Brusa DMC514 Instruction manual

www.brusa.biz
TECHNICAL DATA
AND STARTUP
Translation of the original German operating instructions.
DMC514 (ISU)
DMC524 (ISU)
DMC534 (ISU)
DMC544

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Technical data
and startup
LEGAL NOTICE
Publisher
BRUSA Elektronik AG
Neudorf 14
CH-9466 Sennwald
T +41 81 758 19- 00
Fax: +41 81 758 19 - 99
www.brusa.biz
Date of issue
11. October 2011
Copyright
© 2011
The content of this document may not be passed on to third parties without the written authorisation
of the company BRUSA Elektronik AG- not even in extracts. Any technical information, drawings and
photos used are copyrighted and failure to respect this constitutes a punishable offence!
Updates
In light of the further technical development of our products, we reserve the right for structural
changes. Any changes will be disclosed in the relevant manuals through the replacement of the
relevant pages and/or a revision of the electronic data storage device.
Writer / Author
Holger Schmidt
REVISIONS
REVISION
DATE
NAME
CHANGE
rev11
04.06.2015
F. Müller
- chap. 9.5 add information about cable and terminal insert
rev12
30.09.2015
M. Voppichler
- chap. 8.3.5 “Pin 9 CNH, Pin 10 CNL (CAN-Bus, CAN-
Interface)” deleted
- chap. 8.4 “LV current consumption” added
- Cooling system warnings added (chap. 8.7)
rev13
18.11.2015
M. Voppichler
- adjusted delivery content
- adjusted diameters of cooling water connections
rev14
29.04.2016
M. Voppichler
- adjusted delivery content
- Warning about terminal insert (chap. 9.5)
- Chap. 12 added
rev15
28.11.2016
A. Girod
- Chapter 14 Warranty new
rev16
02.05.2017
M. Cvorak
- Chapter 8.3, LV input voltage range
rev17
15.09.2017
M. Cvorak
- Chapter 4.3, DEL: LEMO-cable from “delivered content”

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VALIDITY
This manual is valid only for the following devices:
TYPE
DMC514 (ISU) - Ser.No. > 1000
DMC524 (ISU) - Ser.No. > 1000
DMC534 (ISU) - Ser.No. > 1000
DMC544 - Ser.No. > 1000

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Table of contents
1Foreword..............................................................................................................................7
2List of abbreviations ...........................................................................................................7
3Safety 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 Interlock ............................................................................................................................13
3.4.2 Short-circuit protection ......................................................................................................13
3.4.3 Automatic discharge of DC-link voltage.............................................................................14
3.4.4 Monitoring of HV voltage...................................................................................................14
3.4.5 Overload protection (derating)...........................................................................................14
3.4.6 Inverter safety unit (ISU)....................................................................................................14
3.5 Safety measures for vehicle installation....................................................................................15
3.5.1 Principle of operation Interlock ..........................................................................................15
3.6 Requirements for the start-up personnel ..................................................................................16
4General...............................................................................................................................17
4.1 Content and scope of this manual............................................................................................17
4.2 Scope of the entire documentation...........................................................................................17
4.3 Delivered mechanical components...........................................................................................18
4.4 Optional delivery contents........................................................................................................20
4.5 EU-guidelines...........................................................................................................................21
4.6 Contact information of the manufacturer...................................................................................21
5Intended use of the device ...............................................................................................22
5.1 Proper use................................................................................................................................22
5.2 Improper use / limits of the product ..........................................................................................23
6About this device...............................................................................................................24

