Vanner HBA400 Series User manual

VANNER Incorporated Owner’s Manual
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
1
High Voltage DC-DC Converter
HBA (Hybrid Beltless Alternator)
Table of Contents
Introduction………………………………………………….………………… 3
Specifications…………………………………………………….………….… 4
Operation……………...………………………………………………………. 6
Installation Instructions…………………………...…………….……………. 8
Testing and Troubleshooting………………………………………………… 15
Vann-Bus Battery Management………....………..………………………… 20
Dual HBA System…………………………………..………………………… 24
CAN Bus Specification……………………………..………………………… 27

VANNER Incorporated Owner’s Manual
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
2
Notes

VANNER Incorporated Owner’s Manual
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
3
Introduction
Thank you for purchasing Vanner’s High Voltage DC-DC Converter. We are confident that you will be
very pleased with its performance because Vanner products are designed and manufactured by skilled
professionals using the highest standards in workmanship. With minimum maintenance and care, you can
be assured of many years of trouble free service.
General Description
The Vanner High Voltage DC-DC Converter (commonly referred to as HBA in this document) is an
efficient and highly reliable method of converting high dc voltage present in hybrid drive systems to low dc
voltage (24V) for auxiliary batteries and loads. The converter is designed to be a direct replacement for a
belt driven alternator to increase reliability and reduce maintenance costs.
The converter is J1939 CAN (Controller Area Network) enabled and is fully configurable and controllable
over a J1939 compliant network but is also capable of autonomous operation. The converter is designed
to monitor and report the status of several critical functions and provides real-time fault signals over the
CAN bus to the vehicle electrical system controller.
A typical system includes a high voltage energy source (500 –780VDC), a Vanner HBA and a low
voltage battery bank for auxiliary loads. The HBA is provisioned with a two pin sealed connector for
integration into the vehicle’s high voltage interlock system and a fourteen pin sealed circular connector for
CAN and vehicle I/O.
Paralleling: The outputs of two HBA's may be connected in parallel to double the output capacity of the
24V charging system. Please contact Vanner engineering and/or sales for the appropriate HBA model
number for your dual application.

VANNER Incorporated Owner’s Manual
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
4
Specifications
High Voltage DC-DC Converter
Model Numbers (250kbps)
HBA400-* and EBA400-*
HBA500-* and EBA500-*
Model Numbers (500kbps)
HBA-5-400-* and EBA-5-400-*
HBA-5-500-* and EBA-5-500-*
Single HBA Current Rating
250A
300A
Dual HBA Current Rating
500A
600A
Input Voltage Range (VDC)
500 –780
Input Voltage (VDC) –Full Power Out
550
600
Input Under-Voltage Range (VDC)
Under-Voltage Current Limit Range (A)
See graph below
See graph below
Efficiency (At Maximum Power)
91%
Max Input Current (AMPS)
15
17
Output Voltage Range (VDC)
24 - 30
Max Output Current (AMPS)
250
300
Max Ripple Voltage (mV)
<100mV RMS
Standby Current (Milliamps)
<20mA
Cooling Method
Forced Air
High Voltage Discharge
Upon removal of high voltage power source or terminal access cover, caps
will discharge to 50 VDC or less within 30 seconds.
Operating Temp.
-40°C to +60°C
Full Power Output
80°C - Half Power Output
Storage Temp.
-40°C to +85°C (-40°F to 185°F)
Serviceable
Internal components to be serviced by Vanner personnel only.
Fan filter/finger guard to be removed and cleaned of dirt/debris quarterly.
Environmental Considerations
IP55 Rated
Plated sheet steel enclosure provides protection against salt, fungus, dust,
water, fuel vapors and all fluids associated with commercial and off-
highway vehicle operations.
Mounting Location
Mount on a flat surface (horizontal or vertical) close to the high voltage
batteries to allow short cable runs.
Weight (lbs.)
75 (34kG)

VANNER Incorporated Owner’s Manual
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
5
Dimensional Specifications
(All Dimensions are in Inches)
Alternate chassis with
integral lifting feature in
four mounting feet

