 HV – Undervoltage shut-down ........................................................................................... 16
3.4.7 LV – Undervoltage shut-down ........................................................................................... 16
3.4.8 HV – Automatic discharge ................................................................................................. 16
3.5 Requirements to the start-up personnel .................................................................................... 17
4 General ............................................................................................................................... 18
4.1 Content and scope of this manual ............................................................................................
4.2 Scope of the entire documentation ........................................................................................... 18
4.3 Scope of delivery ...................................................................................................................... 19
4.4 Applicable standards ................................................................................................................ 20
18
4.5 Contact information of the manufacturer ................................................................................... 20
5 Use and limits of the product ........................................................................................... 21
5.1 Proper use................................................................................................................................ 21
5.2 Improper use / limits of the product .......................................................................................... 21
6 About this device............................................................................................................... 22
6.1 Technical data .......................................................................................................................... 22
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BSC624-12V-B
6.2 Technical properties ................................................................................................................. 25
6.3 Block diagram BSC624-12V-B ................................................................................................. 25
6.4 Basic function / EMC concept ................................................................................................... 26
6.4.1 Topology benefits .............................................................................................................. 26
6.4.2 Internal current supplies .................................................................................................... 27
6.4.3 LV filter concept ................................................................................................................ 28
6.4.4 HV filter concept ................................................................................................................ 29
6.4.5 AUX filter concept ............................................................................................................. 30
6.5 Warnings on the device ............................................................................................................ 31
6.6 Vehicle installation basic principle ............................................................................................ 32
6.7 Safety concept vehicle installation ............................................................................................ 33
6.7.1 Principle of operation Interlock .......................................................................................... 33
6.8 Overview of the main structural 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 interfac es ........................................................................................................... 38
7.1 Pin assignment of control connector (device side) .................................................................... 39
7.1.1 Pin 1 GND ......................................................................................................................... 40
7.1.2 Pin 2 AUX ......................................................................................................................... 41
7.1.3 Pin 3 EN ............................................................................................................................ 42
7.1.4 Pin 4 DO0 – pin 7 DO3 ...................................................................................................... 43
Pin 8 PG1, pin 14 PG2, pin 15 PG3 .................................................................................. 44
7.1.5
7.1.6 Pin 9 CNL, pin 10 CNH ..................................................................................................... 44
7.1.7 Pin 11 TXD, pin 12 RXD .................................................................................................... 45
7.1.8 Pin 13 PRO ....................................................................................................................... 46
7.1.9 Pin 16 DI0, pin 17 DI1, pin 18 DI2 ..................................................................................... 46
7.1.10 Pin 19 IL1, pin 20 IL2 ........................................................................................................ 47
7.1.11 Pin 21 AI1, pin 22 AI2, pin 23 AI3 ...................................................................................... 49
7.2 Pin assignment of HV power connector (device side) ............................................................... 50
7.3 Pin assignment of LV power connector (device side) ............................................................... 50
8 Connections ....................................................................................................................... 51
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8.1 Control connector ..................................................................................................................... 51
8.2 HV power connector ................................................................................................................. 52
8.3 LV power connector ................................................................................................................. 53
8.4 LV- / PGND (power ground) ..................................................................................................... 54
8.5 Cooling system ......................................................................................................................... 55
9 Installation / initial start-up ............................................................................................... 56
9.1 Producing the cable glands for the HV power connector .......................................................... 59
9.2 Ventilating the 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 Operation in the CAN-less mode (automatic mode) .................................................................. 69
11 Firmware update ............................................................................................................ 73
11.1 System requirements ............................................................................................................... 73
11.2 Installation Flash Development Toolkit ..................................................................................... 73
11.3 Preparing measures ................................................................................................................. 76
11.4 Executing the firmware update ................................................................................................. 77
12 Troubleshooting ............................................................................................................. 81
13 Warranty .......................................................................................................................... 81
14 Instructions regarding disposal .................................................................................... 82
15 Index ................................................................................................................................ 83
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BSC624-12V-B
1 Foreword
BMS
HW
BSC
LV
CAN
PDU
EMC
SMD
HF
SW
HV
Dear customer
With the BRUSA BSC624-12V-B, you have purchased a very high performance and versatile product. As the
present device is a high-performance electronics product which uses dangerous voltages and currents, special
expertise in handling and operation are required!
Before installing the dev ice or carrying out an y other work on it, this m anual – in particular the chapter Safety and
warning instructions – is to be read thoroughly.
2 List of abbreviations
Throughout this m anual, som e specific t echnical abbre viations are used. The f ollowing tabl e provides an overview
of these abbreviations and their meaning:
Abbr. Meaning Abbr. Meaning
Battery Management System
Bi-directional Supply Converter
Controller Area Network
Electro-Magnetic Compatibility
High Frequency
High Voltage
Hardware
Low Voltage
Power Distribution Unit
Surface Mounted Device
Software
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Warning signs
Mandatory signs
Information signs
3 Safety and warning instr uc ti ons
In this chapter, you will find safety instructions a pplying to this device. These in structions refer to the assem bly,
start-up and the runn ing operation in the vehicle . Always read and observe these instructions in order to protec t
people's safety and lives and to avoid damage to the device!
3.1 Symbols and their meaning
Throughout this m anual, some specific technic al symbols are used. The f ollowing table provides an overview of
these symbols and their meaning:
Prohibition signs
Symbol Meaning Symbol Meaning
General prohibition
Do not switch
Warning! High voltage!
Do not touch
Symbol Meaning Symbol Meaning
General warning of a dangerous area
Warning! Explosive environment!
Warning! Hot surface!
Warning! High pressure / fluid ejection!
Symbol Meaning Symbol Meaning
Disconnect device from power supply
Wear protective glasses
Warning! Danger due to suspended loads!
Warning! Danger caused by batteries!
Warning! High voltage!
Warning! Fire hazard!
Disconnect device from mains supply
Wear protective gloves
Symbol Meaning Symbol Meaning
Important information on avoiding possible
property damage
Important information
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BSC624-12V-B
3.2 Safety instructions and danger levels
DANGER
This instruction warns about severe irreversible risks of personal injury with fatal
consequences.
This instruction warns about the risk of severe but reversible injury!
CAUTION
This instruction warns about a minor risk of injury!
This instruction warns about possible property damage if the following instructions and work
INFORMATION
Avoid this risk by adhering to this instruction!
WARNING
Avoid this risk by adhering to this instruction!
Avoid this risk by adhering to this instruction!
INSTRUCTION
procedures are not adhered to.
This type of instruction discloses important information for the reader.
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WARNING
Cooling fluid ejection!
DANGER
Explosive environment!
Hot surfaces!
Burn hazard!
3.3 Generally applicable safety measures
The following safety measures have been developed based on the knowledge of the manufacturer. They are
incomplete as they can be supplemented by local and/or country-specific safety instructions and guidelines for
accident prevention.
The system integrator and/or distributor of the device must therefore supplement the present general safety
instructions by country-specific and local guidelines.
3.3.1 Safety instructions for cooling water systems
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 to life!
Do not store any highly flammable substances or combustible fluids in the direct surroundings of
the device!
Sparks forming at the device connections can set these on fire and lead to explosions!
CAUTION
The device produces high temperatures when in operation! Therefore, the device is to be
handled with care and caution at all times!
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BSC624-12V-B
3.3.3 Safety instructions for handling and operation
INSTRUCTION
Damage to the DC/DC converter:
INFORMATION
As a rule, it is to be ensured that the voltage ranges of all devices connected to the DC/DC
converter are identical.
Only use technically suitable and high-quality cables!
A high cooling water temperature and/or ambient temperature reduces the life span! Therefore,
ensure that the device is continuously cooled sufficiently!
Do not place the device in direct sunlight and in direct proximity to heat sources!
Even though the device has a high IP protection class, direct contact with water (rain, splashing
water) is to be avoided if possible!
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 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 the company
BRUSA Elektronik AG.
Always use an insulation monitoring unit to continuously monitor the galvanic isolation between
the HV and LV circuit!
Never connect or disconnect the HV connectors without ensuring the absence of voltage
beforehand!
Before connecting a voltage supply to the HV side of the DC converter (e.g.: HV battery), the
voltage must be pre-charged via a suitable pre-charging device,
see chapter 9.3 Volt age pr e-charging.
The device may be used up to a maximum altitude of 4,000 m above sea level!
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DANGER
High voltage!
INSTRUCTION
Never open the device without authorisation! The opening of the device (sealed housing) directly
INFORMATION
When working on a HV grid, the following 5 safe ty instructions have to be strictly adhered to:
3.3.4 Safety instructions for electrical systems
Danger to life!
Never touch the HV wires or HV connections without ensuring the absence of voltage
beforehand!
The device may only be connected by a qualified electrician!
