Brusa BDC546 Instruction manual

BRUSA Elektronik AG
Neudorf 14
CH–9466 Sennwald
[phone]
[e-mail]
www.brusa.biz
DC/DC converter
BDC546
TECHNICAL DATA
AND START-
UP
Translation of the original German operating instructions

Technical data
and start-up
BDC546
2
L
EGAL NOTICE
Publisher
BRUSA
Elektronik AG
Neudorf 14
CH
–9466 Sennwald
T
[phone]
F +41
8175 809–99
www.brusa.biz
[e-mail]
Date of issue
10
. Oct. 2016
Copyright
©
2013
The content of this document may not be passed on to third parties without the written authorisation
of the company
BRUSA Elektronik AG -
including extracts thereof. All technical information,
drawings and photos used in this document are protected by copyright and any infringement
constitutes a punishable offence!
Updates
Due to the ongoing technical development of our products, we reserve the right to make changes to
their designs. Any changes will be disclosed in individual manuals by replacing relevant pages
and/or revising electronic data storage devices.
Writer/Author
Manuel Tschumper
REVISIONS
REVISION
DATE
NAME
CHANGE
01
24th Feb.
2014
M.Tschumper
Document issued
02
24th Feb.
2014
M.Tschumper
List of parameters translation
03
25th June
2014
M. Schiedermeier
Switching frequency, HS current limited, clock frequency is
new switching frequency (Side 21)
04
30th Oct.
2014
J. Pitschi
Integration of cable length
05
30th April
2015
J. Pitschi
Update ULS to 600V
06
16.07.2016
A. Girod
5. information “evaluation kits”
07
25.10.2016
M. Gern
Validity B05 (OEM Version), 5. “information removed”
08
23.11.2016
A. Girod
13. Warranty new

3
Technical data
and start-up
BDC546
VALIDITY
This manual is only valid for the devices listed in the following table:
BDC546-B04
BDC546-B05 (OEM Version)
BDC546-B06
The breakdown of the device designation is as follows:

Technical data
and start-up
BDC546
4
TABLE OF CONTENTS
1Foreword..............................................................................................................................8
2List of abbreviations ...........................................................................................................8
3Safety and warning instructions........................................................................................9
3.1 Symbols and their meaning........................................................................................................9
3.2 Safety instructions and danger levels.......................................................................................10
3.3 Generally applicable safety measures......................................................................................11
3.3.1 Safety instructions for cooling water systems....................................................................11
3.3.2 Safety instructions for mechanical systems.......................................................................11
3.3.3 Safety instructions for handling and operation...................................................................12
3.3.4 Safety instructions for electrical systems...........................................................................13
3.4 Safety installations / power limitations......................................................................................14
3.4.1 Interlock ............................................................................................................................14
3.4.2 Pyrofuses..........................................................................................................................14
3.4.3 Over temperature protection (derating)..............................................................................15
3.4.4 HV - Automatic intermediate circuit discharge...................................................................15
3.5 Requirements regarding 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 Scope of delivery......................................................................................................................18
4.4 Applicable standards................................................................................................................19
4.5 Manufacturer contact information.............................................................................................19
5Use and limits of the product...........................................................................................20
5.1 Proper use................................................................................................................................20
5.2 Improper use / Limits of the product .........................................................................................20
6About this device...............................................................................................................21
6.1 Technical data..........................................................................................................................21
6.2 Technical properties.................................................................................................................23
6.3 BDC546 block diagram ............................................................................................................23
6.4 Basic function / EMC concept...................................................................................................24

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Technical data
and start-up
BDC546
6.4.1 Topology benefits..............................................................................................................24
6.4.2 Filter concept for highside and lowside..............................................................................25
6.5 Warnings on the device............................................................................................................26
6.6 Vehicle installation basic principle............................................................................................27
6.7 Safety concept for vehicle installation.......................................................................................28
6.7.1 General interlock function..................................................................................................28
6.8 Interlock signal.........................................................................................................................29
6.9 Overview of the main structural components............................................................................30
6.10 Dimensions and installation information ...................................................................................31
6.10.1 Fastening points................................................................................................................31
6.10.2 Dimensions .......................................................................................................................32
6.10.3 Installation position............................................................................................................32
6.11 Type plate ................................................................................................................................33
7Electrical interfaces...........................................................................................................34
7.1 Control connector pin assignment (device side).......................................................................35
7.1.1 Pin 1 GND.........................................................................................................................36
7.1.2 Pin 2 AUX .........................................................................................................................37
7.1.3 Pin 6 TXD, pin 7 RXD, pin 8 P_GND.................................................................................38
7.1.4 pin 9 CNL, pin 10 CNH......................................................................................................39
7.1.5 Pin 11 PFO_VC+, pin 12 PFI_VC+, pin 14 PFO_VC-, pin 15 PFI_VC-..............................40
7.1.6 Pin 13 PRO.......................................................................................................................41
7.1.7 Pin 16 EN..........................................................................................................................42
7.1.8 Pin 17 DO_MC..................................................................................................................43
7.1.9 Pin 19 IL............................................................................................................................44
7.2 Earthing / grounding screw (equipotential bonding)..................................................................45
7.3 Highside and lowside power connections.................................................................................46
8Connections.......................................................................................................................48
8.1 Control connector.....................................................................................................................48
8.2 Highside cable..........................................................................................................................49
8.3 Lowside cable ..........................................................................................................................50
8.4 Cooling water connections .......................................................................................................51
9Installation / initial start-up...............................................................................................52
9.1 Installation and connection of the DC/DC converter .................................................................52

