Vanner HVDM-2CH35A User manual

VANNER Incorporated Owner’s Manual
Vanner High Voltage Distribution Module OWNER’S MANUAL
1
High Voltage Distribution Module
Table of Contents
Introduction………………………………………………….………………… 3
Specifications…………………………………………………….………….… 4
Operation……………...………………………………………………………. 11
Installation Instructions…………………………...…………….……………. 14
Typical Application………………………….………...……………………… 16
Testing and Troubleshooting………………………………………………… 18
CAN Messages Specification…….………………..………………………… 23

VANNER Incorporated Owner’s Manual
Vanner High Voltage Distribution Module OWNER’S MANUAL
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Notes

VANNER Incorporated Owner’s Manual
Vanner High Voltage Distribution Module OWNER’S MANUAL
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Introduction
Thank you for purchasing Vanner’s High Voltage Distribution Module. We are confident that you will be
very pleased with its performance since 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 Distribution Module (commonly referred to as HVDM in this document) is an
efficient and highly reliable method of distributing high voltage, 400 to 800VDC, derived from a traction
battery system. The high voltage is distributed to two fused output channels via high voltage contactors.
The HVDM is also provisioned with pre-charge circuitry for each output channel. Pre-charge circuitry and
contactor closing/opening is controlled independently for each channel to allow for connecting and
disconnecting the individual loads.
The HVDM is controllable over a J1939 CAN (Controller Area Network) with additional discrete controls.
It will also monitor and control the two output channels and report their status over a J1939 CAN network.
The HVDM is provisioned with a two pin sealed connector for integration into the vehicle’s high voltage
interlock system and a twelve pin sealed rectangular connector for CAN and discreet I/O signals.

VANNER Incorporated Owner’s Manual
Vanner High Voltage Distribution Module OWNER’S MANUAL
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Operational Specifications
High Voltage Distribution Module
IAPIModel Numbers (250kbps)
HVDM-2CH35A
HVDM-C135A-C250A
HVDM-C150A-C235A
HVDM-2CH50A
IAPIModel Numbers (500kbps)
HVDM-5-2CH35A
HVDM-5-C135A-C250A
HVDM-5--C150A-C235A
HVDM-5-2CH50A
IAPIFuse Ratings (See notes below table.)
CH1 - 35A
CH2 - 35A
CH1 - 35A
CH2 - 50A
CH1 - 50A
CH2 - 35A
CH1 - 50A
CH2 - 50A
IAPII Model Numbers (250kbps)
HVDM-C135A-C280A
HVDM-C150A-C280A
IAPII Model Numbers (500kbps)
HVDM-5-C135A-C280A
HVDM-5-C150A-C280A
IAPII Fuse Ratings (See notes below table.)
CH1 - 35A
CH2 - 80A
CH1 - 50A
CH2 - 80A
High Input Voltage Range (VDC)
400 –800
High Input Voltage Nominal (VDC)
550 - 700
High Input Voltage Max Survivable (VDC)
1,200
Low Input Voltage Range (VDC)
18 - 32
Max Continuous Current (AMPS)
60A/Channel
Note: The HVDM hardware is capable of supporting 60A/Channel, however, it is limited by the
exportable power rating of the hybrid traction drive system.
Max Pre-Charge Current (AMPS)
10
Max Capacitive Load (µF)
6,800
+24V Battery Input Current (AMPS)
< 200mA
Ignition Input Current (AMPS)
+24V < 5mA
+12V <10mA
Cooling Method
Passive Convection
High Voltage Passive Discharge
Upon opening of contactors, removal of high voltage or terminal access cover, a capacitive load of
3,400µF will discharge to 50 VDC or less within 5 minutes.
A capacitive load of 6,800µF will discharge to 50 VDC or less within 10 minutes.
Ambient Operating Temperatures
Min: -40°C (-40°F)
Max: 70°C (158°F)
Storage Temperature
-40°C to +105°C (-40°F to 221°F)
Serviceable
Internal components to be serviced by Vanner personnel only.
No routine maintenance of module is required.
Note: In the event an internal fuse is blown, it may be replaced by a qualified technician. Care
must be taken in following high voltage safety procedures prior to servicing and tightening
hardware to specified torque values.
Environmental Considerations
IP55 Rated
Powder coated galvannealed 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 orientation) close to the high voltage batteries to
permit short cable runs.
Weight (lbs.)
30 (13.6kg)
Notes:
1. Channel 1 output is reserved for Vanner HBA's. Performance of the HVDM will be compromised if the load
connected to Channel 1 is not single or dual HBA's.
2. Channel 1 output is fused at 50A for Dual HBA's used in IAPIand IAPII applications.
3. Channel 2 output is fused at 80A for the VEPI (Vanner Exportable Power Inverter) used in IAPII applications.