Safety installations must never be by-pass ed or circumvented! Any resulting malfunctions could
have life threatening consequences!
leads to the forfeiture of any guarantee and warranty rights!
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 access (if applicable)
Keep the service / maintenance plug safe in order to prevent unauthorised access and/or
use lockable covers to ensure that the battery main switch cannot restarted.
(if applicable)
Ensure that the device is de-energised by means of a suitable voltage tester (note voltage
range!)
Ground and short-circuit the system.
Cover or seal off adjacent live parts.
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BSC624-12V-B
3.4 Safety installations / power limitations
INSTRUCTION
according the
3.4.1 Short-circuit protection
Since, due to its resonant clock topology, the transform er stage has a certain internal resistance, the device is
generally short-circui t proof. In the case of an external short-circuit (caused by the op erator), this means that the
voltage breaks down while the signal E_LV_UNDERVOL is emitted.
In the buck mode, undervoltage is identified on the LV side in the case of a short-circuit.
In the boost mode, undervoltage is identified on the HV side in the case of a short-circuit.
Independent of the operating mode, undervoltage is also identified at the respective power input.
3.4.2 Interlock
In order to guarante e the f unction of the interloc k , for the cable brid ge (1) in the HV p ower con nector
it is not allowed to use another cable then the delivered. The cable has to prepare
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 an internal as well as an exter nal interlock identif ication, wh ich functio n independe ntly of each ot her. An
interruption of the interlock circuit causes an immediate shut-down of the device. In order to use the external
interlock identification, the respective interlock pins must be connected at the control connector and the error
detection must be activated ( for details, please refer to the PARAM manual). W ith a shut-down of the device, the
signal CRE_INTERLOCK is emitted.
The internal interlock identification m onitors the HV po wer connector exclusi vely and is alwa ys active. T he optiona l
external interlock identification is an interlock loop, which is ideally looped through all HV components in the
vehicle. The interlock signal must be generated and analysed respectively via an upstream control unit (e.g.
BRUSA PDU254).
Further information on the interlock can be found in chapter 7.1.10 Pin 19 IL1, pin 20 IL2
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14
Winding HF power transformer 1 + 2
1 each
yes
Switches buck / boost converter
Since very low losses occur at the switches of the buck
boost converter and an extremely efficient cooling
predominates, these measuring values only show slightly increased values regarding the cooling liquid
temperature. For this reas on, thes e m easuring v alues pr ovide inf orm ation on the actual am bient temperature in the
device. Generally, the d evice shuts down when the temperature of the switches of
boost converter is
>/=
80°C, the device is 100% o perable again. Here, no der ating occurs but a
direct shut
3.4.3 Overload protection – derating
This safety installation is a self-protection feature of the DC/DC converter. If the device reaches a defined
temperature threshold, this reduces the power rating (derating) to protect the device from damage caused by
overheating. Consequentl y, the maxim um pos sible curr ent is reduc ed propor tiona lly to the t em perature incr ease in
order to avoid a further rise in the temperature.
Via the CAN interfac e, the currently transf erable current LVCUR_AVL is reporte d back. Here, it can be ide ntified
whether or not the device is in the derating mode.
A total of 8 temperature sensors are installed to measure the temperature. These sensors are divided into 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
Switches LV side transformer stage 2 yes
2 yes
/
the buck /
81°C. If this temperatur e falls to </=
-down of the device. With a shut-down of the device, the signal E_OVERTEMP is emitted.
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BSC624-12V-B
Windings of the HF power transformers
If the temperature at the windings of the HF power transformers reaches >/= 106°C, the current is reduced
Transformer stage switches
successively to a temperature value of < 131°C.
At >/= 131°C, the device shuts down.
If the temperature falls to </= 129°C, the device is operable again with reduced power according to the
derating diagram.
With a shut-down of the device, the signal E_OVERTEMP is emitted.
If the temperature at the transformer 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 reduced power according to the derating
diagram.
With a shut-down of the device, the signal E_OVERTEMP is emitted.
3.4.4 HV – Overvoltage shut-down
The device provides the following possibilities for identifying an overvoltage at the HV side:
Rapid HW overvoltage identification (immediate shut-down of the device if voltage > 470 V)
Slow SW overvoltage identification (shut-down of the device if voltage > 456 V; automatic reactivation if
voltage < 454 V)
With a shut-down of the device, the signal E_HV_OVERVOL is emitted.
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3.4.5 LV – Overvoltage shut-down
The device provides the following possibilities for identifying an overvoltage at the LV side:
Rapid HW overvoltage identification (immediate shut-down of the device if voltage > 20 V)
Slow SW overvoltage identification (shut-down of the device if voltage > 16.4 V; automatic reactivation if
voltage < 16.2 V)
With a shut-down of the device, the signal E_LV_OVERVOL is emitted.
3.4.6 HV – Undervoltage shut-down
The device provides the following possibilities for identifying undervoltages at the HV side:
Immediate shut-down of the device if HV voltage < 215 V
This error identif ication is d eactivat ed for 3 s when sta rting the d evice in th e boos t m ode. With a shut-down of
the device, the signal E_HV_UNDERVOL 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 identificatio n is deactivat ed for 5 s when s tarting the dev ice in the buck mode. W ith a shut-down of
the device, the signal E_LV_UNDERVOL is emitted.
3.4.8 HV – Automatic discharge
The device has an active as well as a passive intermediate circuit discharge. The active intermediate circuit
discharge is implemented inherently via the internal HV supply and thus cannot be controlled. The passive
intermediate circuit discharge is implemented via a resistor string:
Active intermediate circuit discharge:
As soon as the device is separated from the HV supply, the internal HV circuits discharge to a value of < 50 V
within 350 ms.
Passive intermediate circuit discharge:
As soon as the device is separated from the HV, the internal HV circuits discharge to a value of < 50 V within
120 s.
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BSC624-12V-B
3.5 Requirements to the start-up personnel
All courses of action desc ri bed i n th is manual may only be carried ou t b y a qu al if ied elec tr icia n! Specialist 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 requirements and dangers
for which they can provide proof. Furthermore, they must be able to assess the work assigned to them
independently, identify possible dangers and establish necessary protection measures.
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INFORMATION
To commission the device successfully, the entire documentation as well as diverse software are
customer package, it is ensured that the documentation and
date. The updating of specific documents is carried out
4 General
4.1 Content and scope of this manual
The present documentati on provides th e reader with a n overview of all r equired operati ng steps f or the installation
and operation of the device and the safety measures necessary for these purposes.
Furthermore, it contains technical data, application information a nd a basic des cr ip tion of the de v ice an d its s p ecif ic
components.
The operational and safety instructions given are to be adhered to in order to ensure the ongoing optimum
functioning of the device and to meet the warranty requirements of BRUSA Elektronik AG.
4.2 Scope of the entire documentation
required. With the provision of the
software are complete and up-toautomatically and can be seen in the history.
The customer package includes the following indexes:
Manuals:
Contains all information fundamentally necessary for installation and operation.
Firmware / CAN:
Contains all necessary CAN data as well as current firmware.
PC software:
Contains additional tools for the operation, parameter setting and maintenance as well as the required driver files.
CAD data:
Contains various CAD data in 2D and 3D.
Measurements / tests:
Contains different test results of validating measurements as well as qualifying tests, if applicable.
History:
List of all updates within the customer package, indicating the affected documents or software / firmware etc.
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BSC624-12V-B
4.3 Scope of delivery
Meaning
Pieces
Illustration
1.
1
2.
1
3.
for wire diameter: 0.5 mm2
25
4.
1
5.
1
6.
2
DC/DC converter BSC624-12V-B
23 pole control connector with crimp contacts *
AMPSEAL 770680-1
SN/LP contacts
AMPSEAL 770854-1
Harting high voltage connector set HAN-Modular Compact: *
Straight connector housing HAN-Modular Compact
Carrier housing HAN-Modular Compact
Socket insert HAN CC
2
4 mm
Cable gland HSK-M-EMV M25 x 1.5 for cable diameters 9 - 16 mm
6 cm x 4 mm
crimp contact socket (4 pieces)
2
cable (interlock bridge)
Low voltage connector set: *
Positive pole connector housing for 50 mm
MC contact SP10AR-N/50
O-ring
M3 x 5 threaded pin
2
M8 / 50 mm
M8 / 50 mm
straight cable lug for 12 V ground connection
2
angled cable lug for 12 V ground connection
Protective cap for cooling water connection pieces
* customer side connector
2
cable
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BRUSA Elektronik AG
Neudorf 14
9466 Sennwald
Switzerland
Phone:
Fax:
Internet:
E-mail:
4.4 Applicable standards
This manual has been produced under application and consideration 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
+41 81 758 19 - 00
+41 81 758 19 - 99
www.brusa.biz
support@brusa.biz
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BSC624-12V-B
5 Use and limits of the product
INFORMATION
These equipment are custom built evaluation kits destined for professionals to be used solely at
BSC624-12V-B
Unit
5.1 Proper use
The product BSC624-12V-B has been des igned to supply the 1 2 V wiring system in the applications lis ted below,
taking into consideration the limits indicated in chapter 5.2 :
Integration in hybrid vehicles
Integration in electric vehicles
Integration in fuel cell vehicles
Use in the high-performance area (racing)
Integration in electric motorcycles
Integration in utility vehicles (electric and hybrid)
Integration in electric boats
Test bench applications
research and development facilities for such purposes.