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
6
Operation
Converter Start Up/Normal Operation
In order for the HBA to start successfully, the following conditions must be met;
1. The low voltage battery shall be between 16 –32 VDC.
2. The high voltage battery shall be between 500 –800 VDC.
3. The converter must receive a +24V enable signal on Pin A of the circular I/O connector.
a. For vehicles with pre MY2013 engines, the wakeup signal may come from the engine oil
pressure switch.
b. For vehicles with MY2013 engines or newer, the wakeup signal originates from the hybrid
drive train transmission control module. Contact Vanner engineering for details.
4. The converter must receive a CAN message to turn on.
a. For vehicles with pre MY2013 engines; the HBA must receive an engine RPM signal via
CAN message. The engine speed must be equal to or greater than 400 RPM for 0.1
second. (After start up, the HBA will shut down if the engine speed is less than 350 RPM
for 4.0 seconds.)
b. For vehicles with MY2013 engines or newer; the HBA On/Off controls are handled via
CAN message from the hybrid drive train controller. Note: Contact Vanner engineering
for the latest version of the HBA CAN Messages Specification.
Normal Operation
The HBA can provide up to full rated output (250 or 300 amps) of continuous current and maintain 29
volts out across a DC input range of 550 –800 volts. It can maintain this output in ambient
temperature conditions of -40° to +60°C.
HV Battery Under Voltage Condition –250A Unit
The DC to DC converter will begin to current limit if the input voltage drops below 550V. It will current
limit linearly from 250A –0A between 550V and 500V. (See chart on page 4.) The converter will
shut down completely if the input voltage drops below 500V. Once the input voltage is equal to or
greater than 550V, the converter will restart automatically.
HV Battery Under Voltage Condition –300A Unit
The DC to DC converter will begin to current limit if the input voltage drops below 600 volts. It will
current limit linearly from 300A –250A between 600V and 550V. The converter will continue to
current limit linearly from 250A –0A between 550V and 500V. (See chart on page 4.) The converter
will shut down completely if the input voltage drops below 500 volts. Once the input voltage is equal
to or greater than 550V, the converter will restart automatically.
HV Battery Over Voltage Condition
The DC to DC converter will perform a soft shutdown if the input voltage is above 800V and below
850V. It will restart automatically once the input voltage drops below 750V.
If the input voltage exceeds 850V, the converter will “permanently” shutdown. The unit will not restart
automatically if the input voltage drops below 750V, the ignition switch must be cycled off and on.
LV Battery Conditions
The low voltage battery must be greater than 16V but less than 32V for the HBA to start.
If the low voltage battery drops below 15V or goes above 32V, the HBA will perform a soft shutdown.
The converter will restart automatically if the voltage returns to the normal operating range of 16 –
32V.

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
7
Overload Condition
The HBA is current limited to its rated output current (250 or 300 amps). If the 24V load exceeds the
HBA's rated output current, it will continue to provide its rated output current until the battery voltage
falls below 20V. If the battery voltage falls below 20V the HBA will current limit at 90 amps. If the
battery voltage falls below 16V the HBA will shut down.
Output Short Circuit Protection
There are three ways that the output of the HBA is protected from short circuits.
1. The output current increment is monitored and if the rate is above 10A / 100µs, the HBA will
perform a soft shutdown.
2. A comparator will generate an over-current signal if the current in the high voltage side of the
transformer exceeds 70A. The HBA software will detect this signal and the HBA will perform
a soft shutdown.
3. Hardware will detect an over current condition. Once the current in the high voltage side of
the transformer reaches 90A, the HBA will perform a soft shutdown.
The HBA will automatically restart upon removal of the fault condition.
Thermal Protection
The temperatures of critical components within the HBA are continuously monitored. The highest
temperature of these components will be used for temperature control.
During light load conditions (less than 80% of the nominal current rating) the cooling fan will be turned
on at 75°C and turned off at 70°C.
During high load conditions (greater than 80% of the nominal current rating) the cooling fan will be
turned on at 70°C and turned off at 65°C.
The HBA will shut down if any of the following conditions exist:
temperature on the low voltage power stage reaches 82°C, or
* temperature on the high voltage power stage reaches 98°C, or
* temperature on the control board reaches 98°C
The HBA will restart automatically if all of the following conditions exist:
temperature on the low voltage power stage drops below 78°C, and
temperature on the high voltage power stage drops below 92°C, and
temperature on the control board drops below 92°C
The output of the HBA will current limit if the temperature on the high voltage power stage and
control board is below 98°C but above 92 degree C. The output current will be incrementally
reduced to avoid thermal shutdown conditions.