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6.1 Technical data..........................................................................................................................24
6.2 Type plate................................................................................................................................26
6.3 Device warnings.......................................................................................................................27
6.4 Basic function...........................................................................................................................27
6.5 Covers......................................................................................................................................28
6.6 Assembly information...............................................................................................................29
6.6.1 Installation position............................................................................................................29
6.6.2 Fixing (as in example DMC524) ........................................................................................29
6.7 Example of use ........................................................................................................................30
6.8 Input and output values............................................................................................................31
6.9 Block diagram output stage / power print..................................................................................32
6.10 Operating modes of the inverter...............................................................................................33
6.11 Regulatory approach and limitations ........................................................................................34
6.12 Error and warning messages....................................................................................................34
6.12.1 Error definition...................................................................................................................35
6.12.2 Warning message definition..............................................................................................35
7Level of inverter efficiency...............................................................................................36
7.1 DMC514 measured with HSM1-10.18.04 at 400V (first quadrant)............................................36
7.2 DMC524 measured with HSM1-6.17.12 at 400V (first quadrant)..............................................36
7.3 DMC534 measured with HSM1-10.18.13 at 400V (first quadrant)............................................37
7.4 DMC544 measured with HSM1-10.18.13-W7 at 400V (first quadrant)......................................37
8Connections.......................................................................................................................38
8.1 Circuit connections...................................................................................................................38
8.2 Pin assignment motor sensor connection (device side)............................................................39
8.3 Pin assignment of control connector (device side)....................................................................40
8.3.1 Pin 1 GND (ground terminal 31)........................................................................................41
8.3.2 Pin 2 AUX (Wiring system terminal 30)..............................................................................41
8.3.3 Pin 3 EN (Enable, Power ON) ...........................................................................................42
8.3.4 Pin 8 PG1, 14 PG2, 15 PG3 (Reserve ground, RS232 ground).........................................42
8.3.5 Pin 11 TXD, Pin 12 RXD (RS232 interface).......................................................................43
8.3.6 Pin 13 PRO (Enable firmware programming).....................................................................44
8.3.7 Pin 17 EXT AW1, Pin 18 EXT AW2 (External shut down path 1 + 2).................................45
8.3.8 Pin 19 IL1, Pin 20 IL2 (Interlock 1 + 2) ..............................................................................46

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6
8.4 LV current consumption............................................................................................................47
8.4.1 IAux.....................................................................................................................................48
8.4.2 IAux + IEn + IExt AW1 + IExt AW2..................................................................................................49
8.5 Grounding screw......................................................................................................................50
8.6 Cooling water connections .......................................................................................................51
8.7 Cooling circuit Information and Warnings .................................................................................52
8.7.1 Cooling water filter.............................................................................................................52
9Start-up...............................................................................................................................53
9.1 System requirements for PARAM-tool software........................................................................54
9.2 Ventilate and check cooling system..........................................................................................54
9.3 Load motor parameter table onto inverter.................................................................................54
9.4 Build HV supply........................................................................................................................55
10 Operation of the inverter through CVI..........................................................................59
10.1 Build connection between CVI and the inverter........................................................................60
10.2 Disconnect the communication between CVI and the inverter / Switch off the inverter .............60
10.3 Fix CVI problems......................................................................................................................61
11 Error correction..............................................................................................................62
12 Flooding in the device ...................................................................................................62
13 Instructions for disposal ...............................................................................................63
14 Warranty and guarantee................................................................................................64
15 Index................................................................................................................................65

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1 Foreword
Dear customer!
With the BRUSA inverter DMC5x4 you have received a very capable and versatile product. As this is a component
of high performance electronics, we require specialist knowledge in the dealing with as well as the operation of the
product!
Read the manual - particularly the chapter 3 Safety and warning instructions - carefully before you inverter
DMC5x4 or carry out any other work!
2 List of abbreviations
Throughout this manual, some specific technical abbreviations are used. You will find an overview as well as their
meaning in the following table:
ABBR.
MEANING
ABBR.
MEANING
AUX
Wiring System Plus
Terminal 30
DMC
Digital Motor Controller
DMC5x4
DMC514 inverter, 524,534 and 544
IL1:
Interlock
EN
Device activation
Terminal 15
IL2:
Interlock
GND
Minus wiring System, vehicle ground
Terminal 31
ISU:
Inverter Safety Unit
High
High level (logic level)
Low
Low level (logic level)
HV
High voltage, DC-link voltage
(high voltage)
LV
Low voltage
HV+
High voltage plus (high voltage+)
LV+
Low voltage plus (low voltage+)
HV-
High voltage minus (high voltage-)
LV-
Low voltage minus (low voltage-)