5.2 Improper use / limits of the product
Improper use is an y use carried out under condi tions which deviate from those indicated by the manuf acturer in
their technical docum ents and data sheets. Taking into cons ideration the proper use indic ated in chapter 5.1 , th e
following limits have been stipulated for the operation of the device BSC624-12V-B. The device may not be
used/operated outside of these limits. Any operation outs ide of these limits ma y lead to damage to the device or
even to life-threatening situations.
HV side overvoltage, deactivation of the power stage > 470 V
Max. HV side voltage, no operation, max. 1 min 600 V
LV side overvoltage, deactivation of the power stage > 20.0 V
Max. LV side voltage, no operation, max. 1 min 25.0 V
Max. voltage for signals at the control connector (AUX) 32.0 V
Min. coolant temperature at the input - 40 °C
Max. coolant temperature at the input 65 °C
Cooling water flow rate min. 4 l/min
Cooling water flow rate max. 10 l/min
Ambient temperature range for storage - 40 to + 105 °C
Ambient temperature range in operation - 40 to + 85 °C
Max. static pressure 2.0 bar
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22
High voltage side
Remarks
BSC624-12V-B
Unit
Low voltage side
Remarks
BSC624-12V-B
Unit
Power data
Dynamic behaviour
Standby mode
Remarks
BSC624-12V-B
Unit
6 About this device
6.1 Technical data
Min. voltage, limited power U
Min. voltage, full power - 240 V
Max. voltage, full power - 450 V
Overvoltage, deactivation of the power stage - > 470 V
Max. voltage, no operation, max. 1 min Device may be damaged 600 V
With reverse polarity Fuse triggers - -
= 14 V 220 V
LVmax
Nominal voltage +/-0.1 V 14.0 V
Min. voltage, full power - 8.0 V
Max. voltage, full power - 16.0 V
Overvoltage, deactivation of the power stage - > 20.0 V
Max. voltage, no operation, max. 1 min Device may be damaged 25.0 V
With reverse polarity Fuse triggers - -
Remarks BSC624-12V-B Unit
LV continuous current - 200 A
LV peak current - 250 A
HV continuous current, boost mode @ UHV = 400V, ULV = 14V, η = 90% 6.3 A
HV peak current, boost mode @ UHV = 400V, ULV = 14V, η = 90% 7.9 A
Continuous power, buck mode @ nominal voltage 2.8 kW
Peak power, buck mode @ nominal voltage 3.5 kW
Remarks BSC624-12V-B Unit
LV step response
HV voltage step response
Regular limit frequency PW M variable limited to 1 kHz 1 kHz
= 360V, U
U
HV
I
= 150A, buck mode
LV
ULV = 12.6V, U
ILV = 156A, boost mode
= 13.0V → 14.0V,
LV_com
= 350V → 360V;
HV_com
< 500 us
< 500 us
Typ. current draw at AUX (control connector)
= 0 V, ULV = U
@ U
HV
enable = low
@ UHV = 0V, ULV = U
= high
@ UHV = 330V, ULV = U
enable = high
AUX
= 14 V,
AUX
= 14V, enable
= 14V,
AUX
58.0 µA
220.2 mA
14.2 mA
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23
BSC624-12V-B
Galvanic
isolation Remarks BSC624-12V-B Unit
Control circuit
Clock frequencies
Thermal / cooling system
Withstand voltage between HV and LV Test voltage 2’700 V
Galvanic isolation between signal and power ground Test voltage 10 V
Isolation resistance HV-side against chassis/GND - > 5 MΩ
Remarks BSC624-12V-B Unit
Min. voltage for signals at the control connector
(AUX)
Max. voltage for signals at the control connector
(AUX)
Buck mode:
Boost mode:
LV voltage measuring range - 0 to 20.0 V
LV voltage signal accuracy Referring to scale end +/-1 %
HV voltage measuring range Limited by value range in CAN matrix 0 to 480.0 V
HV voltage signal accuracy Referring to scale end +/-1 %
HV (Low Side) current measuring range Limited by value range in CAN matrix +/-25.0 A
HV (Low Side) current signal accuracy LEM +/-3.5 %
- 7 V
- 32 V
LV control with HV undervoltage
limitation and current limits
HV control with LV undervoltage
limitation and current limits
- -
- -
Remarks BSC624-12V-B Unit
Transformer stage - 197 kHz
Buck / Boost converter min. @ UHV = 220V, ULV = 14.0V, ILV = 250A
Buck / Boost converter max. @ UHV = 450V, ULV = 16.0V, ILV = 0A 150 kHz
Crystal oscillator - 6 MHz
Microcontroller Hitachi HD64F7045FI28 4 x f
Supply HV 12.4VDC @ UHV = 85V 88 kHz
Supply HV 12.4VDC @ UHV = 170V 126 kHz
Supply HV 12.4VDC @ UHV = 240V 142 kHz
Supply HV 12.4VDC @ UHV = 450V 166 kHz
Supply 12.4VDC 5VDC - 260 kHz
Supply AUX 11.7VDC - 260 kHz
Supply CAN - 230 kHz
24 MHz
crystal
40 kHz
Remarks BSC624-12V-B Unit
Coolant (water / glycol mixing ratio) - 50 / 50 Amount of coolant in device including junction 225 ml
Min. coolant temperature - - 40 °C
Max. coolant temperature - 65 °C
Cooling water flow rate min. - 4 l/min
Cooling water flow rate max. - 10 l/min
Drop in pressure @ 4 l/min < 0.1 bar
Max. static pressure - 2 bar
Ambient temperature range (storage) - - 40 to + 105 °C
Ambient temperature range (operation) - - 40 to + 85 °C
DC
DC
Technical information
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BSC624-12V-B
24
Level of efficiency
Basic mechanical data
Remarks BSC624-12V-B Unit
Typical @ U
= 330V, U
HV
= 14.0V, ILV = 150A 94.4 %
LV
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) +/- 0.05kg 4.8 kg
IP protection - IP65 External diameter of cooling water connection pieces - 16.0 mm
Water-tight pressure compensation membrane Integrated - -
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25
BSC624-12V-B
6.2 Technical properties
Compact and light-weight construction
Vibration-resistant construction for mobile usage
Coverage of a large HV range (220 – 450 V
Bi-directional functioning
All connections are pluggable (exclud ing LV negat iv e pol e)
Excellent EMC properties
Very high power and efficiency levels
Resonant topology of the transformer stage
Galvanic isolation between HV and LV side by means of integrated HF power transformer
High IP protection class
CAN interface integrated by default
DC
)
6.3 Block diagram BSC624-12V-B
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BSC624-12V-B
26
6.4 Basic function / EMC concept
The BSC624-12V is a bi-direc tional DC/DC converter with galvanic isolation betw een the high voltage and the low
voltage circuit. The devic e is bas ed on a trans f ormer stage working in a serial-resonant manner, b y m eans of which
the galvanic isolatio n is rea lised. Furth erm ore, by means of two b uck / boos t converters working in a geared mode
for the purpose of ripple reduction, the desired voltage can be set in the respective operating mode. With the
resonant topology of the trans former stage and t he auto-comm utation 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 construction was prioritised in order to
enable the usage in almost all applications and installat io n loc a t io n s .
6.4.1 Topology benefits
The power component of the transformer stage is based on a resonant switching topology which is used for
switching in the current zero-crossing. The buck / boost converter required for the voltage adaptation uses the
auto-commutation pr inciple, which leads to a soft commuting of the bridge point. Due to the significant ly slower
changes of current and voltage, EMC faults can be significantly reduced in comparison to hard-switching
topologies.
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27
BSC624-12V-B
6.4.2 Internal current supplies
Generally, the device c an be supplied by HV as well as via pin 2 AUX. For the full operational availabilit y,
however, the 12.5 V / 2.5 A supply must be ac tive. This suppl y starts autom atically at a H V voltage of > 75 V.
Due to the greater output voltage, th e 11.3 V / 1 A sup pl y of pin 2 AUX is deactivated autom aticall y in order to
reduce the current consumption from the wiring system.