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
8
Installation Instructions
These symbols are used to note procedures that if not closely followed could lead to loss of life or
damage to equipment or property due to electrocution.
Electrocution hazard exists
Fire hazard exists
A potentially dangerous condition
Explosive hazard exists
Corrosive hazard exists
Do not exceed the specified torque of 100 lb-in when connecting cables to the 5/16-18
terminal posts (±24 and ±600V) during installation of the HBA. Torque values higher than specified may
damage the product, reduce performance, and/or create hazardous conditions. Products damaged by
improper torque are not covered by the warranty.
Do not connect more than one conductor per terminal post on Vanner HBA. Multiple wires
and cables may overstress internal components, resulting in poor performance or creating hazardous
conditions. Products damaged by the installation of multiple conductors per post are not covered by the
warranty.
Fault protection devices must be installed between the HBA and the power
source (battery). A fault protection device would be any fuse or circuit breaker properly rated for the
maximum DC current obtainable. This advisory is in accordance with SAE, NEC and UL, for mobile power
applications. Install per applicable codes or within 18” of the battery. See Wire and Fuse Sizing Chart on
page 13 of this manual or contact Vanner at 1-800-227-6937 or pwr[email protected] if assistance is
needed in sizing fault protection devices.
Caution: This equipment tends to produce arcs and sparks during
installation. To prevent fire or explosion, compartments containing batteries or flammable materials must
be properly ventilated. Safety goggles should always be worn when working near batteries.
Mounting Location –The HBA must be mounted on a flat horizontal or vertical surface suitable
for support during application. The HBA must be mounted under a cover to protect it from direct exposure
to the elements, i.e., rain, sun, sleet/snow. Do not mount in a zero-clearance compartment that may
result in overheating. Care should also be taken when selecting a mounting location to ensure the fan
inlet and outlet locations are not blocked. A minimum of four inches should be allowed at fan inlet and
outlet. Locate the HBA so that contact by unauthorized personnel is unlikely.

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
9
Mounting Dimensions
(Bottom View –Dimensions are in Inches)
10.5 12.2
23.1
.406 x .750 OBROUND, TYP 4 PL
Environmental Protection
Although your HBA has been designed to an IP55 rating, it must be mounted under a cover to protect
it from direct exposure to environmental elements such as sun, rain, sleet and snow. The converter
has also been designed for exposure to direct pressure spray, but continual exposure to direct
pressure spray may reduce the serviceable life. Any damage due to water contamination is covered
by Vanner only through the terms of the factory warranty.
Wiring Sequence
High Voltage Input: The HBA's high voltage input is internally protected for reverse polarity.
24V Output: The HBA’s 24V output is not reverse polarity protected. The HBA will be damaged if the
24V battery is connected to the HBA with the positive and negative reversed. To protect the positive
cable, it shall be fused as close to the battery as practical.
1.25”Dia. masked area on
topside of mounting foot to
ground chassis to bus frame

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
10
Wiring Input/Output Definitions
+
-
Low Voltage Output Terminal
Designations
CAN and Ignition I/O
See Wiring Diagram
for Pin Designations
5/16-18 Low Voltage
Output Terminals.
Terminating hardware
provided by Vanner.
High Voltage Lug Box
STUD
LUG
FLAT WASHER
CONICAL
WASHERS
NUT
LUG INSTALLATION DETAIL
TORQUE = 100LB-IN
120LB-IN MAX.
Optional High Voltage Lug
Box and Cover w/Open
Top Access

