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

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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:

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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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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

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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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BDC546
14 Instructions for disposal ...............................................................................................79
15 Index................................................................................................................................80
16 Attachments ...................................................................................................................82
16.1 Cable fitting..............................................................................................................................82
16.2 Cable lugs................................................................................................................................86

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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

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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

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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.

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BDC546
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!
These 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
Cooling fluid ejection!
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
Explosive environment!
Danger of death!
Do not store any highly flammable substances or combustible fluids in the direct vicinity of
the device!
Sparks forming at the device's connections can set them on fire and lead to explosions!
CAUTION
Hot surfaces!
Burn hazard!
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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3.3.3 Safety instructions for handling and operation
NOTICE
Damage to the DC/DC converter:
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 BRUSA
Elektronik AG!
Always use an isolation 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 highside or lowside of the DC/DC converter (e.g.: HV
battery), the voltage must be pre-charged by means of a suitable pre-charging device. Refer to
chapter 9.4 Voltage pre-charging.
INFORMATION
The device may be used up to a maximum altitude of 4,000 m above sea level!

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BDC546
3.3.4 Safety instructions for electrical systems
DANGER
High voltage!
Danger of death!
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 bypassed or circumvented! Any resulting malfunctions could
have life threatening consequences!
NOTICE
Never open the device without authorisation! Opening the device (sealed housing) voids any
guarantee and warranty rights immediately!
INFORMATION
When working on an HV grid, the following 5 safety rules must generally be strictly
adhered to:
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 restart.
(if applicable)
Ensure that the device is de-energised by means of a suitable voltage tester (note voltage
range!)
Earth and short-circuit the system.
Cover or seal off adjacent live parts.

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3.4 Safety installations / power limitations
3.4.1 Interlock
The interlock loop is looped through all plug-in device connections to check them for proper connection
(rectangular signal with frequency: 88 Hz ±2 Hz). The BDC546 continuously evaluates the signal from the interlock
loop. If a plug-in connection becomes loose, the BDC546 is immediately switched off. A missing change in polarity
for 9 ms. is regarded as an error.
3.4.2 Pyrofuses
The BDC546 offers two digital inputs/outputs for application in a fuel cell system as follows:
To protect the fuel cell in case of an overvoltage on the lowside, a pyrofuse is provided to disconnect the
connection between the fuel cell and the BDC546. For this, a fuse with a resistance of approx. 2 Ohm can be
applied. The BDC546 offers a digital input/output each for both connection wires from the DC/DC converter to the
fuel cell. It can be connected with one pyrofuse each. The outputs are permanently supplied by the plus wiring
system/terminal 30. For a permissible LS voltage, the input has almost the same potential. In this state, a current of
approximately 20 mA flows through the fuse. This enables detection of correct wiring as well as their state (not
triggered). The signal is evaluated with a frequency of 1.5 kHz through the micro controller.
If the voltage permissible on LS is exceeded, the two inputs are set to the potential of the minus wiring
system/terminal 31. The resulting current flow ignites the pyrofuses and respectively leads to galvanic isolation of
the fuel cell from the converter.

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BDC546
3.4.3 Over temperature protection (derating)
This protective system is a self-protection feature of the BDC546. If the device reaches a defined temperature
threshold, the power rating is reduced (derating) to protect the device from damage caused by overheating. The
maximum permissible lowside current (400 A) will subsequently be reduced in proportion to the temperature
increase until the temperature falls back to the target range. The module and choke temperatures are measured.
Derating is activated if a temperature value of ≥ 95 °C is reached. The power or choke current is now reduced in
stages to a temperature not lower than 115 °C (0 A). This means that the choke current is reduced by 20 A for
every degree temperature increase. If a temperature sensor is defective, derating is activated at temperatures ≥
80 °C for safety reasons, and, correspondingly, the lowside current is reduced to 0 A at a temperature of 100 °C.
3.4.4 HV - Automatic intermediate circuit discharge
The BDC546 is equipped with an active as well as passive feature for discharging the HV circuit. This includes the
highside as well as the lowside. Active intermediate circuit discharge is implemented inherently via an internal HV
supply and cannot be controlled. Passive discharge is achieved by means of 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 < 60 V
within <5 s.
Passive intermediate circuit discharge:
As soon as the device is separated from the HV supply, the internal HV circuits discharge to a value of < 60 V
within <300 s.

