Brusa BDC546-B User manual

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BDC546-B
Operating instructions
Version 1.1

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Document version
Version
Date
Name
Comment
1.0
18.12.2012
M.Haller
Document released
1.1
05.01.2015
J. Pitschi
- Update of some descriptions of CAN-signals.
- Update of value for the current regulators based
on tolerances of the internal current measurement.

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Inhalt
Version 1.1 ................................................................................................................................................1
Document version...............................................................................................................................................2
Introduction.........................................................................................................................................................4
List of abbreviations........................................................................................................................................4
Valid regulator-values.....................................................................................................................................4
UHS-main-regulator............................................................................................................................................5
Interpretation of the internal current measurement............................................................................................5
Boostmode .....................................................................................................................................................5
Buckmode.......................................................................................................................................................5
Limit regulators...............................................................................................................................................5
Regulator priorities .........................................................................................................................................6
Recommended current settings for BDC operation ...........................................................................................6
Recommended BDC-settings for a test assembly .............................................................................................7
Recommended BDC-settings for operation “fuel cell to battery”:...................................................................7
Recommended BDC-settings for operation “battery to fuel cell”:...................................................................8
Examples of critical operating states..................................................................................................................9
Condition ULS > ULS_MAX.......................................................................................................................9
Condition ULS < ULS_MIN........................................................................................................................9
Condition UHS_COM < UHS_MIN ..........................................................................................................10
Condition UHS_COM > UHS_MAX .........................................................................................................10
Other important CAN-signals............................................................................................................................11

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Introduction
This document has to be read before startup the device first time. Otherwise damage on the device and
external connected devices can occur.
The signal names in squared brackets ([ ]) are the references to the CAN-matrix.
List of abbreviations
U: Voltage
I: Current
HS: High-Side
LS: Low-Side
LIM: Limit
MAX: Maximum
MIN: Minimum
REG: Regulator
COM: Commanded
Valid regulator-values
ULS_MIN: 0V (CAN-error is set, if the value is out of the range.)
ULS_MAX: 600V (CAN-error is set, if the value is out of the range.)
UHS_MIN: 0V (CAN-error is set, if the value is out of the range.)
UHS_MAX: 750V (CAN-error is set, if the value is out of the range.)
ILS_MIN: 0 to -400A (CAN-error is set, if the value is out of the range.)
ILS_MAX: 0 to 400A (CAN-error is set, if the value is out of the range.)
IHS_MIN: 0 to -400A (CAN-error is set, if the value is out of the range.)
IHS_MAX: 0 to 400A (CAN-error is set, if the value is out of the range.)
UHS_COM: 0 to 1024V (0 to -1024V) (The device doesn’t check this value. If the UHS_COM
value is higher than UHS_MAX or lower than UHS_MIN, the device
is going to regulate on the limiting-values.)

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UHS-main-regulator
The main-regulator regulates the high-side-voltage. For a functional operation, the following CAN-messages
have to be set correctly:
[SG_Sollwert]: Value of the commanded high-side voltage.
(Sollwert engl.: desired value)
[SG_HR_Mode_Check]: 0x1
Interpretation of the internal current measurement
Boostmode
Direction of current from LS to HS.
Current measurements have a positive value.
[BDC_ILS_act] & [BDC_IHS_act] > 0
Responsible current-limit-regulators:
IHS_MAX [SG_IHS_max] > 0
ILS_MAX [SG_ILS_max] > 0
Buckmode
Direction of current from HS to LS.
Current measurements have a negative value.
[BDC_ILS_act] & [BDC_IHS_act] < 0
Responsible current-limit-regulators:
IHS_MIN [SG_IHS_min] < 0
ILS_MIN [SG_ILS_min] < 0
With the current-limit-regulators, the user can avoid an unexpected change of the mode. (Boostmode to
buckmode or buckmode to boostmode.)
Limit regulators
On reaching one or more set limit-values, the device will regulate on this values under compliance of the
regulator-priority. The device won’t switch off.