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
11
High Voltage Input and Interlock Designations
-
+
High Voltage Lug Box Provisioned
with a 1.85" Diameter Hole for a
Threaded Connector, PG-36 Size Threads
HVIL Connector (High Voltage Interlock)
Molex Panel Mounted Plug, Part #19429-0033
Mates with Molex Receptacle, Part #19418-0007
and Molex 14-16 AWG Socket, Part #19420-0009
Limit Switch for HVIL,
Detects When Cover
has Been Removed
HVIL Connector
Molex #194290033
For mating connector use
Molex #19418-0007 (14 - 16 AWG)
or Molex #19418-0008 (18 - 22 AWG)
For terminals use
Molex #19420-0009 (14 - 16 AWG)
or Molex #19420-0010 (18 - 22 AWG)
5/16-18 High Voltage
Input Terminals.
Terminating hardware
provided by Vanner.
STUD
LUG
FLAT WASHER
SPRING
WASHER
NUT
HIGH VOLTAGE LUG
INSTALLATION DETAIL
TORQUE = 100LB-IN
120LB-IN MAX.

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
12
HBA Wiring Diagram w/Vanner 70 Series Equalizer
Vanner High
Voltage DC-DC
Converter
High
Voltage
Interlock
High
Voltage
Battery
12V Battery A
Vanner
70 Series
Equalizer
F3 F2
F1
A
BC
D
E
F
G
HJK
L
M
N
P
A
B
C
D
E through P TBD
CAN - High
CAN - Shield
+24V Enable
CAN - Low
12V Loads
+24V
+12V
GND
12V Battery B
24V Loads

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
13
I/O Definitions and Functionality (Pins E through P are Optional)
A. +24V Enable Input
This input “wakes up” the HBA and must be present for the HBA to turn on.
B. CAN Shield
This connection is used to make the shield on the CAN cable common. This is required for
electrical noise considerations in vehicle electrical systems.
C. CAN Low
This is the low signal connection for the vehicle’s CAN bus. The HBA will communicate faults to
the vehicle’s electrical system controller via the CAN bus.
D. CAN High
This is the high signal connection for the vehicle’s CAN bus. The HBA will communicate faults to
the vehicle’s electrical system controller via the CAN bus.
E through L - TBD
M. For DUAL HBA Installations only. (See wiring diagram on page 24.)
Installing a jumper between Pins M and N designates the HBA as the PRIMARY unit.
N. For DUAL HBA Installations only. (See wiring diagram on page 24.)
Installing a jumper between Pins M and N designates the HBA as the PRIMARY unit.
Installing a jumper between Pins N and A designates the HBA as the SECONDARY unit.
P. TBD
Note: The HBA I/O connector is a panel mounted Deutsch receptacle P/N: HDP24-18-14PN. A typical
mating connector is Deutsch plug P/N: HDP26-18-14SN provisioned with Deutsch socket contacts
P/N: 1062-16-0622. The Deutsch part numbers for the mating plug and contacts will vary depending on
the wire gauge, insulation type and back-shell used. Select the proper sealing ring option for the wire
insulation diameter to ensure proper sealing.

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
14
Wire Size and Temperature Rating
Cables connecting the HBA to the 24V batteries must be sufficiently sized to prevent unwanted voltage
drop. The temperature rating of the wire should be a minimum of 90ºC.
Vanner recommends the following wire and fuse sizes for the 250A and 300A HBA's. To protect the
positive cable, it shall be fused as close to the 24V battery as practical.
HBA Low Voltage Output Wire and Fuse Size Chart
Wire
Size
AWG
Ring Terminal
Panduit
Fuse F3
#4/0
*LCD4_0-56000-CUST
400 amp
* The Panduit part number listed is recommended, not required, by Vanner. Equivalent substitutes may
be used. Contact Vanner engineering for a drawing of the Panduit ring terminal.
The recommended terminal is a right angle lug that enables the installer to route the 4/0 cables along the
side of the HBA. Factory installed tie wrap bases are present on the side of the HBA for strain relief.
Crimp the ring terminals using Panduit CT-930 manual/hydraulic crimping tool.
Use Panduit die CD-920-4/0 die. (Purple P54).