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BDC546
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3.5 Requirements regarding the start-up personnel
All courses of action described in this manual may only be carried out by a qualified electrician! Specialist staff are
defined as electricians who possess
professional training,
knowledge and experience in the field of high voltage electronics / electric mobility,
as well as knowledge of the relevant requirements and dangers
which they can demonstrate in practice. 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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BDC546
4 General
4.1 Content and scope of this manual
This documentation provides the reader with an overview of all required operating steps for the installation and
operation of the device and the safety measures necessary for these purposes.
Furthermore, it contains technical data, application information and a basic description of the device and its specific
components.
The operational and safety instructions given are to be adhered to in order to ensure ongoing optimum functioning
of the device and to meet the warranty requirements of BRUSA Elektronik AG.
4.2 Scope of the entire documentation
INFORMATION
To commission the device successfully, the entire set of documentation as well as diverse pieces of
software are required. The provision of the customer package ensures that the docume
ntation and
software are complete and up-to-
date. Specific documents are updated automatically 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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4.3 Scope of delivery
MEANING
QUANTITY
ILLUSTRATION
1.
BDC546-B
1
2.
Protective cap for cooling water connection pieces
2
3.
M8 x 16 screws for the cable lugs
4
4.
M8 washer for M8 x 16 screws
4
5.
M10 x 16 hexagonal screw
(ground GND)
1
6.
M10 washer for M10 x 16 screws
(ground GND)
1
7.
M25 cable fittings
Pflitsch prod. no. 22554e-1814
2
8.
M32 cable fittings
Pflitsch prod. no. 23255e-2520
2
9.
crimp type cable lug, flat (HS), 70 mm²
Ferratec AG / Klauke – 16578
2
10.
crimp type cable lug, flat (LS), 95 mm²
Ferratec AG / Klauke – 16588
2
11.
23-pole control connector with crimp contacts *
AMPSEAL – 770680-1
1
12.
SN/LP contacts
AMPSEAL 770854-1
for wire diameter: 0.5 mm²
28
* customer side connector

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BDC546
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 relevant to the product BDC546.
4.5 Manufacturer contact information
BRUSA Elektronik AG
Neudorf 14
9466 Sennwald
Switzerland
Phone:
[phone] - 00
Fax:
[phone] - 99
Internet:
www.brusa.biz
Email:
[e-mail]

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BDC546
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5 Use and limits of the product
5.1 Proper use
Taking into consideration the limits indicated in chapter 5.2 Improper use / Limits of the product, the product
BDC546 has been designed for the following applications:
Installation in a drive train for hybrid vehicles (cars, utility vehicles, buses)
Installation in a drive train for electric vehicles (cars, utility vehicles, buses)
Installation in a drive train for fuel cell vehicles (cars, utility vehicles, buses)
On-board charger for DC quick charging (in combination with a stationary transformer)
Installation in a drive train for electric boats
Test bench applications
If the device is to be used for applications in areas other than those previously defined, the buyer is obliged to
coordinate these applications with the manufacturer and to obtain a written approval for these uses.
5.2 Improper use / Limits of the product
Applications that do not conform to the conditions and requirements stated in the technical documents and data
sheets of the manufacturer are regarded as improper use. Taking into consideration the proper use indicated in
chapter 5.1 , the following limit values have been stipulated for the operation of the product BDC546. The product
may not be used outside these limit values. Operation outside these limit values can lead to life-threatening
situations.
BDC546-B
UNIT
Highside overvoltage, the switch-off threshold of the power stage can be set up to 800 VDC
Lowside overvoltage, the switch-off threshold of the power stage can be set up to 650 VDC
Max. voltage on highside, no operation, max. 1 min 900 VDC
Max. voltage on highside, no operation, max. 1 min 900 VDC
Max. voltage for signals at the control connector (AUX) 16 VDC
Max. pre charging current on lowside / highside 50 A
Min. coolant temperature at the input -40 °C
Max. coolant temperature at the input 65 °C
Cooling water flow rate max. 17 l/min
Cooling water flow rate min. 15 l/min
Ambient temperature range for storage -40 to +105 °C
Ambient temperature range in operation -40 to +85 °C
Max. cooling system pressure 2.0 bar