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3 Safety and warning instructions
In this chapter you will find safety instructions which apply to this device. These refer to assembly, start-up and
running operation in the vehicle. Always read and observe these instructions in order to protect people's safety and
lives and to avoid damage to the device!
3.1 Symbols and their meaning
Throughout this manual, some specific technical abbreviations are used. You will find an overview as well as their
meaning in the following table:
PROHIBITION SYMBOLS
SYMBOL
MEANING
SYMBOL
MEANING
General prohibition
Warning high voltage
Touching forbidden
Switching on forbidden
WARNING SYMBOLS
SYMBOL
MEANING
SYMBOL
MEANING
General hazard warning
Electromagnetic field warning
Potentially explosive warning
Battery hazard warning
Hot surface warning
High electrical voltage warning
High pressure warning / fluid spurting out
Fire hazard warning
MANDATORY SIGNS
SYMBOL
MEANING
SYMBOL
MEANING
Disconnect device from voltage
Disconnect device from mains
INFORMATION SIGNS
SYMBOL
MEANING
SYMBOL
MEANING
Important information on avoiding possible
damage to property
Important information

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3.2 Safety instructions and danger levels
DANGER
This instruction warns against serious, irreversible risks of injury and in some cases death!
Avoid these dangers by observing these instructions!
WARNING
This instruction warns against serious, irreversible risks of injury!
Avoid these dangers by observing these instructions!
CAUTION
This instruction warns against serious, irreversible risks of injury!
Avoid these dangers by observing these instructions!
INSTRUCTION
This instruction warns against possible damages to property if the following instructions and work
procedures are not observed.
INFORMATION
This type of instruction discloses important information for the reader.

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3.3 Generally applicable safety measures
The following safety measures have been developed based on the knowledge of the manufacturer. They are not
complete, they can be supplemented by place and/or country specific safety instructions and guidelines for
accident prevention!
The present safety instructions from the system integrator and/or distributor must therefore be supplemented by
specific country and local guidelines.
3.3.1 Safety instructions for cooling water systems
WARNING
Spurting cooling fluid!
Skin burning hazard!
Check the tightness of the cooling water system, particularly the pipes, screw joints and pressure
tanks.
Resolve recognisable leakages immediately!
3.3.2 Safety instructions for mechanical systems
DANGER
Potential explosion area!
Danger to life!
Do not store any highly flammable materials or combustible fluids in the direct surroundings of the
device!
Sparks at the device connections can set these on fire and lead to explosions!
CAUTION
Hot surfaces!
Burn hazard!
The device produces high temperatures when in operation!
Handle the device with care and caution!

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3.3.3 Safety instructions for handling and operation
INSTRUCTION
A high cooling water temperature reduces the life span! So take ongoing care to ensure sufficient
cooling of the device!
Do not place the device in direct sunlight and in close proximity to heat sources!
Although if the device has high IP protection, you should avoid placing it in direct contact with water
(rain, spurting water) if possible!
Under no circumstances should you put a low-resistance connection between the HV contacts, the
housing contacts and the LV contacts! This will lead to malfunctions and furthermore to the
destruction of the device!
Prevent any penetration of fluids into the device (e.g. during assembly work)! The penetration of fluids
will lead to a short circuit and subsequent damage to the device!
Under no circumstances should you operate the device if liquid is leaking in anywhere, refer
immediately to the company BRUSA Elektronik AG!

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3.3.4 Safety instructions for electrical systems
DANGER
High voltage!
Danger to life!
Under no circumstances should you touch the HV wires or HV connections without ensuring that
there is no voltage beforehand!
The device may only be connected by a qualified electrician!
Under no circumstances should you bypass or avoid security installations! Any malfunctions resulting
from this could have life threatening consequences!
Always use an insulation monitoring unit for ongoing monitoring of the galvanic isolation between HV
and LV circuits!
Before starting work with the device, the shut-down of the coupled motors must be ensured! Even
when the HV supply is switched off, a turning motor can still produce voltage!
INSTRUCTION
Under no circumstances should the device be opened without authorisation! The opening of the
device (housing sealed-up) leads directly to the forfeit of any guarantee and warranty rights!
INFORMATION
Adhere strictly to the following 5 safety rules when working on a HV grid:
Disconnect system from power.
Switch off the ignition
Remove service / maintenance plug and/or turn off main battery switch
Remove fuse
Ensure that system does not reconnect.
Keep ignition key safe to prevent unauthorised access.
Keep service / maintenance plug safe to prevent unauthorised access.
Use lockable cover cap to ensure that the main battery switch does not reconnect.
Check that it is not live with a suitable voltage tester (note voltage range!)
Ground and short-circuit the system.
Cover or seal-off adjacent live parts.