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
15
Testing and Troubleshooting
CAUTION
Servicing of electrical systems should only be performed by trained and qualified technical personnel.
Equipment Required
Required: A laptop provisioned with Vanner's Dashboard software, supporting hardware and
interface cables.
Note: There are kits available for purchase that include Vanner's Dashboard software, a USB to CAN
adapter module and a harness to connect to the vehicle's CAN network. Please contact Vanner's
inside sales department for the appropriate kit part number for your application.
Optional: Volt Meter having 0.01 volt resolution. (Fluke Model 87 Multimeter recommended).
Clamp-on current meter (Fluke Model 36 Clamp-on Meter recommended).
Test Procedure for HBA
The HBA is working properly if:
1. The 24 volt DC loads are being operated continuously and are within the rated capacity of the HBA
and;
2. The power drawn from the hybrid drive train system is within its rated capacity.
HBA Test Procedure:
1. Field-test the HBA while fully connected to the vehicles high and low voltage batteries.
The 24V battery must measure between 16 and 32 volts. If the 24V battery is below 16 volts,
apply a 24 volt battery charger to the batteries.
The high voltage battery must measure between 500 and 780 volts for the HBA to start properly.
2. Start the vehicle normally while monitoring the HBA status with a laptop provisioned with Vanner’s
Dashboard software. The laptop must be connected to the vehicle CAN Bus utilizing a USB to CAN
adapter and harness.
The HBA will turn on automatically upon receiving the engine RPM signal or CAN On/Off
command via CAN bus and a +24V enable signal.
Upon normal system startup, the output voltage will increase to 28.5 volts and the output current
will increase indicating charging of the 24V batteries and providing power for the 24V auxiliary
loads.
3. The Vanner Dashboard software monitors the following data which can be observed on the laptop;
High Input Voltage High Input Current Low Output Voltage Low Output Current
Engine RPM Heartbeat Power Stage Temps. Control Board Temp
CAN On/Off Command Message Status Converter Status and Faults

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
16
Dashboard screenshot of a system under normal operating conditions
4. If the Vanner Dashboard software isn’t utilized or available, proper start up can be validated by
measuring the 24V output terminals with a Volt Meter. Upon start up, the voltage will increase from
the 24V battery nominal value up to ≈ 28.5 volts. Note: The measurement is dependent on the
voltage drop in the cables/bolted connections between the HBA output terminals and the 24V
battery terminals.
5. A clamp on style current meter can also be used to validate the output current of the HBA.
6. Important: The high voltage terminals are inaccessible for measurement. A high voltage interlock
circuit is implemented for safety purposes to prevent an accidental and potentially lethal shock to
personnel. The high voltage input to the HBA can only be read via the Dashboard software.

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
17
Trouble Shooting an HBA No-Start Situation
In the event the Vanner HBA does not start, the following need to be reviewed/validated;
1. Is the high voltage battery within the acceptable input range? 550 - 780VDC
2. Is the 24V battery within the acceptable range? 20 –32VDC
3. Is 24V battery voltage present at the output terminals of the HBA upon closing the battery disconnect
switch?
4. If not, verify the fuse between the 24V battery and the HBA is installed and hasn’t cleared.
5. Upon startup of the engine, does the 24V battery remain within the acceptable range? If the health of
the 24V batteries is questionable, the voltage may collapse below 20 volts before the HBA starts.
There is an approximate 2 - 3 second delay from the time the engine starts to the start of the HBA.
6. Is the +24V enable signal present at the I/O connector?
7. If the +24V enable signal is present, is the wire in the proper location of the mating I/O connector?
8. For vehicles with pre MY2013 engines: Is the engine rpm data being transmitted properly via the
CAN Bus? PGN 61444 (0xF004)
9. If so, is the engine rpm greater than 400 rpm?
10. For vehicles with MY2013 engines or newer, is the "Converter Control" command message being
received? PGN 65498 (0xFFDA)
11. If the answers to 5 and 6 are yes, are the CAN signal wires (HI,LO and Shield) in the proper locations
of the mating connector?
HBA Status and Fault Indication Definitions
The HBA monitors several status and fault conditions. If any faults occur, they are reported via CAN
bus and can be observed with the Dashboard software. The HBA status and fault indications in the
lower left corner of the screenshot on page 16, are defined as follows;
DC/DC Converter ON: Green indication that HBA has turned on successfully
DC/DC Converter OFF: Red indication that HBA is off. If the reason is due to a fault, that condition
will be indicated by a red icon.
Engine RPM/ Low or CAN Data Loss: The HBA will perform a soft shutdown if the engine speed
drops below 350 RPM for four seconds or there is a loss of CAN communication. The HBA will
restart automatically when the engine speed exceeds 400 RPM for 0.1 seconds or CAN
communication is restored.
HVPS (High Voltage Power Stage) Imbalance Fault: Internal circuitry detects if the voltage
differential between the center point to negative and center point to positive is excessive, > 200V. If
an imbalance fault is detected, the HBA will "permanently" shut down. The unit will not restart
automatically if the imbalance condition clears, the ignition must be cycled off and on. See note
below.
Note: An imbalance fault can be caused by leakage current or a defective detection circuit within the
HBA. However, the HBA will also detect external leakage paths. The external leakage path could be
caused by water ingress in a high voltage cable assembly or junction box. It could also be caused by
damaged shielding on a high voltage cable assembly. If the high voltage imbalance fault does not
clear after cycling the ignition, Vanner recommends inspecting the high voltage cable assemblies for
leakage paths.
Over Temperature Fault: The HBA will perform a soft shutdown if any of the following conditions
exist: the temperature on the low voltage power stage reaches 82°C, or the temperature on the high
voltage power stage reaches 98°C, or temperature on the control board reaches 98°C. The HBA will
restart automatically if all of the following conditions exist: the temperature on the low voltage power
stage drops below 78°C, and the temperature on the high voltage power stage drops below 92°C,
and the temperature on the control board drops below 92°C.

