Upload
ravi-kumar
View
45
Download
3
Embed Size (px)
Citation preview
Vanner HBA400/500-H40/50EP
High Voltage DC-DC Converter
What is the function of the Vanner HBA (Hybrid Beltless Alternator)?
• The HBA’s primary function is to convert the high voltage present in an electric hybrid drive
system from 700 volts to 28 volts for auxiliary batteries and loads.
• The HBA is a direct replacement for belt driven alternators. It increases the reliability of the low
voltage charging system and reduces overall maintenance costs associated with alternator
replacement.
• The HBA output voltage is user configurable via Vanner’s CAN Interface Software.
Vanner HBA400/500-H40/50EP
Electrical and Environmental Specifications
Model Number HBA400-H40EP HBA500-H40EP HBA500-H50EP
Input Voltage Range (VDC) 500 – 780
Input Voltage (VDC) – Full Power Out 550 600 600
Input Under-Voltage Range (VDC)
Under-Voltage Current Limit Range (A)
500 – 550
0 – 250
500 – 550
0 – 250
550 – 600
250 - 300
500 – 550
0 – 250
550 – 600
250 - 300
Efficiency (Full Power) 91%
Max Input Current (A) 15 17 17
Output Voltage Range (VDC) 20 - 30
Max Output Current (A) 250 300 300
Max Ripple Voltage <100mV RMS
Standby Current <20mA
Cooling Method Forced Air
High Voltage DischargeUpon 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
ServiceableInternal components to be serviced by Vanner personnel only.
Fan filter/finger guard to be removed and cleaned of dirt/debris quarterly.
IP Rating 55
Weight (lbs.) 75 (34kG)
Vanner HBA400/500-H40/50EP
Dimensional Specifications(Dimensions are in inches)
Vanner HBA400/500-H40/50EP
High Voltage Lug Box
CAN and Ignition I/O
Low Voltage Output Terminals
5/16-18 Studs
Nuts tightened to 100lb-in
Wiring Input/Output Definitions
Vanner HBA400/500-H40/50EP
Wiring Input/Output Definitions Cont’d.
-
+
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
High Voltage Input Terminals
5/16-18 Studs
Nuts tightened to 100lb-in
Vanner HBA400/500-H40/50EP
Typical Application/Wiring for Transit Bus
High
Voltage
Interlock
High
Voltage
Battery
12V Battery
12V Battery
Vanner
Equalizer
F1
F2
F3
+12V
GND
+24V
A
B
C
D
E
F
G
HJ
K
L
M
N P A
B
C
D
E through PTBD
CAN - High
CAN - Shield
+24V Enable
CAN - Low
Vanner HBA400/500-H40/50EP
Installation Photos
HV Battery
HBA
DPIM
Unit Installed on Roof of Bus (Fiberglass Cowling Removed)
Vanner HBA400/500-H40/50EP
Vanner HBA400/500-H40/50EP
Installation Photos Cont’d
Components Covered by Fiberglass Cowling
HBA LOCATION
Installation Photos Cont’d
HV Input Cable
HV Interlock Cable
HV Lug Box
HV Lug Box
Cover Removed
High Voltage Input
Vanner HBA400/500-H40/50EP
Installation Photos Cont’d
Fuse Panel
LV Cables
from Converter
I/O and CAN Connector
LV Output Terminals
and Cables
Low Voltage Output
Vanner HBA400/500-H40/50EP
Proper Start-Up of Converter
The following conditions must exist for the proper start-up/operation of the DC-DC converter:
• The low voltage battery must measure between 16 and 32 volts
• The high voltage battery must measure between 500 and 780 volts
• The RPM signal received via CAN Bus must be ≥ 400 RPM for 0.1 seconds
• The +24V wake-up signal is received from the body controller
Verification of Operation
The following are two ways that proper operation of the DC-DC Converter can be confirmed:
• Vanner’s CAN Interface Software (Commonly referred to as the Dashboard)
• This requires a CAN cable, CAN interface module and a laptop provisioned with Vanner’s CAN
Interface Software. (Reference Vanner’s “CAN Interface User’s Manual” for more details.)