Technical data
and start-up
BDC546
6
9.2 Building the HV wiring ..............................................................................................................55
9.3Ventilating the cooling system..................................................................................................58
9.4 Voltage pre-charging................................................................................................................59
10 Parameterization and operation....................................................................................61
10.1 Parameterization by means of PARAM tool..............................................................................61
10.1.1 PARAM application ...........................................................................................................61
10.1.2 Installation and operation of the PARAM software.............................................................62
10.2 Parameters...............................................................................................................................63
10.2.1 Parameter representation..................................................................................................63
10.2.2 Parameter groups .............................................................................................................64
10.2.3 [01] CAN Configuration - CRC...........................................................................................66
10.2.4 [02] Device Configuration – CRC.......................................................................................67
10.2.5 [09] FW Gains, Offset – CRC ............................................................................................68
10.2.6 [0A] FPGA Gains, Offsets and Settings – CRC .................................................................68
10.2.7 [10] Digital IO ....................................................................................................................69
10.2.8 [11] Analog Input...............................................................................................................69
10.2.9 [12] Analog Values calculated and Offsets........................................................................70
10.2.10 [13] PWM Input..............................................................................................................70
10.2.11 [20] Status .....................................................................................................................70
10.2.12 [22] Temperatures .........................................................................................................71
10.2.13 [23] Stored App Data .....................................................................................................71
10.2.14 [23] Stored App Data.....................................................................................................72
10.2.15 [31] General Parameters................................................................................................73
10.2.16 [32] Revision Info...........................................................................................................73
10.3 DC/DC converter operation......................................................................................................74
10.4 Brusa CVI.................................................................................................................................75
10.4.1 CVI software installation....................................................................................................75
10.4.2 CVI operation....................................................................................................................76
11 Firmware update ............................................................................................................77
11.1 FDT installation and firmware download instructions................................................................77
11.2 Additional information for firmware download...........................................................................77
12 Troubleshooting.............................................................................................................78
13 Warranty..........................................................................................................................78

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Technical data
and start-up
BDC546
14 Instructions for disposal ...............................................................................................79
15 Index................................................................................................................................80
16 Attachments ...................................................................................................................82
16.1 Cable fitting..............................................................................................................................82
16.2 Cable lugs................................................................................................................................86

Technical data
and start-up
BDC546
8
1 Foreword
Dear customer,
By purchasing the BRUSA BDC546, you have chosen an efficient and versatile product. As this device is a high-
performance electronics product which uses dangerous levels of voltage and current, special expertise with respect
to handling and operation is required!
Before installing the device or carrying out any other work on it, this manual – in particular chapter 3 Safety and
warning instructions – is to be read thoroughly.
2 List of abbreviations
Throughout this manual, some specific technical abbreviations are used. You will find an overview of these
abbreviations as well as their meanings in the following table:
ABBR.
MEANING
ABBR.
MEANING
BDC
Bidirectional High Power DC/DC
Converter
FC
Fuel Cell
CAN
Controller Area Network
VC
Traction intermediate circuit
HV
High Voltage
PDU
Power Distribution Unit
HS
Highside (higher of the two HV potentials
of the DC/DC converter)
BMS
Battery Management System
LS
Lowside (lower of the two HV potentials of
the DC/DC converter)
FCC
Fuel Cell Converter

9
Technical data
and start-up
BDC546
3 Safety and warning instructions
This chapter contains safety instructions applying to this device. These instructions refer to the 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, a variety of symbols are used. For an overview of symbols as well as their meanings, refer
to the following table:
Prohibition symbols
SYMBOL
MEANING
SYMBOL
MEANING
General prohibition
Warning! High voltage!
Do not touch!
Do not switch!
Warning symbols
SYMBOL
MEANING
SYMBOL
MEANING
General hazard warning
Warning! Danger caused by suspended
loads!
Warning! Explosive environment!
Warning! Danger caused by batteries!
Warning! Hot surface!
Warning! High voltage!
Warning! High pressure/fluid ejection!
Warning! Fire hazard!
Mandatory signs
SYMBOL
MEANING
SYMBOL
MEANING
Disconnect device from voltage Disconnect device from mains
Wear protective glasses Wear protective gloves
Information signs
SYMBOL
MEANING
SYMBOL
MEANING
Important information on avoiding possible
damage to property
Important information

Technical data
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BDC546
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3.2 Safety instructions and danger levels
DANGER
This notice is a warning against serious, irreversible risks of personal injury with possibly
fatal consequences!
Avoid these risks by observing this notice!
WARNING
This notice is a warning against serious but reversible risks of injury!
Avoid these risks by observing this notice!
CAUTION
This notice is a warning against a minor risk of injury!
Avoid these risks by observing this notice!
NOTICE
This notice is a warning against possible damage to property if the following instructions and work
procedures are not observed.
INFORMATION
This type of notice discloses important information to the reader.