Brusa BSC624-12V-B Series Manual

BRUSA Elektronik AG
Neudorf 14
CH–9466 Sennwald
[phone]
[e-mail]
www.brusa.biz
DC/DC converter
BSC624-12V-B
TECHNICAL INFORMATION
AND START-
UP
Translation of the original German operating instructions

Technical information
and start-up
BSC624-12V-B
2
L
EGAL NOTICE
Publisher
BRUSA
Elektronik AG
Neudorf 14
CH
–9466 Sennwald
T +41
8175 809–00
F +41
8175 809–99
www.brusa.biz
[e-mail]
Date of issue
06
. Dezember 2012
Copyright
©
2012
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. All technical information, drawings and
photos used in this document are protected by copyright and any infringement constitutes a
punishable offence!
Updates
In light of the further technical development of our products, we reserve the right to make
constructional changes. Any changes will be disclosed in the relevant manuals through the
replacemen
t of the relevant pages and/or a revision of the electronic data storage device.
Originator / author
Holger Schmidt
REVISIONS
Revision
Date
Name
Change
01 05.02.2013 HS Kleine Optimierungen ÜM
02 30.09.2013 MT 6.7 Grafik Sicherheitskonzept
03 28.04.2014 RB Optimierungen ÜM, Versionserhöhung
04 16.10.2014 JP Update of the interlock bridge and CVI installation
05 16.07.2016 AG 5. Information new
06 28.11.2016 AG 13. Warranty new

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VALIDITY
This manual is only valid for the devices listed in the following table:
BSC624-12V-B01
BSC624-12V-B02
BSC624-12V-B03
BSC624-12V-B04
BSC624-12V-B05
BSC624-12V-B06
BSC624-12V-B07
The decoding of the device designation is as follows:

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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 Short-circuit protection ......................................................................................................13
3.4.2 Interlock ............................................................................................................................13
3.4.3 Overload protection – derating ..........................................................................................14
3.4.4 HV – Overvoltage shut-down.............................................................................................15
3.4.5 LV – Overvoltage shut-down .............................................................................................16
3.4.6 HV – Undervoltage shut-down...........................................................................................16
3.4.7 LV – Undervoltage shut-down ...........................................................................................16
3.4.8 HV – Automatic discharge.................................................................................................16
3.5 Requirements to the start-up personnel....................................................................................17
4General...............................................................................................................................18
4.1 Content and scope of this manual............................................................................................
18
4.2 Scope of the entire documentation...........................................................................................18
4.3 Scope of delivery......................................................................................................................19
4.4 Applicable standards................................................................................................................20
4.5 Contact information of the manufacturer...................................................................................20
5Use and limits of the product...........................................................................................21
5.1 Proper use................................................................................................................................21
5.2 Improper use / limits of the product ..........................................................................................21
6About this device...............................................................................................................22
6.1 Technical data..........................................................................................................................22

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6.2 Technical properties.................................................................................................................25
6.3 Block diagram BSC624-12V-B .................................................................................................25
6.4 Basic function / EMC concept...................................................................................................26
6.4.1 Topology benefits..............................................................................................................26
6.4.2 Internal current supplies....................................................................................................27
6.4.3 LV filter concept ................................................................................................................28
6.4.4 HV filter concept................................................................................................................29
6.4.5 AUX filter concept .............................................................................................................30
6.5 Warnings on the device............................................................................................................31
6.6 Vehicle installation basic principle............................................................................................32
6.7 Safety concept vehicle installation............................................................................................33
6.7.1 Principle of operation Interlock ..........................................................................................33
6.8 Overview of the main structural components............................................................................34
6.9 Dimensions and installation information ...................................................................................35
6.9.1 Fixing points......................................................................................................................35
6.9.2 Dimensions .......................................................................................................................36
6.9.3 Installation position............................................................................................................36
7Electrical interfaces...........................................................................................................38
7.1 Pin assignment of control connector (device side)....................................................................39
7.1.1 Pin 1 GND.........................................................................................................................40
7.1.2 Pin 2 AUX .........................................................................................................................41
7.1.3 Pin 3 EN............................................................................................................................42
7.1.4 Pin 4 DO0 – pin 7 DO3......................................................................................................43
7.1.5 Pin 8 PG1, pin 14 PG2, pin 15 PG3 ..................................................................................44
7.1.6 Pin 9 CNL, pin 10 CNH .....................................................................................................44
7.1.7 Pin 11 TXD, pin 12 RXD....................................................................................................45
7.1.8 Pin 13 PRO.......................................................................................................................46
7.1.9 Pin 16 DI0, pin 17 DI1, pin 18 DI2.....................................................................................46
7.1.10 Pin 19 IL1, pin 20 IL2 ........................................................................................................47
7.1.11 Pin 21 AI1, pin 22 AI2, pin 23 AI3......................................................................................49
7.2 Pin assignment of HV power connector (device side)...............................................................50
7.3 Pin assignment of LV power connector (device side) ...............................................................50
8Connections.......................................................................................................................51