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Technical data
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3.4 Safety installations / power limitations
3.4.1 Interlock
INFORMATION
The pins IL1 and IL2 on the control connector must be connected and evaluated by the customer for
this.
The interlock switch (1) protects the operator from injuries from the HV connections. The interlock switch (1) is
automatically activated as soon as the service cap is opened.
1. Interlock switch
3.4.2 Short-circuit protection
If a short-circuit of the power output stage is detected (e.g. short circuit of the motor phases) then the power output
stage is immediately deactivated. A corresponding error is detected over CAN. The error must be confirmed before
further operation.

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3.4.3 Automatic discharge of DC-link voltage
DANGER
High voltage!
Danger to life!
If the High voltage is present, the HV connections are live!
Under no circumstances should you touch the HV connections without ensuring that there is no
voltage beforehand!
In the case of additional connected capacities, consider a correspondingly longer discharge time!
As soon as the voltage on the HV connections is switched off (manually or automatically), active discharge of DC-
link capacitors takes place in the inverter.
3.4.4 Monitoring of HV voltage
Integrated in the inverter is an overvoltage protective circuit, which deactivates the inverter immediately when the
HV voltage is too high (Error mode). A corresponding error is detected over CAN. The error must be confirmed
before further operation.
If the voltage of the HV input falls below the minimum voltage, the inverter is again deactivated (Error mode). A
corresponding error is detected over CAN. The error must be confirmed before further operation.
3.4.5 Overload protection (derating)
INSTRUCTION
Continuous operation at the temperature limit will inevitably lead to a higher level of wear of the
components!
This security installation is the inverter's self-protection. If the inverter rises in temperature, this means a decrease
in power (derating) to protect the inverter from damage through overheating. The power will subsequently be
reduced until the temperature falls back to the target range.
The temperature measurement takes place in the high power switches and is set in the factory.
3.4.6 Inverter safety unit (ISU)
INFORMATION
In general, the customer or the integrator is responsible for the safety of the system, in which the
inverter is integrated. The device is set up for the use of an Inverter Safety Unit (ISU). This protective
function was developed in accordance with ISO26262 and can meet the criteria of ASIL-C.
The ISU is not a standard protective function and can be applied by BRUSA optionally.
You can find detailed information on the ISU on the attached sheet DMC_ISU.pdf

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Technical data
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3.5 Safety measures for vehicle installation
INFORMATION
This safety measure is a recommendation by the company BRUSA Elektronik AG and is understood
as a basic requirement for the safe operation of electric vehicles!
3.5.1 Principle of operation Interlock
The interlock switch (1) is closed if the corresponding interlock condition of each device is met (closed service
cover, plugged HV connections ...). The interlock evaluation of the PDU switches the 12V supply voltage (2) of the
HV contactors (4) in the battery if the interlock circuit is closed. The emergency stop switch (3) also interrupts the
12V supply voltage of the HV contactors (4). The second interlock (5) of the line insulation guard interrupts the
interlock circuit, if a fault in the HV- insulation is detected.

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3.6 Requirements for the start-up personnel
All courses of action described in this manual may only be carried out by a qualified electrician! Specialist staff is
defined as electricians who dispose of
professional training,
knowledge and experience in the field of electronics / electric mobility,
as well as knowledge of relevant requirements and dangers
which they can display in practice. Furthermore, they must be able to assess the work assigned to them
independently, detect possible dangers and establish necessary protection measures.