The 5V supply is guaranteed as soon as eit her pin 3 EN or pin 13 PRO are connecte d with pin 2 AUX. For
safety reasons, the hardware-side self-retaining function (uC via Enable1) is deactivated at the software-side.
In order to guarantee an optional autark ic operation of the device, a 10.7 V / 0.1 A supply is implemented.
Thus, for instance, pin 3 EN can be activat ed via a c onnect ion w ith pin 2 AUX in the customer side connector,
by which means the device remains switched on at all times.
The 12.5V / 2.5A supply is also realised with the auto-commutation topology (analogous buck / boost
converter
optocoupler.
In the boost mode, the drivers are initially supplied during the start-up by pin 2 AUX.
All supply circuits are short-circuit proof.
The signal ground pin 1 GND is gal vanically isolated from the power ground PGND. Thereby, stray volta ge
and/or ground loops are avoided.
). This supply is galvanicall y isolated from the high vo ltage circuit and fur thermore functions without
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BSC624-12V-B
28
6.4.3 LV filter concept
Component Value Unit
E
The capacitors E
LV1
C
LV1
Ls
C
LV2
E
LV2
CX
C
1‘683.6 µF
total
LV1
and E
are implem ented as SM D tantalum capacitors in or der to ach ieve the res pective
LV2
680.0 µF
40.0 µF
364.0 nH
130.0 µF
816.0 µF
17.6 µF
capacity values required.
The capacitors C
and C
LV1
are implemented as SMD ceramic capacitors; thereby, a connection with
LV2
extremely low impedance is achieved.
The capacitor C
is situated directl y at the LV power connector. Since, in the case of a defect of these filter
X
capacitors (e.g. short-circuit caused by a breakage of the component), the LV fuse does not provide any
protection for the device, special and extremely reliable types are used which offer a very high degree of
robustness with respect to mechanical forces.
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29
BSC624-12V-B
6.4.4 HV filter concept
Component Value Unit
Cy1
Lh
Ls
Cy2
Cb
6.6 nF
2314.0 µH
5.8 µH
15.0 nF
16.2 µF
The HV choke located at the input is generally of the common-mode choke type (Lh). However, it also helps to
filter the differential mode interferences by means of the existing leakage inductance (L
The wired Y capacitors (C
) together with the common-mode choke (Lh) form the common-mode filter.
y2
In order to filter particular high-frequency common-mode interferences, Y capacitors (C
).
s
) with very low
y1
impedance are directly connected at the input.
The intermediate circuit capacitor (C
) together with the leakage inductance of the HV choke (Ls) forms the
b
differential mode filter. Due to the high clock frequencies, the capacitor may have very small dimensions.
Thus, a rapid discharge of the intermediate circuit is possible.
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BSC624-12V-B
30
6.4.5 AUX filter concept
In order to achieve an ideal cushioning of the line-bound interferences, all pins of the control connector are
filtered to GND by means of SMD capacitors. GND, on the other hand, is connected to the housing with very
low impedance. Thereby, a cross-talk of common-mode interferences from one pin to others can be largely
suppressed.
Pin 2 AUX is additionally equipped 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 interferences by means of a special choke. All pins of the control connector are
protected against air- or contact-discharged ESD faults. In the case of a CAN and RS232 interface, this is
implemented by using special ESD diodes.
For suppressing high-frequency common-mode interferences, all pins are led through a ferrite core. For
details on the wiring of individual pins, please refer to chapter 7.1 Pin assignment of control connector (device
side)
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31
BSC624-12V-B
6.5 Warnings on the device
Warning signs are installe d on the device to warn the operator of possible dangers. Should one of these wa rning
signs be missing or bec ome illegible due to wear and tear, it is to be r enewed immediately. In or der to obtain an
original label, please refer to the BRUSA support at the manufacturer's address indicated in chapter 4.5 .
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BSC624-12V-B
32
6.6 Vehicle installation basic principle
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33
BSC624-12V-B
6.7 Safety concept vehicle installation
INFORMATION
This safety concept is a rec ommendation of BRUS A Elektronik AG and is a general requirem ent for
the safe operation of electric vehicles!
6.7.1 Principle of operation Interlock
The interlock switch (1) is closed if the cor responding interlock condit ion of each devices is met (closed service
cover, plugged HV con nections ...). T he interlock evaluati on of the PDU sw itches the 12V supp ly voltag e (2) of the
HV contactors (4) in the battery if the int erlock circuit is clos ed. The emergency stop switch (3) also int errupts the
12V supply voltage of the HV contactors (4). The second i nterlock (5) of the line insulation guard in terrupts the
interlock circuit, if a fault in the HV- insulation is detected.
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BSC624-12V-B
34
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
9. Cooling water connections
10. HV power connector
6.8 Overview of the main structural components
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35
BSC624-12V-B
6.9 Dimensions and installation information
Nm! F or
which are tightened with a
1.
2.
For the installation of the device, the following points must be generally adhered to:
Despite the existing IP protection, the device should only be exposed to environmental influences to the
extent required by the application.
The device may not be installed in the direct vicinity of heat sources (e.g. combustion motor).
The mechanical fix ture is t o be d ir ecte d i n a w ay that the device is ins ta l led in a f i x ed pos it ion and with as littl e
vibrations as possible.
The cable inlets and coolin g water ducts should have enou gh space and must never touc h components with
sharp edges.
All electrical connec tions are to be fixed within a dis tance of < 30 cm from the devic e with a strain relief in
order to protect the cable and/or the cable harness at the control connector against vibration.
6.9.1 Fixing points
INSTRUCTION
The housing has been designed f or a maximum admiss ible torque of the fixing scr ews of 5
fixing the device, we recommend screws of the strength category 8.8,
torque of 5 Nm.
2 pcs. thread M5, stud hole with depth: = 15 mm
Technical information
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4 pcs. thread M5, stud hole with depth: = 11 mm
BSC624-12V-B
36
6.9.2 Dimensions
6.9.3 Installation position
Generally, no spec ial insta llation pos ition f or the dev ice is prescribed as the inter nal com ponents are m ounted in a
vibration-resistant 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
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 may be cooled insufficiently.
Technical information
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37
BSC624-12V-B
6.10 Type plate
1.
2.
3.
4.
5.
6.
7.
9. LV voltage range for operation
10. LV peak current
11. Peak power, buck mode
12. IP protection class
Classification
Date of production
Supplier number (specified by the customer)
Level of efficiency
Serial number
Product number (specified by the customer)
HV voltage range for operation
8. Max. admissible cooling water temperature at the
input
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BSC624-12V-B
38
1.
2.
3.
4.
of HV power connector
7 Electrical interfaces
Control connector
Chap.7.1 Pin assignment of control connector
(device side)
LV- / PGND (power ground)
8.4 LV- / PGND (power ground)
Chap.
LV power connector
Chap. 7.3 Pin assignment of LV power connector
(device side)
HV power connector
Chap. 7.2
(device side)
Pin assignment
Technical information
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39
BSC624-12V-B
7.1 Pin assignment of control connector (device side)
INSTRUCTION
recommended for operation or necessary f or programm ing
1.
GND
2.
AUX
3.
EN
4.
DO0
5.
DO1
6.
DO2
7.
DO3
8.
PG1
9.
CNL
10.
CNH
11.
TXD
12.
RXD
13.
PRO
14.
PG2
15.
PG3
16.
DI0
17.
DI1
18.
DI2
19.
IL1
20.
IL2
21.
AI1
22.
AI2
23.
Information on the pins requir ed and / or
can be found in chapter 8.1 Control connector
Signal ground
(Minus wiring system, terminal 31)
Enable (power ON, terminal 15)
Digital output 2 (programmable)
Digital output 4 (programmable)
CAN low
RS232 Transmit (9 pole D-Sub: pin 2)
Enable firmware download
RS232 ground (9 pole D-Sub: pin 5)
Digital input 2
HV interlock loops input
Analogue input 1 (programmable)
AI3
Analogue input 3 (programmable)
+12V
(Plus wiring system, terminal 30)
Digital output 1 (programmable)
Digital output 3 (programmable)
Analogue ground (for pins 21 – 23)
CAN high
RS232 Receive (9 pole D-Sub: pin 3)
Ground reserve
Digital input 1
Digital input 3
HV interlock loop output
Analogue input 2 (programmable)
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BSC624-12V-B
40
INFORMATION
is
Internal wiring
galvanically isolated from the
control signals with other vehicle components (e. g. t rac tion dr ive, veh icle battery,
1MΩ
23,5μF
Pin 1 GND
housing
7.1.1 Pin 1 GND
If control signals of the device are connected with other vehicle com ponents, the vehicle's ground
to be connected at this pin.
Direct connection to the ground of the control unit.
The signal ground is only capacitively connected to the housing and is thus
power ground. This helps to avoid ground loops.