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8.1 Control connector.....................................................................................................................51
8.2 HV power connector.................................................................................................................52
8.3 LV power connector .................................................................................................................53
8.4 LV- / PGND (power ground).....................................................................................................54
8.5 Cooling system.........................................................................................................................55
9Installation / initial start-up...............................................................................................56
9.1 Producing the cable glands for the HV power connector ..........................................................59
9.2 Ventilating the cooling system..................................................................................................64
9.3 Voltage pre-charging................................................................................................................65
10 Operation........................................................................................................................67
10.1 Installation and operation of the PARAM software....................................................................67
10.2 CVI software installation...........................................................................................................67
10.3 Operation of the device ............................................................................................................68
10.4 Operation in the CAN-less mode (automatic mode)..................................................................69
11 Firmware update ............................................................................................................73
11.1 System requirements ...............................................................................................................73
11.2 Installation Flash Development Toolkit.....................................................................................73
11.3 Preparing measures.................................................................................................................76
11.4 Executing the firmware update.................................................................................................77
12 Troubleshooting.............................................................................................................81
13 Warranty..........................................................................................................................81
14 Instructions regarding disposal....................................................................................82
15 Index................................................................................................................................83

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1 Foreword
Dear customer
With the BRUSA BSC624-12V-B, you have purchased a very high performance and versatile product. As the
present device is a high-performance electronics product which uses dangerous voltages and currents, special
expertise in handling and operation are required!
Before installing the device or carrying out any other work on it, this manual – in particular the chapter Safety and
warning instructions – is to be read thoroughly.
2 List of abbreviations
Throughout this manual, some specific technical abbreviations are used. The following table provides an overview
of these abbreviations and their meaning:
Abbr. Meaning Abbr. Meaning
BMS
Battery Management System
HW
Hardware
BSC
Bi-directional Supply Converter
LV
Low Voltage
CAN
Controller Area Network
PDU
Power Distribution Unit
EMC
Electro-Magnetic Compatibility
SMD
Surface Mounted Device
HF
High Frequency
SW
Software
HV
High Voltage

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3 Safety and warning instructions
In this chapter, you will find safety instructions applying to this device. These instructions refer to the assembly,
start-up and the 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 symbols are used. The following table provides an overview of
these symbols and their meaning:
Prohibition signs
Symbol Meaning Symbol Meaning
General prohibition Warning! High voltage!
Do not touch
Do not switch
Warning signs
Symbol Meaning Symbol Meaning
General warning of a dangerous area Warning! Danger due to 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 power supply Disconnect device from mains supply
Wear protective glasses Wear protective gloves
Information signs
Symbol Meaning Symbol Meaning
Important information on avoiding possible
property damage
Important information