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Regulator priorities
The main-regulator is the high-side voltage regulator (UHS_REG). This regulator has the lowest priority.
The high-side-voltage-limit-regulators (UHS_LIM) have a higher priority than the low-voltage-limit-regulators
(ULS_LIM). This can result in an operation mode where ULS is getting higher than the set ULS_MAX (or lower
than ULS_MIN).
UHS_COM: The commanded voltage of the high-side-regulator.
UHS_REG: HS -voltage-regulator main regulator
ULS_LIM: LS-over- and undervoltage-regulators. If ULS reaches this value, the device tries to
regulate to this value and to keep the operation.
UHS_LIM: HS-over- and undervoltage-regulators. If ULS reaches this value, the device tries to
regulate to this value and to keep the operation.
IHS_LIM: HS-current-regulator for buck- and boostmode where IHS_MAX is set for boostmode and
IHS_MIN is set for buckmode.
ILS_LIM: LS-current-regulator for buck- and boostmode where ILS_MAX is set for boostmode and
ILS_MIN is set for buckmode.
ILS_COM: The LS-current generated by the regulators. (This value is not set by CAN. It is an
internal generated value.)
Recommended current settings for BDC operation
Due to measurement tolerances a parametrization of the current regulators to zero in order to avoid a
change of operating direction may cause problems (especially at no load conditions). Therefore BRUSA
recommends to set the current regulators to MIN_CURRENT_LIM, whereby |MIN_CURRENT_LIM| ≥2A.
Recommended current setting
Boostmode: IHS_MIN = ILS_MIN = -2 (to avoid Buckmode)
Buckmode: IHS_MAX = ILS_MAX = 2 (to avoid Boostmode)
UHS_Reg
ULS_Lim
-Max
-Min
UHS_Lim.
-Max
-Min
IHS_Lim
-Max
-Min
ILS_Lim
-Max
-Min
UHS_com
ILS_com
High
Low
[SG_Sollwert]
[SG_ULS_max]
[SG_ULS_min]
[SG_UHS_max]
[SG_UHS_min]
[SG_IHS_max]
[SG_IHS_min]
[SG_ILS_max]
[SG_ILS_min]

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Recommended BDC-settings for a test assembly
Recommended BDC-settings for operation “fuel cell to battery”:
BDC_1:
UHS_COM_1 > 170V
ILS_MAX_1 > |ILS_MIN_2|
ILS_MIN_1 = -2 (prevention of buckmode)
IHS_MAX_1 > |IHS_MIN_2| (Recommendation: IHS_MAX_1 > ILS_MAX_1)
IHS_MIN_1 = -2 (prevention of buckmode)
BDC_2:
UHS_COM_2 < UHS_COM_1
|ILS_MIN_2|< ILS_MAX1
ILS_MAX_2 = 2 (prevention of boostmode)
|IHS_MIN_2|< IHS_MAX_1 (Recommendation: |IHS_MIN_2| > |ILS_MIN_2|)
IHS_MAX_2 = 2 (prevention of boostmode)
HS- and LS-voltage limit regulators have to be set according to the fuel cell and battery specifications.
BDC546
ILS_MIN active
UHS_MAX [SG_UHS_max]
IHS_MAX
[SG_IHS_max]
IHS_MIN [SG_IHS_min]
ULS_MAX [SG_ULS_max]
ILS_MAX [SG_ILS_max]
ILS_MIN [SG_ILS_min]
ULS_MIN [SG_ULS_min]
High-Side (HS) Low-Side (LS)
UHS_MIN [SG_UHS_min]
BDC546
UHS_COM active
ULS_MAX [SG_ULS_max]
ILS_MAX [SG_ILS_max]
ILS_MIN [SG_ILS_min]
UHS_MAX [SG_UHS_max]
IHS_MAX [SG_IHS_max]
IHS_MIN [SG_IHS_min]
UHS_MIN [SG_UHS_min]
High-Side (HS)
Low-Side (LS)
ULS_MIN
[SG_ULS_min]
Fuel Cell
Battery
BDC_1
UHS_COM [SG_Sollwert]UHS_COM [SG_Sollwert]
BDC_2
ULS1
UHS ULS2

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Recommended BDC-settings for operation “battery to fuel cell”:
BDC_2:
UHS_COM_2 > 170V
ILS_MAX_2 > |ILS_MIN_1|
ILS_MIN_2 = -2 (prevention of boostmode)
IHS_MAX_2 > |IHS_MIN_1| (Recommendation: IHS_MAX_2 > ILS_MAX_2)
IHS_MIN_2 = -2 (prevention of boostmode)
BDC_1:
UHS_COM_1 < UHS_COM_2
|ILS_MIN_1|< ILS_MAX_2
ILS_MAX_1 = 2 (prevention of buckmode)
|IHS_MIN_1|< IHS_MAX_2 (Recommendation: |IHS_MIN_1| > |ILS_MIN_1|)
IHS_MAX_1 = 2 (prevention of buckmode)
HS- and LS-voltage limit regulators have to be set according to the fuel cell and battery specifications.