When wiring BSC624-12V-B-
battery management (BMS), fuel cell), the vehicle ground is to be connected here.
Technical information
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41
BSC624-12V-B
7.1.2 Pin 2 AUX
Internal wiring
14.0 1 0
330
14.1800
1.76uF
Pin 2
AUX
100uH
1.5A
5V
36V
5V
Supply
12.5V
14.1uF
12.5V-
Supply
HV
11.3V
Supply
10.7V
Supply
If no voltage is present at the HV power connector, the device is supplied via this pin by the 12 V wiring
system. It is then possible to communicate with the device by means of Pin 3 EN = high, via CAN or RS232.
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)
Voltage, current and temperature measurement
Voltage
Pin 2 AUX (V)
Pin 3 EN
(terminal 15)
12.0 0 0 0 0.0559
14.0 0 0 0 0.0578
12.0 1 0 0 250.8000
14.0 1 0 0 220.2000
12.0 1 0 330 10.7200
RUN command
(sent via CAN)
HV voltage (V) Typ. Current draw at
Pin 2 AUX (mA)
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BSC624-12V-B
42
7.1.3 Pin 3 EN
INFORMATION
Internal wiring
into the operational mode. Most
with the Plus wiring system via a
3 is
The admissible voltage range for pin 3 EN = high is 7 - 32 V.
For a pin 3 EN = low, a voltage of < 1 V is required.
To programme a new firmware, pin 13 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
appropriately, this is im plemented by means of a connection of pin 3 EN
switch.
Even if high voltage is applied to the HV connector, the device-internal logic is only supplied if pin
EN = high (or pin 13 PROG = high).
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43
BSC624-12V-B
7.1.4 Pin 4 DO0 – pin 7 DO3
INFORMATION
Internal wiring
optionally realised , such as e.g.
in functional. One exce ption are cases in which the
kHz. In order to enable cor rect signal sequences
10nF
Pin 4 DO0
-
Pin 7 DO3
AUX
500Ω
33V
These digital outputs all have the following characteristics:
R
V
V
Short-circuit resistance (I
Deactivation in the case of excessive temperatures due to overload
= 1.7 Ω at Ta = 25°C
DSON
= 32 V
OUTmax
≥ 45 V (voltage resistance for inductive loads)
CLAMP
= 700 mA)
max
With these programm able, digital outputs, low-frequenc y applications can be
controlling external LEDs f or various status functions or controlling oth er external components, such as e.g.
PWM for display instruments, relays or small fan units.
If an error occurs at o ne output, the other outputs rema
error triggers a deactivation of the device due to an excessive temperature (overload).
The outputs can be operated with frequencies of up to 10
even with these frequencies, each output is connected with a 500 Ω / 2 W pull-up resistor.
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BSC624-12V-B
44
Internal wiring
connections are av ai la ble. T hey are connected wit h the
INFORMATION
Ω terminating resistor) may be
Internal wiring
and the rem aining contro l signals ( avoiding disturbanc es caus ed
provided by BRUSA
4.7μF
Pin 8 PG1
Pin 14 PG2
Pin 15 PG3
300mA
47pF
Pin 9
CNL
33V
51uH
47pF
Pin 10
CNH
120Ω
33V
51uH
Termination
resistor is
optional
CAN-Transceiver
and galvanic
isolation
7.1.5 Pin 8 PG1, pin 14 PG2, pin 15 PG3
For simplifying the external wiring, three addi tio na l ground
GND supply ground via one PTC fuse each.
The following assignment is recommended:
pin 8 PG1 = analogue ground (for pin 21 AI1, pin 22 AI2, pin 23 AI3)
pin 14 PG2 = reserve ground
pin 15 PG3 = RS232 ground (9 pole D-Sub: pin 5)
7.1.6 Pin 9 CNL, pin 10 CNH
The termination of the CAN lines (optional positioning of the 120
executed by BRUSA. This is to be indicated by the customer when making the order.
CAN 2.0 B (baud rate can be parameterised, e.g. 125k, 250k, 500k, 1Mbit)
Both pins are isolat ed from the GND ground
by stray voltage).
Via the CAN interface, messages can be transmitted in ac cordance with the CAN m atrix
as .dbc-file.
The following parameters of the CAN messages can be modified via the PARAM software:
identifier
baud rate
scanning spot
Technical information
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45
BSC624-12V-B
7.1.7 Pin 11 TXD, pin 12 RXD
INFORMATION
Internal wiring
The firmware for the m icroproc essor can be downloa ded via th is interf ace (provi ded by BRU SA). Pin 1 3 PRO
CAN parameters and c urrent operating data, such as vo ltages, currents a nd temperatures of the device, ca n
be read out and dis played via this int erface. The Hyperter minal software requir ed for this purpose is usually
covered
PARAM software r unning via CAN. Further inform ation in this respect can be found in the PARAM
Pin assignment of the 9 pole D-Sub cable bushing
470pF
Pin 12
RXD
10V
470pF
Pin 11
TXD
15V
RS232-
Transeiver
200Ω
200Ω
470pF
470pF
100Ω
100Ω
33V
33V
RXD (12)
TXD (11)
9-polige D-Sub
Kabelbuchse
PG3 (15)
5
2
3
This RS232 interface is exclusively designed for firmware updates, monitoring or adjustments of
CAN parameters.
The RS232 interface enables a direct serial connection between the device and a PC. For test
benches or prototype vehicles in particular, we strongly recommend this connection in order 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.
must be high for this.
included in the standard installation of Windows. Please note that this functionality is more convenient
by the
manual.
Technical information
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BSC624-12V-B
46
7.1.8 Pin 13 PRO
INFORMATION
). For this
Internal wiring
Internal wiring
47nF
Pin 13
PRO
5V
2.7kΩ
220pF
1,0V
3,3V
Schmitt
Trigger
120kΩ
5V Supply
Enable
23.5kΩ
2.7kΩ
5V
Supply
11.3V
Supply
100nF
100nF
11.3V Supply
Enable
22kΩ
33V
10nF
Pin 16 DI0
Pin 17 DI1
Pin 18 DI2
5V
220pF
1,0V
3,3V
Schmitt
Trigger
22kΩ
23.5kΩ
uC
33V
The programming of an incorrect firmware may damage the device!
Therefore, the programming may only be carried out after consultation with BRUSA Elektronik AG!
This pin is only activated for the programming of a new firmware (pin 13 PRO = high
purpose, pin 3 EN must not be high.
INSTRUCTION
Both with the supply via high voltage as well from the wiring system, pin 13 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 16 DI0, pin 17 DI1, pin 18 DI2
Via the digital inputs, various functions can be realised optionally, such as:
DI0: Enable of automatic mode
DI1: Activation of current limits
DI2: Voltage or current regulation mode
Technical information
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47
BSC624-12V-B
7.1.10 Pin 19 IL1, pin 20 IL2
In order to guara ntee the funct ioning of the interlock , the signal of the intern al interloc k identificati on
INFORMATION
relevant function, which is proc ess ed internal l y but can al so be an al ysed via
an upstream system (e.g.: veh icle system). The interl ock connection is looped vi a the HV connector
nables to check wh ether or not this connector
Internal wiring
The internal interlock identification works independen tly from the usage of the exter nal interlock identificati on
and it exclusively monitor s wheth er or not the H V conn ector is properl y connec ted. In the c ase of an error, t he
is emitted via CAN. For safety reasons, the
By using the externa l interlock identificat ion, no t o nly the HV connector of the respective de vice but also those
For this purpose, the custom er must feed in the interlock signal in the form of a DC current of at least
internal resistor
By means of the PARAM software, it is to be checked whether or not the externa l interlock identificatio n
correctly, the loop is open and the input current can no
is set, while the error
leads to an
By means of the PAR AM s of tware, it c an be det er mined whether an existing interlock err or has bee n d etec t ed
in the HV connector may not be modified or distorted!
The interlock is a s afet y(bridge in the HV cus tom er side conn ector) an d thus e
is properly connected. The device has two independent interlock monitoring circuits:
internal interlock identificati on
external interlock identification
INSTRUCTION
signal INTL_OC_int* is set and the error CRE_INTERLOCK
internal interlock identification cannot be deactivated.
of additional devices can be checked.
20 mA at pin 19 and / or pi n 20. Here, th e polarit y is not rele vant. To avoid dam aging the
and optocoupler, the DC current must be limited to a maximum of 40 mA.
has been activated and corrected if applicable.
If one of the monitored connectors is not contacted
longer flow. If a threshold of appr ox. 15 mA is undercut, the signal INTL_OC_ext*
CRE_INTERLOCK is emitted via CAN.
The identification of the int ernal a nd extern al interl ock error – provided that the l att er is activ ated –
immediate shut-down of the device.
Technical information
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BSC624-12V-B
48
by the internal or external identification.