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3.2 Safety instructions and danger levels
DANGER
This instruction warns about severe irreversible risks of personal injury with fatal
consequences.
Avoid this risk by adhering to this instruction!
WARNING
This instruction warns about the risk of severe but reversible injury!
Avoid this risk by adhering to this instruction!
CAUTION
This instruction warns about a minor risk of injury!
Avoid this risk by adhering to this instruction!
INSTRUCTION
This instruction warns about possible property damage if the following instructions and work
procedures are not adhered to.
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
incomplete as they can be supplemented by local and/or country-specific safety instructions and guidelines for
accident prevention.
The system integrator and/or distributor of the device must therefore supplement the present general safety
instructions by country-specific 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 to life!
Do not store any highly flammable substances or combustible fluids in the direct surroundings of
the device!
Sparks forming 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! 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
INSTRUCTION
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 the company
BRUSA Elektronik AG.
Always use an insulation 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 HV side of the DC converter (e.g.: HV battery), the
voltage must be pre-charged via a suitable pre-charging device,
see chapter 9.3 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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3.3.4 Safety instructions for electrical systems
DANGER
High voltage!
Danger to life!
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 by-passed or circumvented! Any resulting malfunctions could
have life threatening consequences!
INSTRUCTION
Never open the device without authorisation! The opening of the device (sealed housing) directly
leads to the forfeiture of any guarantee and warranty rights!
INFORMATION
When working on a HV grid, the following 5 safety instructions have to 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 restarted.
(if applicable)
Ensure that the device is de-energised by means of a suitable voltage tester (note voltage
range!)
Ground 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 Short-circuit protection
Since, due to its resonant clock topology, the transformer stage has a certain internal resistance, the device is
generally short-circuit proof. In the case of an external short-circuit (caused by the operator), this means that the
voltage breaks down while the signal E_LV_UNDERVOL is emitted.
In the buck mode, undervoltage is identified on the LV side in the case of a short-circuit.
In the boost mode, undervoltage is identified on the HV side in the case of a short-circuit.
Independent of the operating mode, undervoltage is also identified at the respective power input.
3.4.2 Interlock
INSTRUCTION
In order to guarantee the function of the interlock, for the cable bridge (1) in the HV power connector
it is not allowed to use another cable then the delivered. The cable has to prepare
according the
manual chapter 9.1 Producing the cable glands for the HV power connector.
With this safety installation, the proper connection of the connectors on the device is monitored. The device
comprises an internal as well as an external interlock identification, which function independently of each other. An
interruption of the interlock circuit causes an immediate shut-down of the device. In order to use the external
interlock identification, the respective interlock pins must be connected at the control connector and the error
detection must be activated (for details, please refer to the PARAM manual). With a shut-down of the device, the
signal CRE_INTERLOCK is emitted.
The internal interlock identification monitors the HV power connector exclusively and is always active. The optional
external interlock identification is an interlock loop, which is ideally looped through all HV components in the
vehicle. The interlock signal must be generated and analysed respectively via an upstream control unit (e.g.
BRUSA PDU254).
Further information on the interlock can be found in chapter 7.1.10 Pin 19 IL1, pin 20 IL2

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3.4.3 Overload protection – derating
This safety installation is a self-protection feature of the DC/DC converter. If the device reaches a defined
temperature threshold, this reduces the power rating (derating) to protect the device from damage caused by
overheating. Consequently, the maximum possible current is reduced proportionally to the temperature increase in
order to avoid a further rise in the temperature.
Via the CAN interface, the currently transferable current LVCUR_AVL is reported back. Here, it can be identified
whether or not the device is in the derating mode.
A total of 8 temperature sensors are installed to measure the temperature. These sensors are divided into 4
measuring groups:
Installation position / measuring point Number of temp. sensors Active regulation max. current
Switches buck / boost converter 2 no
Switches HV side transformer stage 2 yes
Switches LV side transformer stage 2 yes
Winding HF power transformer 1 + 2
1 each
yes
Switches buck / boost converter
Since very low losses occur at the switches of the buck
/
boost converter and an extremely efficient cooling
predominates, these measuring values only show slightly increased values regarding the cooling liquid
temperature. For this reason, these measuring values provide information on the actual ambient temperature in the
device. Generally, the device shuts down when the temperature of the switches of
the buck /
boost converter is
>/=
81°C. If this temperature falls to </=
80°C, the device is 100% operable again. Here, no derating occurs but a
direct shut
-down of the device. With a shut-down of the device, the signal E_OVERTEMP is emitted.