• Measure the voltage at the DC-DC converter output terminals (if there is roof access)
• The voltage should measure 28.5 ± 0.1 volts.
• Note: For Gillig buses, the factory default setting is 28.5 volts.
• If the terminals aren’t accessible due to a lack of roof access, measure the voltage at the batteries.
Depending on voltage drop, the voltage should measure 28.5 +0.0 / -0.5 volts.
Vanner HBA400/500-H40/50EP
Vanner’s CAN Interface SoftwareThe snapshot at the left represents the
data that can be viewed with the CAN
interface software.
Upper Section
• Input and Output voltages and currents
• Temperatures of high and low voltage
power boards and control board
• This information can be viewed
graphically and saved for later viewing
Middle Section
• Engine RPM, Converter Control and
communication heartbeat
CAUTION: Never select “Transmit Engine
Speed” icon while bus is running.
Lower Section
• Converter Status and Fault Indication
• Battery Status – Not enabled at this time.
It will be enabled with release of VannBus
system.
Vanner HBA400/500-H40/50EP
Vanner’s CAN Interface Software Cont’d
Set Output Voltage
• The converter output voltage can be
adjusted between 25 – 30 volts.
• After selecting the “Set Output Voltage”
icon in the main dashboard, the icon to the
left will be displayed.
• After choosing the desired voltage
setting, select “OK”. The new voltage
setting will be communicated to the
converter as a CAN message and stored in
non-volatile memory so it will not be lost at
power down.
• If a Vann-Bus system is installed along
with the HBA, select the “Enable Battery
Management” icon. This will permit
dynamic regulation of the output of the
HBA based on the low voltage batteries
SOH and SOC.
Vanner HBA400/500-H40/50EP
Vanner’s CAN Interface Software Cont’d
Viewing Graphical Data
• The snapshot at the left is the upper
section data that can viewed graphically by
selecting the “View Data Curve” tab.
• Data is recorded every three seconds.
• One screen represents 30 minutes of
data.
• The data is saved as a text file and can
be recalled at a later time for
viewing/analyzing.
Top Four Sections
• Input and Output voltages and currents
Lower Section
• Temperatures of high and low voltage
power boards and control board
• Engine RPM data is collected as well but
not displayed graphically
Data values at
cursor position
Open saved data
file
Log data in file
Vanner HBA400/500-H40/50EP
Vanner’s CAN Interface Software Cont’d
Viewing Diagnostic Messages
• The snapshot at the left will be displayed
after selecting the “View Diagnostic
Messages” icon from the main dashboard.
• This can be used to view diagnostic
messages (DM1) sent from the converter.
• The software and component ID’s can be
retrieved from the converter by selecting
the appropriate icon.
• Not sure what to say about DM1
message request here if anything.
Vanner HBA400/500-H40/50EP
Shutdown or No Start Conditions
The following conditions will cause the DC-DC converter to shutdown, not start or current limit:
• 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. 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. 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.
Vanner HBA400/500-H40/50EP
Shutdown or No Start Conditions Cont’d
The following conditions will cause the DC-DC converter to shutdown, not start or current limit:
• LV Battery Conditions
• The low voltage battery must be greater than 16V but less than 32V for the DC-DC converter to
start. If the low voltage battery drops below 15V or goes above 32V, the DC-DC converter will perform
a soft shutdown. The converter will restart automatically if the voltage returns to the normal operating
range of 16 – 32V.
• Overload Condition
• The DC-DC converter is current limited to 250A or 300A. If the load is above 250A or 300A, the
output voltage will be reduced to 20V. If the load continues to increase and the output voltage drops
below 20V, the output voltage will be clamped at 15V with a maximum output current of 90A. (Note:
The output voltage is reduced from 29V gradually to 20V if the load continues to increase.)
Vanner HBA400/500-H40/50EP