The installed wire
interlock concept (e.g. feeding of a square wa ve signal, c omparis on of the
Ω
t, in such case, t he external inter lock identification of the device no longer functions and
k concept to
The LV connector is not integrated into the interlock circuit.
For the wire bridge in the HV customer side connector the de li vere d wir e has to be installed.
bridge may not be removed or modified (e.g. extended)!
For customers using an al ternative
voltage level in the begin ning and in the end of the interlock loop), R4 ma y be optionally equ ipped with a 0
resistor in order to avoid any undesired voltage drop.
Please note tha
that, therefore, it must be deactivated in the PARAM software.
When placing the order , it is to be ens ured that a de vice version which is suitabl e for the inter loc
be used is selected:
BSC624-12V-B01: R4 = 62R (this is a customer-specific version)
BSC624-12V-B02: R4 = 62R
BSC624-12V-B03: R4 = 0R
BSC624-12V-B04: R4 = 62R
BSC624-12V-B05: R4 = 0R
BSC624-12V-B06: R4 = 62R
BSC624-12V-B07: R4 = 0R
Technical information
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49
BSC624-12V-B
7.1.11 Pin 21 AI1, pin 22 AI2, pin 23 AI3
INFORMATION
Internal wiring
Each of the three analo gue inputs can be individual ly programmed. When s etting all three inputs as current
°C) of external com ponents, for instance, the
10nF
Pin 21 AI1
Pin 22 AI2
Pin 23 AI3
5V
Analog
Multiplexer
22kΩ
150Ω
33kΩ
10nF
I
= 1mA
5V
Analog
Multiplexer
uC
Via these three analogue inputs, two different functions each can be realised optionally:
1 mA – current supply for external 5 kΩ potentiometer
33 kΩ pull-up resistor for external 33 kΩ NTC temperature sensor.
supply, it is possible to implement the following functions for instance:
pin 21 AI1: LV voltage control
pin 22 AI2: Buck mode c ur ren t limit
pin 23 AI3: Boost mode current limit
During the set-up for the t emperature measurement (T
min
= 25
following configuration is possible:
pin 21 AI1: Battery temperature
pin 22 AI2: Cooling water temperature
pin 23 AI3: Reserve
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50
1. HV interlock loop input
2. HV interlock loop output
3. HV+ (high voltage Plus)
4. HV- (high voltage Minus)
1. LV+ wiring system Plus
2. LV- / PGND wiring system power ground / vehicle
7.2 Pin assignment of HV power connector (device side)
Information on the interlock function can be found in chap. 3.4.2 Interlock
7.3 Pin assignment of LV power connector (device side)
ground
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51
BSC624-12V-B
8 Connections
INSTRUCTION
cycles of connector
(conductance, tightness) up to this
INFORMATION
in accordance with the
respective requirem ents (EMC, environm ental impac ts etc.). Here, on ly the actually used pi ns are to
hicle via the ignition key with the
1.
GND *
2.
AUX *
3.
EN *
4.
DO0
5.
DO1
6.
DO2
7.
DO3
8.
PG1
9.
CNL *
10.
CNH *
11.
TXD **
12.
RXD **
13.
PRO **
14.
PG2
15.
PG3 **
16.
DI0
17.
DI1
18.
DI2
19.
IL1 **
20.
IL2 **
21.
AI1
22.
AI2
23.
AI3
8.1 Control connector
The control connector has been designed for a maximum number of 10
operation! The manufacturer guarantees the full functioning
quantity.
For a professional mounting of the AMPSEAL contacts SN/LP, we recommend the usage of the
following crimping tool: Tyco 58440-1
Control connector included in the scope of delivery has to be assembled
be wired (mandatory* and/or urgently recommended**).
Pin 3 EN is to be connec te d to pin 2 AUX via a switch ( e.g.: in t he v e
wiring system Plus).
Signal ground
(Minus wiring system, terminal 31)
Enable (power ON, terminal 15)
CAN low
RS232 Transmit (9 pole D-Sub: pin 2)
Enable firmware download
RS232 ground (9 pole D-Sub: 5 pin)
HV interlock loop input
+12 V
(Plus wiring system, terminal 30)
CAN high
RS232 Receive (9 pole D-Sub: pin 3)
HV interlock loop output
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52
DANGER
High voltage!
cycles of connector
operation! The manufacturer guarantees the full functioning (conductance, tightness) up to this
INFORMATION
with a cable in
accordance with the following specifications. On request, this process m ay also be carried out by
1. Socket insert
2. Straight carrier housing
3. Carrier housing
4. Gasket
5. Housing screws (4 pieces)
6. 4 mm2 crimp contact socket
7. Cable wire for the interlock bridge
8.2 HV power connector
Danger to life!
Before starting the assembly process, ensure that the HV cables are de-energised.
Generate the interlock loop in the HV connector insert according chapter 9.1 Producing the cable
glands for the HV power connector. Use exclusively the delivered wire.
Any circumvention of safety installations may have life threatening consequences!
The HV power connector has been designed for a maximum number of 500
quantity.
The HV power connector included in the scope of delivery is to be assembled
INSTRUCTION
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 crimping depth adjustment mandrel: 09 99 000 0379 (recommended)
Harting crimping tool 4.0 - 6.0 mm
or Harting crimping tool 1.5 - 4.0 mm
Dismounting tools for crimp contacts 1.5 - 6.0 mm
2
: 09 99 000 0110 (optional)
2:
09 99 000 0303 (optional)
2
: 09 99 000 0305 (optional)
In order to guarantee a reliable oper ation of all controllers - in particular of the HV voltage contr oller in the boost
mode - the following instructions are to be strictly adhered to:
Max. cable length between the device and the HV battery = 5 m
Required cable diameter = 2 x 4 mm² (screened two-core cable)
Admissible cladding diameter = 9 - 16 mm
Screen connection to both sides (recommended for reasons of EMC)
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BSC624-12V-B
8.3 LV power connector
INSTRUCTION
. In order to separate the c onnector, the latter is to
cycles of connector
operation. The manufacturer guarantees the full functioning (conductance, tightness) up to this
In order to guaran tee this num ber of c ycles of conn ector oper ation, a lubricat ing film is to be a pplied
e pole connector housing. The following lubricants are suitable for this purpose
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 process m ay also be carried out by
1. MC contact (12 V+)
2. Positive pole connector housing (push-pull)
3. Cable lug M8 / 50 mm2 – flat
4. Cable lug M8 / 50 mm2 - 90°
The LV power connector is a push-pul l connector
be pushed in the plugging direction (unlocked) and then be pulled out in the pulling direction.
The LV power connector has been designed for a m aximum number of 1000
quantity.
to the positiv
according to the connector manufacturer Multicontact.
Metalon HAT-1.5 - 50 ml (73.1052)
Kontasynth BA100 SPRAY (73.10 51)
Barrierta I EL-102
Barrierta I S-402
Barrierta I MI-202
INFORMATION
BRUSA.
For proper assembly, the following tools are recommended:
Crimping tool Elpress M-PZ-T2600: 18.3710
Crimping insert TB11-14,5 (KRF): 18.3713
For information on assembly please refer to
8.4 LV- / PGND (power ground)
chap.
For information on assembly please refer to
8.4 LV- / PGND (power ground)
chap.
In order to guarantee a reliable oper ation of all controllers - in particular of the HV voltage contr oller in the boost
mode - the following instructions are to be strictly adhered to:
Max. cable length between the device and the 12 V LV battery = 2 m.
Required cable diameter = 50 mm
Select the cladding diameter in accordance with the connector housing.
2
(unscreened single core cable).
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54
Fire hazard!
INFORMATION
) is
to be assembled with a cable in accordance with the following specifications. On request, this
1. Ground screw M8 x 16 mm
2. Washer
For the assembly of the LV-connector a hexagonal crimping of the 50mm2 contact element is prescribed. It is
recommended to make two to three crimpings next to each other in order to ensure a reliable contact.
The contact element and the connector housing are to be aligned in a way that the threaded pin can be
screwed in entirely.
8.4 LV- / PGND (power ground)
WARNING
Severe burns!
With a loose or non-existing ground connection, the current of the wiring system may return via
the screen of the HV cable and thus cause a cable fire or, consequently, a vehicle fire!
You have to ensure in any case that the ground connection is properly connected!
Always adhere to the prescribed torque!
The cable lug included in the s cope of delivery (flat o r 90° - see chapter 8.3 LV power connector
process may also be carried out by BRUSA.
The mounting of a washer (2) between ground screw (1) and cable lug is mandatory!
Hexagonal crimping of the cable lug (check tight fit!). We recommend to execute up to three crimpings in a
row in order to guarantee a safe connection.
Max. cable length between the device and the 12 V LV battery = 2 m.