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
18
HBA Status and Fault Indications Cont'd
Input Overvoltage Fault: The HBA will perform a soft shutdown if the input voltage is above 800V
and below 850V. It will restart automatically once the input voltage drops below 750V. If the input
voltage exceeds 850V, the converter will “permanently” shut down. The unit will not restart
automatically if the input voltage drops below 750V, the ignition switch must be cycled off and on.
Input Under Voltage Fault: The HBA will perform a soft shut down if the input voltage drops below
500V. Once the input voltage is equal to or greater than 550V, the converter will restart
automatically.
Output Overvoltage Fault: The HBA will perform a soft shutdown if the low voltage battery exceeds
32V. The HBA will restart automatically if the voltage returns to the normal operating range of 16 -
32V.
Output Under Voltage Fault: If the low voltage battery drops below 15V, the HBA will perform a soft
shutdown. The converter will restart automatically if the voltage returns to the normal operating range
of 16 –32V.
Output Overload Fault: The HBA is current limited to 250A or 300A. If the load is above 250A or
300A, the unit will begin current limiting and gradually reduce the output voltage. Once the HBA
output voltage decreases to a value less than or equal to the battery voltage, the batteries will begin
to assist in supporting the load. If the load continues to increase and the output voltage drops to 20V,
the output current will begin to fold back. If the output or battery voltage is reduced to 16V, the HBA
will turn off. The HBA will restart automatically if the loads are reduced and the battery voltage
returns to the normal operating range of 16 - 32V.
Over Maximum Current Fault: The HBA will perform a soft shutdown if the current flowing through
an internal power stage current transformer exceeds 90A. The HBA will restart automatically if the
current returns to a value below 90A.
+12V Power Supply Failure Fault: The HBA will perform a permanent shutdown in the event of a
+12V power supply failure. The unit should be replaced and the failed unit returned to Vanner for
evaluation.
LV Gate Drive +12V Failure: The HBA will perform a permanent shutdown in the event of a LV Gate
Drive +12V power supply failure. The unit should be replaced and the failed unit returned to Vanner
for evaluation.