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Technical data
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4 General
4.1 Content and scope of this manual
The present documentation gives the reader an overview of all required working steps in the installation and
operation of the device and the safety measures necessary for these.
Furthermore, you can find technical information, usage information and a basic description of the inverter and its
specific components.
The operation and safety instructions given in the previous chapters must be strictly adhered to ensure the ongoing
optimum functioning of the inverter and to meet the guarantee requirements of BRUSA Elektronik AG.
All work sequences and illustrations are based on the DMC524 model and are applicable to all model versions
mentioned in this handbook. In the case of model-specific deviations, corresponding instructions are available.
4.2 Scope of the entire documentation
INFORMATION
To start up the inverter successfully, you will need the entire documentation as well as different
software and firmware. With the provision of the customer package, it is ensured that they are
complete and up-to-date. The updating of specific documents is carried out automatically and can be
seen in the history.
The customer package includes the following indexes:
Manual:
Contains all information fundamentally necessary for the installation and operation of the inverter.
Firmware / motor table:
Contains the necessary firmware, a motor specific motor parameter table and instructions for installation.
Tools:
Contains additional tools for the operation, parameter setting and maintenance of the inverter.
Debugging / calibration:
Contains additional specific documentation for further work on the inverter (e.g. error analysis, rotor offset
adjustment).
History:
Listing of all upgrades within the customer package with a specification of the affected documents or software /
firmware etc.

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4.3 Delivered mechanical components
INFORMATION
The components stated below are contained in the delivery and are necessary for the start-up! In the
case of possible missing parts, please refer to the manufacturing address given in chapter 4.6.
INFORMATION
For the DMC544, you can use the same cable lugs as for the DMC534. The diameter of 70mm2
cables fits without problems into 50mm2cable lugs and is qualified by BRUSA Elektronik AG.
MEANING
PIECES
ILLUSTRATION
1.
DMC5x4 inverter
1
2.
M8 x 10 screws for the cable lugs
6
3.
M8 serrated lock washer for M8 x 10 screws
6
4.
Cable lugs (compression cable lugs)
for HV and motor cables
M8 x 25 mm2without insulation (DCMC514)
VOGT AG type. 3575A
M8 x 35 mm2without insulation (DCMC524)
VOGT AG type. 3584A
M8 x 50 mm2without insulation (DCMC534 and DMC544)
VOGT AG type. 3590A
5
5.
Cable lug (compression cable lugs)
for grounding
M8 x 25 mm290° without insulation (DCMC514)
GLOMAR AG type. DIN-25-08-W
M8 x 35 mm290° without insulation (DCMC524)
GLOMAR AG type. DIN-35-08-W
M8 x 50 mm290° without insulation (DCMC534 and DMC544)
GLOMAR AG type. DIN-50-08-W
1

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Technical data
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MEANING
PIECES
ILLUSTRATION
6.
23 pole control connector with crimp terminals
AMPSEAL 770680-1
1
7.
SN/LP contacts
AMPSEAL 770854-1
for wire diameter: 0.5 mm2
We recommend the use of the following
crimping tool: Tyco 58440-1
25
8.
Normaquick cooling water connection pieces 0° Norma PS3
2
9.
Software package
(For a listing see chapter 4.2 Scope of the entire documentation)
1
---
10.
Entire documentation
(For a listing see chapter 4.2 Scope of the entire documentation)
1
---

Technical data
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20
4.4 Optional delivery contents
INFORMATION
These accessories can be obtained optionally from BRUSA Elektronik AG.
MEANING
TYPE
ILLUSTRATION
1.
Special key for HV cable fitting
RAAA041
---
2.
Normaquick cooling water connection pieces 90° Norma PS3
MHAA776
1.
M18x1.5 D16 cooling water connection
MAAA366
1.
Rubber seal for M18x1.5 D16 cooling water connection
MAAA365
2.
Protective cap for M18x1.5 D16 cooling water connection
MHAA682
3.
Cable glands for 13 mm - 18 mm cable diameter
RAAA040
4.
Cable glands for 9 mm - 16 mm cable diameter
RKAA144
5.
14 pole Lemo connecting cable (inverter - motor) 2 m
11140
6.
14 pole Lemo connecting cable (inverter - motor) 4 m
11141
7.
Spare- CEQ 25 mm2
11471
---
8.
Spare- CEQ 35 mm2
11472
9.
Spare- CEQ 50 mm2
11473
10.
Conversion switch resolver to digital
MHAA745
---
This manual suits for next models
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Table of contents