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Examples of critical operating states
The following examples shows critical operating states who can occur due to regulator priorities. The
examples refer to schematic diagram below.
Operating mode of the devices:
BDC: Boostmode, UHS_COM active [SG_Sollwert]
Condition ULS > ULS_MAX
BDC regulates ULS_MAX by converting energy from LS to HS.
ILS_MAX or IHS_MAX is active.
UHS rises till UHS = UHS_MAX.
UHS_MAX is active, because of the higher priority of the HS-limit-regulators.
BDC changes the operating mode to buckmode by converting energy from HS to LS.
ILS_MIN or IHS_MIN is active.
UHS falls till UHS < UHS_MAX or ULS overvoltage detection (ULS > 600V) is active.
Inadvertent operating-mode-changes from boost- to buckmode can be avoided by setting ILS_MIN
and/or IHS_MIN to zero. (See chapter “Recommended BDC operating settings”)
Condition ULS < ULS_MIN
BDC regulates ULS_MIN by converting energy from HS to LS.
BDC changes the operating mode to buckmode.
ILS_MIN or IHS_MIN is active.
UHS falls.
ULS rises till ULS > ULS_MIN or UHS < UHS_MIN.
Inadvertent operating-mode-changes from boost- to buckmode can be avoided by setting ILS_MIN
and/or IHS_MIN to zero. (See chapter “Recommended BDC operating settings”)
ULS_MAX [SG_ULS_max]
BDC546
UHS_COM active
ILS_MIN [SG_ILS_min]
Battery 1
Battery 2
UHS_COM [SG_Sollwert]
UHS_MAX [SG_UHS_max]
IHS_MAX [SG_IHS_max]
IHS_MIN [SG_IHS_min]
ILS_MAX [SG_ILS_max]
Low-Side (LS) High-Side (HS)
UHS_MIN [SG_UHS_min]ULS_MIN [SG_ULS_min]
ULS
UHS

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Condition UHS_COM < UHS_MIN
Device in boostmode: BDC regulates UHS_MIN.
Device in buckmode: BDC regulates UHS_COM till UHS < UHS_MIN. Then the BDC regulates on
UHS_MIN as well.
Condition UHS_COM > UHS_MAX
Device in buckmode: BDC regulates UHS_MAX.
Device in boostmode: BDC regulates UHS_COM till UHS > UHS_MAX. Then the BDC regulates on
UHS_MAX as well.

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Other important CAN-signals
[SG_DigOut_Activate]:
Activ high sets AMP_PIN17 to LV_BUS+ (+12V)
Ipeak = 4A (120ms)
Icont. = 200mA
[SG_Activate]:
Activ high, device starts to work (if there is no error).
[BDC_Ready]:
Information if the device is ready or not.
[BDC_Running]:
Information if the device is running or not.
[BDC_Warning] & [BDC_Error]:
Information if the device has been set a warning or an error or not.
[BDC_UHS_min_Lim]:
Information if the UHS_MIN-regulator is active.
[BDC_UHS_max_LIM]:
Information if the UHS_MAX-regulator is active
[BDC_IHS_min_Lim]:
Information if the IHS_MIN-regulator is active.
[BDC_IHS_max_Lim]:
Information if the IHS_MAX-regulator is active.
[BDC_ULS_min_Lim]:
Information if the ULS_MIN-regulator is active.
[BDC_ULS_max_Lim]:
Information if the ULS_MAX-regulator is active.
[BDC_ILS_min_Lim]:
Information if the ILS_MIN-regulator is active.
[BDC_ILS_max_Lim]:
Information if the ILS_MAX-regulator is active.
[BDC_ILS_act]:
Information about the actual low side current value.
[BDC_IHS_act]:
Information about the actual high side current value.
[BDC_ULS_act]:
Information about the actual low side voltage value.
[BDC_UHS_act]:
Information about the actual high side voltage value.
[BDC_ILS_available]:
Derating current.
[BDC_T_max]:
Maximum measured transformer or choke temperature.
[BDC_ULS_act_red] & [BDC_UHS_act_red]:
Redundant low-side- and high-side-voltage measurement.