Brusa DMC514 Instruction manual

BRUSA Elektronik AG
Neudorf 14
CH-9466 Sennwald
[phone]
[email protected]
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 [phone]
Fax: [phone] - 99
www.brusa.biz
[email protected]
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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Technical data
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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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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.

Technical data
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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!