2
Required cable diameter = 50 mm
When installing the cables (LV+ and LV-) in the vehicle, ensure that the spanned area remains as small as
possible and that no sensitive control signals are implemented in between.
(unscreened single core cable).
Torque = 16 Nm
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BSC624-12V-B
8.5 Cooling system
INSTRUCTION
Ensure that no trapped air is present in the cooling system! The venting may also be implemented
pressure is not
1. Connection of cooling water input
2. Connection of cooling water output
via pressure or vac uum filling. Here, ensure that th e admissible maximum system
exceeded!
Trapped air in the cooling system may lead to an overheating of the device!
(external Ø 16 mm)
(external Ø 16 mm)
The cooling water hoses are to be implemented in accordance with the cooling water connection pieces
(external diameter 16 mm) in order to guarantee a water tight connection.
Ensure that the cooling water hoses are properly mounted onto the connection pieces in order to avoid leaks.
Please also ensure that the specified flow direction is adhered to.
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56
DANGER
High voltage!
Danger to life!
INSTRUCTION
1.
2.
3.
9 Installation / initial start-up
Never touch the HV wires or HV connections without ensuring the absence of voltage
beforehand!
The device may only be connected by a qualified electrician!
Safety installations must never be by-passed or circumvented! Any resulting malfunctions could
have life threatening consequences!
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 tree at the control connector against vibration
and consequential damage.
Ensure that the HV battery used has a pre-c har gin g un it. Any connection without pre-charging
unit may cause the formation of sparks / voltage peaks and thus damage to the device!
Procedure step Illustration / other information
Mechanically install the device in its specified
position.
Please refer to the installation instructions
See chap. 6.9 Dimensi ons and installation
information
Connect the cooling water hoses (1).
See chap. 8.5 Cooling system
Ventilate the cooling system.
Ensure that no trapped air is present in the
cooling system!
See chap. 9.2 Ventilating the cooling system
---
---
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57
BSC624-12V-B
Procedure step Illustration / other information
4.
5.
6.
7.
8.
Produce a ground connection (1) (LV).
See chap. 8.4 LV- / PGND (power ground)
Maximum cable length 2m!
Produce the cable connections of the control
connector.
See chap. 8.1 Control connector
Connect the control connector (1) with the device.
---
Ensure that the control connector (1) fully
engages and is tightly fit.
Implement the LV power connector in accordance
with the manufacturer's specifications.
See chap. 8.3 LV power connector
Connect the LV power connector (1) with the device
(push-pull connector).
---
Das Bild kann zurzeit nicht angezeigt werden.
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58
9.
10.
11.
12.
INFORMATION
The installation of the devic e is no w com plete. You c an c omm iss ion the de vice. T he operatio n of the
specific
nd can be purchased option ally. To
Procedure step Illustration / other information
Implement the HV lines and the HV power
connector.
See chap. 8.2 HV power connector
See chap. 9.1 Producing the cable glands for the
HV power connector
Connect the HV power connector (1) with the device.
Connect the battery cable to the HV battery.
See chap. 9.3 Voltage pre-charging
Manually check that all cable and 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 the control connector against
vibration.
device may be im plemented by means of customer-specific CAN tools or via the BRUSAPARAM s oftware. This software is ideall y aligned to the device a
do this, please contact the manufacturer under the address provided in chapter 4.5 .
---
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59
BSC624-12V-B
9.1 Producing the cable glands for the HV power connector
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
1.
2.
The HV wiring is to be implem ented in accordance with the following instr uctions. Here, it is important to ensure
that no strands are damaged. For this reason, check the correct mounting of the screw connection of each
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 connector set HAN-Modular Compact, see chapter 4.3 Scope of delivery
When assembling the cable lugs, using the appropriate crimping tool is absolutely necessary!
Strip the HV cable (1) to a length of 40 mm.
Ensure that the braid underneath is not
damaged!
Shorten the braid (1) to 15 mm.
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60
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
3.
4.
5.
Strip both strand ends (1) to a length of 9 mm.
Mount the crimp contact sockets (2) included in the
scope of delivery onto the strand ends (1).
Further information can be found in chap. 8.2 HV
power connector
Lead the HV cable through the union nut (1).
Lead the HV cable through the terminal insert (2).
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.g. with insulating tape (4).
Ensure that no individual strands of the braid (1)
protrude beyond the O-ring (3)! Once installed,
this will damage the sealing lip and subsequently
cause an ingress of water into the housing!
Therefore, cut all protruding strands to the
admissible length.
Das Bild kann zurzeit nicht angezeigt werden.
Das Bild kann zurzeit nicht angezeigt werden.
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61
BSC624-12V-B
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
6.
Put the gland base (1) over the terminal insert (2).
7.
8.
Remove the insulating tape.
Screw together the gland base (1) with the union
nut (3).
At this stage, only attach the union nut manually.
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.
Strip both strand ends (1) of the delivered interlock
bridge to a length of 9 mm.
Mount the crimp contact sockets (2) included in the
scope of delivery onto the strand ends (1).
Further information can be found in chap. 8.2 HV
power connector
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62
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
9.
10.
11.
Insert the crimp contact socket of the interlock loop
(1) into the socket insert.
For the pin assignment, please refer to chapter
7.2 Pin assignment of HV power connector
(device side)
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 assignment of HV power connector
(device side)
Put the gasket (1) onto the carrier housing (2).
Put on the straight carrier housing (3).
Screw together the carrier housing (2) with the
straight carrier housing (3).
Before tightening, check the tight fit of the gasket
(1).
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BSC624-12V-B
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
12.
Tighten the union nut (1).
13.
Tighten the union nut (1) with a torque of 12 Nm.
Manually check the tight fit of the cable gland. ---
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64
INSTRUCTION
Trapped air in the cooling duct along with a generally insufficient cooling of the device lead to
1.
Check the cooling water connections on the device
2.
3.
4.
9.2 Ventilating the cooling system
increased wear and tear!
Ensure that the cooling circuit is fault-free.
Procedure step illustration / other information
for water tightness and firm fit.
Switch on the cooling circuit. --Leave the cooling circuit turned on for around 30 s. --Switch off the cooling circuit. ---
---
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BSC624-12V-B
9.3 Voltage pre-charging
INSTRUCTION
In order to avoid the formation of sparks as well as damage to the device during activation, 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 processes. If the PTC overheats, another pre-charging process is temporarily
impossible. The pre-charging resistor must be cooled down for a certain period of time in such
case.
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66
The main contactor (3) closes.
The pre-charging contactor (1) closes.
The main contactor (2) closes.
The pre-charging contactor (1) opens.
The functional routine of the pre-charging un it is as follows:
1.
2.
3.
4.
Ensure that the pre-charging contactor (1) as well as the pre-charging resistor R
maximum 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 contactor (1) again if the condition U
< 10 V is not fulfilled even after a specified maximum period.
The main contactor (2) may only close if the condition U
- U2 < 10 V is fulfilled.
1
(4) are designed for the
P
- U2
1
The HV connection to the device is now produced.
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67
BSC624-12V-B
INFORMATION
All CAN applications are based on the CAN hardware of PEAK System
10 Operation
10.1 Installation and operation of the PARAM software
The PC software folder of the customer package includes the software PARAM_2.0.zip. For the
PARAM_Manual_Installation_Usage manual, refer to Manuals. This manual describes the installation of the
required PCAN_API drivers as well as of the PARAM tool. Additionally, the user interface and the operating
functions of the PARAM tool are generally described.
The BSC6_PARAM_Manual_xxxxxx describes the operating functions of the PARAM tool for the BSC6. The
manual is field in the same folder of the customer package.
(www.peak-system.com). For CAN comm unication, it is recom mended to use a galvanically isolated
USB adapter with suitable 120 OHM terminating resistor:
IPEH-002022 (PCAN USB adapter)
IPEK-003003 (PCAN terminating resistor)
10.2 CVI software installation
The CVI CAN user interface can be found in the PC software folder as CVI.zip.
If the PARAM software has alread y been insta lled with the require d driver s, the CVI f older of the Z ip files
only needs to be copied to the PARAM instal lation folder. T he CVI software doe s not require any further
installation steps.
If the PCAN USB adapter (dongle) is connected t o the PC, the C VI and PARAM software can be started
over the “StartBSC6xx.cmd”-File.
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68
INFORMATION
Optionally, the CAN user interface (CVI) ma y also be implem ented by BRUSA if the device is not
integrated into an existing CAN communication network . The following image shows an ex ample of
CVI software serves as user interface for internal laboratory applications for
BRUSA Elektronik AG. The CVI is provid ed to custom ers as ex ample f or a custom user inter face f or
10.3 Operation of the device
the user interface. Here, the start-up is implemented as described.
The
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 with the device.
Press the Run button in order to activate the power stage. The communication with the device is ensured
when the displays Tx and Rx are flashing.
first tests with no guarantee.