VANNER Incorporated Owner’s Manual
Vanner High Voltage Distribution Module OWNER’S MANUAL
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Dimensional Specifications
(All Dimensions are in Inches)

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage Distribution Module OWNER’S MANUAL
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Mounting Specifications
(All Dimensions are in Inches)
1” Dia. masked area on
topside of mounting foot to
ground chassis to bus
frame. (CH1 Exit)

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Wiring Input/Output Specifications
Note: Deutsch part number suffix (**) is dependent on wire gage and insulation diameter.
CAN and I/O Connector
Deutsch #DT13-08PA
For mating connector use
Deutsch #DT06-08SA
For terminals (size 16) use
Deutsch #1062-16-**77
Pinout Definitions
1 - +24V Input
2 - Ignition Signal
3 - CAN Shield
4 - CAN Low
5 - CAN High
6 - Spare
7 - Command Signal (Active Low)
8 - Ground
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)
Note: HVIL connector is
mounted to this surface
for IAPImodels.

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CAN and I/O Definitions and Functionality
1. +24V Input
The +24V input powers the HVDM control board. The input shall come from the most convenient
termination point that is on the secondary side of the house battery main disconnect switch.
2. Ignition Signal
The ignition signal "wakes" the HVDM up. It may be +12V or +24V.
3. 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.
4. CAN Low
This is the low signal connection for the vehicle’s CAN bus. The HVDM will communicate faults
to the vehicle’s electrical system controller via the CAN bus.
5. CAN High
This is the high signal connection for the vehicle’s CAN bus. The HVDM will communicate faults
to the vehicle’s electrical system controller via the CAN bus.
6. Spare
7. Command/Hardware Enable Signal
This is an active low signal that comes from the TCM (Transmission Control Module) of the hybrid
drive system. Reference Allison Transmission's Technical Document 192 for circuit requirements
for this input.
8. Ground
The ground input powers the HVDM control board. The input shall come from the most
convenient termination point tied to battery negative. Do not terminate to vehicle chassis.

VANNER Incorporated OWNER’S MANUAL
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Wiring Input/Output Specifications Cont'd
* The HVDM is provisioned with two gland seal holes for Channel 1 and three gland seal holes for Channel 2.
The Channel 1 access points are for HBA’s only in IAPI or IAPII applications. The Channel 2 access points are
for pre-approved high voltage DC loads (IAPI) or a Vanner Exportable Power Inverter (VEPI) and pre-approved
high voltage DC load (IAPII).
Two studs per pole/channel are also provided to prevent installing two lugs on one stud.
EMI blanking plugs will be installed in any unused gland seal holes at the factory.
HV Input Conduit Access
1.85" Diameter Hole
Accommodates PG36 gland seal
Note: The HV input
conduit access hole is
located on this surface
for IAPImodels .
* Channel 1 and Channel 2 Outputs
1.12" Diameter Holes
Accommodate PG21 gland seals
Note: Channel 1 is reserved for HBA's only.
Channel 1
Channel 2
Channel 2.1

VANNER Incorporated OWNER’S MANUAL
Vanner High Voltage Distribution Module OWNER’S MANUAL
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Wiring Input/Output Specifications Cont'd
Positive Terminals and Fuse Terminals
The positive and fuse terminals are M8 x 1.25 studs
Tighten to a torque value of 100 lb-in (11 Nm)
Negative Terminals
The negative terminals are M10 x 1.5 studs
Tighten to a torque value of 150 lb-in (17 Nm)
Chassis Ground Terminal
The ground terminal is an M8 x 1.25 stud
Tighten to a torque value of 100 lb-in (11 Nm)
-
-
+
+
-
Channel 1
Output
+ and -
Channel 2
Output
+ and -
HV Input
+ and -
HVIL Switch
Channel 2
Fuse
Channel 1
Fuse
+
Note: HVIL
switch and
connector are
mounted to this
surface on IAPI
models.
Pre-charge
Relay
Board