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Windings of the HF power transformers
If the temperature at the windings of the HF power transformers reaches >/= 106°C, the current is reduced
successively to a temperature value of < 131°C.
At >/= 131°C, the device shuts down.
If the temperature falls to </= 129°C, the device is operable again with reduced power according to the
derating diagram.
With a shut-down of the device, the signal E_OVERTEMP is emitted.
Transformer stage switches
If the temperature at the transformer stage switches reaches >/= 95°C, the current is reduced successively to
a temperature value of >/= 120°C .
At >/= 120°C, the device shuts down.
If the temperature falls to < 120°C, the device is operable again with reduced power according to the derating
diagram.
With a shut-down of the device, the signal E_OVERTEMP is emitted.
3.4.4 HV – Overvoltage shut-down
The device provides the following possibilities for identifying an overvoltage at the HV side:
Rapid HW overvoltage identification (immediate shut-down of the device if voltage > 470 V)
Slow SW overvoltage identification (shut-down of the device if voltage > 456 V; automatic reactivation if
voltage < 454 V)
With a shut-down of the device, the signal E_HV_OVERVOL is emitted.

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3.4.5 LV – Overvoltage shut-down
The device provides the following possibilities for identifying an overvoltage at the LV side:
Rapid HW overvoltage identification (immediate shut-down of the device if voltage > 20 V)
Slow SW overvoltage identification (shut-down of the device if voltage > 16.4 V; automatic reactivation if
voltage < 16.2 V)
With a shut-down of the device, the signal E_LV_OVERVOL is emitted.
3.4.6 HV – Undervoltage shut-down
The device provides the following possibilities for identifying undervoltages at the HV side:
Immediate shut-down of the device if HV voltage < 215 V
This error identification is deactivated for 3 s when starting the device in the boost mode. With a shut-down of
the device, the signal E_HV_UNDERVOL is emitted.
3.4.7 LV – Undervoltage shut-down
The device provides the following possibilities for identifying undervoltages at the LV side:
Immediate shut-down of the device if LV voltage < 7 V
This error identification is deactivated for 5 s when starting the device in the buck mode. With a shut-down of
the device, the signal E_LV_UNDERVOL is emitted.
3.4.8 HV – Automatic discharge
The device has an active as well as a passive intermediate circuit discharge. The active intermediate circuit
discharge is implemented inherently via the internal HV supply and thus cannot be controlled. The passive
intermediate circuit discharge is implemented via 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 < 50 V
within 350 ms.
Passive intermediate circuit discharge:
As soon as the device is separated from the HV, the internal HV circuits discharge to a value of < 50 V within
120 s.

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3.5 Requirements to the start-up personnel
All courses of action described in this manual may only be carried out by a qualified electrician! Specialist staffs are
defined as electricians with
professional training,
knowledge and experience in the field of high voltage electronics / electric mobility,
as well as knowledge of the relevant requirements and dangers
for which they can provide proof. 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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4 General
4.1 Content and scope of this manual
The present 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 the 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 documentation as well as diverse software are
required. With the provision of the
customer package, it is ensured that the documentation and
software 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:
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
Pieces
Illustration
1.
DC/DC converter BSC624-12V-B
1
2.
23 pole control connector with crimp contacts *
AMPSEAL 770680-1
1
3.
SN/LP contacts
AMPSEAL 770854-1
for wire diameter: 0.5 mm
2
25
4.
Harting high voltage connector set HAN-Modular Compact: *
Straight connector housing HAN-Modular Compact
Carrier housing HAN-Modular Compact
Socket insert HAN CC
4 mm2crimp contact socket (4 pieces)
Cable gland HSK-M-EMV M25 x 1.5 for cable diameters 9 - 16 mm
6 cm x 4 mm2cable (interlock bridge)
1
5.
Low voltage connector set: *
Positive pole connector housing for 50 mm2cable
MC contact SP10AR-N/50
O-ring
M3 x 5 threaded pin
M8 / 50 mm2straight cable lug for 12 V ground connection
M8 / 50 mm2angled cable lug for 12 V ground connection
1
6.
Protective cap for cooling water connection pieces
2
* customer side connector

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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 and relevant to the product BSC624-12V-B.
4.5 Contact information of the manufacturer
BRUSA Elektronik AG
Neudorf 14
9466 Sennwald
Switzerland
Phone:
[phone] - 00
Fax:
[phone] - 99
Internet:
www.brusa.biz
E-mail:
[e-mail]