To allow for the main controller to fulfil its function, it is to be guaranteed that no limiting controller is
meshed.
The device can be switched off in every operating mode by another actuation of the Run button and a
deactivation of pin 3 EN. In the case of an emergency, an abrupt disconnection of the high voltage by opening
the contactors is also admissible.
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69
BSC624-12V-B
10.4 Operation in the CAN-less mode (automatic mode)
INFORMATION
less mode via the buck mode. In
this operating mode, the d evice is able to convert energy obtained f rom a HV circuit to a LV level
to be implement ed
1.
2.
3.
The BSC624-12V-B m ay be operated autonom ously in the CANwithout CAN connection.
For the autonom ous operation in the CAN-less mode, the f ollowing settings are
Open the PARAM software.
Change to the Parameter List tab (1)
by means of the PARAM software.
Procedure step Illustration / other information
---
In the drop-down menu, select [04] Control
configuration – CRC.
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70
4.
5.
6.
Procedure step Illustration / other information
In field (1), enter the value 2 (automatic mode).
For the autonomous operation without CAN
connection, value = 2 must be set.
In field (1), enter the duration in seconds during
which a HV voltage must be present until the CANless mode is started (HV-ready time).
Requirement:
The device is released via DI0.
In field (1), enter the LV which is applicable for
commanding the automatic mode (AUTO ULV com)
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71
BSC624-12V-B
Procedure step Illustration / other information
7.
8.
9.
In the fields (1-3), set the voltage and current limits
for the automatic mode (AUTO UHV lim, AUTO IHV
lim, AUTO ILV lim)
In order to accept the modified data, click on the Set
key button (1).
Change over to the Main Parameter register (1).
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72
10.
INFORMATION
must be set. If the HV is set subsequently, the BSC starts the autonomous operating mode upon
ready time. For this purpose, no CAN connection is
Procedure step Illustration / other information
Click the Update & Reset Target button (1).
Requirements:
The user must be logged in via the user
password monitor (via Login button (2)).
In order to activate the CAN-less mode, at the digit al input DI0 (contr ol connector pin 16), a High
expiration of the previously defined HV-
necessary.
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73
BSC624-12V-B
11 Fi rmware update
INSTRUCTION
INFORMATION
software functions with the following operating
Procedure step
Illustration / other information
1.
2.
3.
The programming of an incorrect firmware may damage the device!
Therefore, a firmware update may only be carried out after consultation with BRUSA Elektronik
11.1 System requirements
AG!
A firmware update may only be carried out at an error-free, functioning device!
The Flash development toolkit (Release 4.08)
systems:
Win2000
Win XP
Win Vista
Win 7
11.2 Installation Flash Development Toolkit
Install the FDT Flash development toolkit software
as well as the FDT Protocol A plug-in while taking
into consideration the settings listed below.
Download under: www.renesas.com
Start the installation of the FDT Flash
development toolkit 4.08 software.
In the dialogue check FDT Application (1). If
required, uncheck other kernels.
Click Next (2).
---
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74
Procedure step
4.
5.
6.
Illustration / other information
In this dialogue, you can select and unselect the file
formats to be opened with FDT optionally.
Click Next (1).
In this dialogue, you can change the installation path
if required.
Click Next (1).
In this dialogue, you can check your settings again
and change them if required (Back button (1))
Click the Install button (2) in order to proceed.
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75
BSC624-12V-B
Procedure step
Illustration / other information
7.
8.
9.
10.
The installation process will be carried out.
After the installation has been successfully
completed, the following dialogue appears.
Click the Finish button (1).
The installation of FDT is now completed. Now,
follow the further instructions.
Upon completion of the installation, execute the file
fdt3_05_prota_A.EXE.
Select the installation directory.
The installation path is to be adapted in order to
allow for the kernels to be installed in the
FDT4.08 folder.
Example: C:\Programme\Renessas\FDT4.08
Click the Next button (1).
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76
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
1.
2.
3.
11.3 Preparing measures
At the control connector, connect pin 2 AUX with
pin 13 PRO.
See chap. 7.1 Pin assignment of control
connector (device side)
Connect the device with your PC (RS232 interface).
See chap. 7.1.7 Pin 11 TXD, pin 12 RXD
Before executing this step, it is to be ensured
that the RS232 interface is not already assigned!
Establish an HV or LV supply (AUX) to the device. ---
---
---
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BSC624-12V-B
11.4 Executing the firmware update
INFORMATION
Depending on the software version and the operating system used, the graphical user interfaces may
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
1.
2.
3.
4.
deviate.
Start the Flash Development Toolkit 4.08 Basic
software.
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).
Open the folder in which FDT Flash Development
Toolkit 4.08 and FDT 3.0 5 Protocol A Plugin are
installed.
Follow the path:
Renesas → FDT 4.08 → Kernels → ProtA →
7045 → Hitachi → 0_0_00.
---
---
Select the file 7045.fcf.
Click the Open button (1).
The kernel SH/7045F is now included in the list.
Return to step 2.
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78
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
5.
6.
7.
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).
Click the Next button (1).
Select BOOT Mode (1).
Uncheck field (2).
Select 57600 (3).
Click the Next button (4).
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BSC624-12V-B
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
8.
Select Automatic (1).
9.
Select Advanced (2).
Click the Finish button (3).
You have now created the project and/or the
device. The new firmware can be programmed
as described below.
Check field (1).
Click the button (2) and select the new firmware file
from the list which appears.
Click the Program Flash button (3).
The firmware update is now executed. After the
update has been completed successfully, the
message Image successfully written to device
appears in field (4).
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and start-up
BSC624-12V-B
80
PROCEDURE STEP
ILLUSTRATION / OTHER INFORMATION
10.
11.
12.
13.
Click the Disconnect button (1) in order to securely
separate the connection to the device.
Click the Exit button (2).
Separate the HV or LV supply to the device. --Disconnect the device from your PC (RS232
interface).
At the control connector, disconnect pin 2 AUX from
pin 13 PRO.
See chap. 7.1 Pin assignment of control
connector (device side)
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BSC624-12V-B
12 Troubleshooting
The device differentiates between two error categories:
Critical errors (CRE):
Normally, this type of error does not occur if the device is properly operated and installed. Except for the error
message CRE_INTERLOCK, such error message probably indicates a defective component in the device.
Errors (E):
This type of error normally occurs in the case of an error when operating the device. This does not include the
errors E_TEMP 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 errors (CRE): 10
Errors (E): 50
For a list of all possible errors, please refer to the manual BSC624-12V-B Documentation of Errors and Warnings.
Always try to clear all error s which occur with the help of this manual. Should errors reappear, please refer to the
BRUSA support under the manufacturer address indicated in chapter 4.5 .
13 Warranty
The warranty corresponds to the regulations in our currently valid general terms and conditions see under
www.brusa.biz/en/support/terms-conditions.html.
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BSC624-12V-B
82
14 Instructions regarding di s pos a l
A basic requirement for the re-use and recycling of used electronic devices is the correct disposal.
With the implem entatio n of the electric an d elec tro nic d ev ice r eg ul ati on ( El ektroG), since 24 Marc h 2006, electronic
devices may no longer be dispos ed of along with ord inary household wast e but must be separat ely collected and
recorded by a specialist services.
Disposal through a spec ialist service significantl y helps to avoid dangers to people and nature. Therefore, in the
case of disposal, we recommend contacting a recognised specialist disposal service.
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BSC624-12V-B
15 Index
A
Avoidance of damage to the device 73
B
Block diagram
BSC624-12V-B basic concept 25
Installation into the vehicle 32
C
Control connector Pin assignment on device side 39
Control connector Pin assignment, connector side 51
Controller 42
cooling system
Specification 24
Cooling system
Connections 38
Customer package 18
D
Derating 14
Designation of the device
Decoding 3
Device limits 21
Device specification 24
Disposal 82
E
EMC concept 26
Error messages 81
F
firmware 42
Firmware 41, 45, 46, 76, 77
Important instructions 73
HV power connector
Mounting the cable glands 59
Pin assignment (device side) 50
I
Interlock 13, 33, 47, 50
L
LV power connector
Installation instructions 53
Pin assignment on device side 50
N
Notes on life span 11
O
operating ranges 21
P
Pictograms 8
Prevention of damage to the device 64
programming 41, 42, 46
protective functions
LV side 16
Protective functions
general 13, 65
HV side 15, 16
S
Safety
Important instructions 10
Serial number 37
Support contact 20
Switches buck / boost converter 14
G
Ground connection 40
Guarantee 82
Instructions 12
H
HF power transformers 15
High voltage
The 5 safety rules 12
Technical information
and start-up
T
Temperature measurement 14
transformer stage switches 15
V
Validity of the manual 3
W
Warranty 82
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