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
19
Testing an HBA for an Isolation Fault
In the event the vehicle is experiencing an isolation fault, the HBA should be eliminated as the cause of
the fault prior to replacing any hybrid drive components. The isolation resistance of an HBA can be
tested using an Amprobe AMB-45 Megohmmeter, commonly referred to as a "megger".
1. Before beginning, reference Allison Transmission's "Electrical Disconnect Verification Procedure" for
the H 40/50 EP product family. It contains important steps that are not covered in these instructions.
2. High Voltage Personal Protective Equipment (PPE) must be worn for this procedure.
3. Assure that the vehicle ignition switch is in the OFF position.
4. Assure that the vehicle master battery disconnect switch is in the OFF position. Use lockout devices
to assure the switch cannot be moved to the ON position until the test procedure is complete.
5. Disconnect the high voltage positive and negative cables from the HBA input studs.
6. Insulate the ring terminals.
7. Do not disconnect the 24V positive and negative cables, 14 pin Deutsch connector, and chassis GND
from the HBA. Note: If bench testing, connect HBA 24V negative to HBA chassis.
8. Set the AMB-45 to the 250V scale.
9. Connect AMB-45 negative to HBA chassis.
10. Connect AMB-45 positive to HBA high voltage positive stud. Measure and record resistance.
11. Connect AMB-45 positive to HBA high voltage negative stud. Measure and record resistance.
12. See table below for proper resistance readings.
13. If either resistance reading is significantly lower than specified, the HBA may be defective and should
be returned to Vanner for repair.
HBA Serial Number
Positive to Chassis
Negative to Chassis
Actual Measurement
Prior to 13246-250093
810kΩ ±10%
Pos to Chassis:
Neg to Chassis:
After 13246-250093
2.8MΩ ±10%
Pos to Chassis:
Neg to Chassis:
Vanner Repair Service
Vanner offers a quick turnaround factory repair service. Send the unit to the address on last page
with a note instructing us to repair it. Include your name, phone number, shipping address (not a
P.O. Box Number), and your purchase order number.
WARNING! The Vanner HBA uses potentially lethal voltages for operation. DO NOT attempt to test
the HBA unless you have been trained to work with the Allison H 40/50 EP system.

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage DC-DC Converter OWNER’S MANUAL
20
Vann-Bus Battery Management
Vanner 80 Series Equalizer and Sensors
A vehicle with 12 and 24 volt loads may be provisioned with the following Vanner parts to permit
dynamic voltage regulation of the HBA.
1. 80 Series Equalizer
When connected to the I/O of the current and voltage/temperature sensors listed below, the 80 series
equalizer utilizes Vanner's MBBM (Model Based Battery Monitoring) algorithm to determine the SOH
(State of Health) and SOC (State of Charge) of the 12 and 24 volt batteries.
The equalizer will communicate the appropriate voltage requirement, based on the battery
manufacturers data, to the HBA which will adjust its output accordingly. The voltage requirement
communicated to the HBA is based on the voltage at the battery terminals, therefore, voltage drop
contributed by the cables and bolted connections is taken into consideration.
Note: The appropriate battery model must be loaded in the equalizer for maximum accuracy of the
SOH and SOC calculations. Please contact Vanner for a library of batteries that are modeled to
ensure the proper equalizer part number is ordered or the proper battery profile is loaded in memory.
2. Dual Current Sensor (80A/600A)
The dual current sensor, VSS-C80/600, monitors the current flowing into and out of the 24V battery.
3. Single Current Sensor (80A)
The single current sensor, VSS-C80, monitors the current flowing into and out of the 12V battery.
4. Voltage and Temperature Sensor
The voltage and temperature sensor, VSS-VT, monitors the 12V battery voltage as well as the
temperature. It is mounted to the positive terminal of the 12V battery.
See page 21 for the HBA/Equalizer wiring diagram with the addition of the sensors and their pinout
definitions.
Operational Theory
There are two operating modes for the HBA, standalone and battery management. If battery
management is turned off or CAN messages from the equalizer/battery monitor are not received, the
HBA defaults to standalone mode and regulates the output voltage locally at a fixed value. Note: the
factory default is 28.5V but is user configurable via the dashboard interface.
In battery management mode, the output voltage reference is adjusted to regulate the output voltage
remotely at the battery. The reference is adjusted at a rate of 0.1V/second. The upper limit of the
reference voltage is 1.0V above the standalone output voltage.
If the battery SOC is 100% or the battery status is quiescent (quiescent is defined as when there is
less than 5 amps going into or out of the batteries), the remote voltage is set to the float voltage
value. Otherwise it is set to the absorption voltage value. The float voltage and absorption voltage
are adjusted automatically with temperature according to a pre-defined curve.