DTI HV-500 User manual

Drivetrain Innovation kft.
Eötvös Károly street 32.
H-2750 Nagykőrös
Hungary, EU
[e-mail]
www.drivetraininnovation.com
HV-500 SERIES HIGH POWER INVERTER
User manual for HV-500
Version 2.2
Please read the user manual carefully before using the controller! Electrical
systems can cause danger to humans, property and nature; therefore,
precautions shall be taken to avoid any risk.

HV-500 USER MANUAL
Version: 2.2 2
Table of contents
1. History and related documents ............................................................................ 4
1.1 Document history ........................................................................................... 4
2. Liability and safe use of this unit .......................................................................... 5
2.1 Discharge ...................................................................................................... 6
3. Warning sign explained ....................................................................................... 7
4. Overview ............................................................................................................. 8
4.1 Main features of the HV-500 .......................................................................... 8
4.2 Distinction of HV-500 models ........................................................................ 9
4.3 Name plate explained .................................................................................... 9
4.4 Technical specifications ............................................................................... 10
4.4.1 DC characteristics ................................................................................. 10
4.4.2 AC characteristics ................................................................................. 10
5. Thermal and mechanical specification ............................................................... 11
6. HV-500ACx Air COOLING Parameters ............................................................. 12
7. HV-500LCX Liquid cooling connection .............................................................. 13
8. Power losses ..................................................................................................... 14
9. System Efficiency .............................................................................................. 15
10. HV-500LCN-Mechanical drawings .................................................................. 16
11. Compatible motor position sensors ................................................................. 18
12. Compatible motors .......................................................................................... 19
13. Electrical Connections .................................................................................... 20
13.1 Harness connector pinout (H) (Inverter side) ........................................... 20
13.2 Motor sensor connector pinout (M)........................................................... 21
13.3 HALL sensor ............................................................................................ 22
13.4 High power connection ............................................................................. 22
13.5 Case grounding ........................................................................................ 23

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Version: 2.2 3
14. PC connection and control .............................................................................. 24
14.1 DTI Tool ................................................................................................... 24
14.2 Firmware update ...................................................................................... 24
15. Wiring the controller ........................................................................................ 25
15.1 Overview .................................................................................................. 25
15.2 Harness connector wiring ......................................................................... 25
15.2.1 CAN Wiring ........................................................................................... 27
15.3 Electrical connection schematics ............................................................. 28
15.4.1 Input supply ....................................................................................... 28
15.3.2 Analog input ....................................................................................... 28
15.3.3 Digital input ........................................................................................ 28
15.3.4 Digital output ...................................................................................... 28
15.3.5 CAN peripheral .................................................................................. 29
15.3.6 RS 232 peripheral .............................................................................. 29
15.4 Minimal system schematic ....................................................................... 30
16. List of tables .................................................................................................... 31
17. List of figures .................................................................................................. 32

HV-500 USER MANUAL
Version: 2.2 4
1. HISTORY AND RELATED DOCUMENTS
1.1 Document history
07/2018
V1.0
Document created; basic specifications added.
01/2019 V1.1 User interface. Digital I/O and low power wiring
diagrams added
03/2019
V1.2
Added efficiency measurement graphs
04/2019
V1.3
High voltage wiring description
08/2019
V1.4
Added instructions for
Inverter
case
grounding
11/2019
V2.0
Updated connectors and raised voltage range
08/2020 V2.2 Actualization, introducing uniformized datasheets, fixed
typos,
HV-500 variants diversified
Added
information about active air
-
cooled fans.
1.2 Related documents
 DTI HV-500 Interlock manual
 DTI HV-500 CAN manual
 DTI Tool User manual
 DTI Motor setup manual
 DTI Firmware update manual
 DTI Resolver interface manual
 DTI Encoder splitter manual
 SurLok Connector manuals

HV-500 USER MANUAL
Version: 2.2 5
2. LIABILITY AND SAFE USE OF THIS UNIT
DTI Controller hardware, DTI Tool and the DTI
firmware are experimental products designed to
develop and test electrical systems incorporating
electric motors or actuators. Electrical systems can
cause danger to humans, property and nature;
therefore, precautions shall be taken to avoid any risk.
Under no circumstances shall the device be used
where humans or property are put to risk without thoroughly validating and testing the
whole system. Software and hardware interact in various ways, and developers cannot
foresee all possible combinations of hardware used together with software, nor
problems that can occur in these different combinations. Tool and the DTI firmware are
experimental software designed to develop and test. Electrical systems can cause
danger to humans, property and nature; therefore, precautions shall be taken to avoid
any risk.
Things that can happen, even when using the correct settings, are
 electrical failure
 fire
 electric shock
 hazardous smoke
 overheating motors and actuators
 overloaded power sources, causing fire or explosions (e.g. Lithium Ion
Batteries)
 motors or actuators stopping from spinning/moving
 motors or actuators locking in, acting like a brake (full stop)
 motors or actuators losing control over torque production (uncontrolled
acceleration or braking)
 interferences with other systems
 other non-intended or unforeseeable behaviour of the system
DTI Tool and the DTI firmware are developer tools that for safety reasons may only be
used
 by experts and experienced users, knowing exactly what they do.
 following safety standards applicable in the area of usage.
 under safe conditions where software or hardware malfunction will not lead to
death, injuries or severe property damage.

