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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Technical information
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BSC624-12V-B
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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BSC624-12V-B
4
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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BSC624-12V-B
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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BSC624-12V-B
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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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BSC624-12V-B
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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BSC624-12V-B
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!