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 keeping in mind that software and hardware failures can happen. We can't give
any warranty because every system is unique and we cannot make sure its
safety. Although we design our products to minimize such issues, you should
always operate with the understanding that a failure can occur at any point of
time and without warning. As such, you shall take the appropriate precautions
to minimize danger in case of failure.
DTI does not assume any responsibility for difficulties, which are the result of
inappropriate configuration, electric system structure and settings that are not in
accordance with the latest version of the manual for DTI inverters.
Every inverter is being tested before shipping. DTI assumes no liability in case a
customer uses components for the purposes for which they have not been developed
or tested.
DTI reserves the right to change any information included this manual. All connection
circuitry described is meant for general information purposes and is not mandatory.
DTI does not assume any liability, expressively or inherently, for the information
contained in this manual, for the functioning of the device or its suitability for any
specific application.
2.1 Discharge
The Inverter has internal discharge resistors. The discharge time after powering off
the high voltage system is 5 minutes. The resistance is 188kΩ.

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Version: 2.2 7
3. WARNING SIGN EXPLAINED
The Warning sign contains the most important safety notices that has to be taken into
consideration by everyone who approaches the inverter. The sign cannot be removed
from the inverter and cannot be covered.
In case of the sign is being damaged, or detached from the inverter, please get in touch
with DTI as soon as possible at the availability mentioned on the cover page.
Figure 1. Safety note
Table 1. Safety notes explained
Description
Please read this manual carefully, with particular regard to safety
notes.
Danger of electric shock!
Touching HV wires and HV connectors are prohibited without
ensuring that the HV is disconnected.
Danger of high voltage
The device is attached to high voltage.
Danger of hot surfaces
The inverter case, and /or the coolant fluid can get hot during and
after operation, touching any of these can cause burn damage.
General Warning
Only trained and educated personnel can do integration and
maintenance.

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Version: 2.2 8
4. OVERVIEW
4.1 Main features of the HV-500
 Sensored FOC motor control
 Analog and digital inputs for control
 CAN (ISO 11898-2)
 UART communication
 Duty-cycle, speed or torque control
 Regenerative braking
 Hand brake function
 Motor angle positioning
 Motor sensors: UVW Hall sensors, SSI, resolver or ABI encoder
 Hardware and Software overcurrent and overvoltage protection
 Undervoltage limitation and protection
 IGBT and motor overtemperature protection
 Encoder wire damage protection
 Maximum motor speed limitation
 Maximum power limitation
 DC and AC current limitation
 Different setup for reverse operation
 Adjustable non-linear or linear analogue input characteristics
 Double redundant throttle input
 Adjustable reverse switch or centralized analogue input for reverse operation
 Simplified motor setup for perfect current control

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Version: 2.2 9
4.2 Distinction of HV-500 models
Figure 2. Distinction of HV-500 models
 Active air-cooled variants include two high power fans along with a carbon
plate for the air conduction through the integrated heatsink.
 Passive air-cooled variants include only an integrated heatsink.
4.3 Name plate explained
Figure 3. HV-500 Nameplate
Table 2. HV-500 Nameplate explained
No. Description No. Description
1. Manufacturer information 7. Product net weight
2. Inverter Type 8. Input voltage rating
3. Part Number 9. Input DC current rating
4. Serial Number 10. Maximum Power output
5. Manufacturing date 11. Maximum Peak- to- Peak Current
6. IP Protection rating 12. Maximum working temperature
12
11
10
9
8
7
6
5
4
3
2
1

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Version: 2.2 10
4.4 Technical specifications
4.4.1 DC characteristics
Table 3. DC Characteristics
Value Unit
Low voltage input range 9 – 28 V
Low voltage maximum input current 2 A
Maximum voltage on digital outputs 28 V
Maximum current on digital outputs 240 mA
Maximum input voltage on digital inputs 28 V
Logical LOW voltage on digital inputs ≤ 1 V
Logical HIGH voltage on digital inputs ≥ 2 V
High voltage input range 200 – 800 V
High voltage absolute maximum input voltage 830 V
High voltage maximum input current 350 A
DC link capacitor 200 μF
DC link capacitor internal discharge time 5 Min
4.4.2 AC characteristics
Table 4. AC Characteristics
Value Unit
Continuous AC current (peak-to-peak current)1 400 Apk-pk
Maximum AC current for short period (peak-to-peak current)2 500 Apk-pk
Maximum AC current for short period (RMS)3 350 ARMS
Switching frequency 8 – 14 kHz
Maximum power dissipation 6000 W
Maximum electric RPM4 100 000 eRPM
Typical efficiency 95 %
1 The continuous AC current can only be delivered if the cooling system conditions are match the
description of the user manual.
2 The maximum AC current period is depending on the cooling system.
3 The maximum AC current period is depending on the cooling system.
4 100 000 ERPM means 10 000 RPM on a 10-pole pair motor