THUNDERSTRUCK MOTORS TSM-HV DC-DC Converter Instruction Manual

: June 5, 2024
: THUNDERSTRUCK MOTORS

Table of Contents

THUNDERSTRUCK MOTORS TSM-HV DC-DC Converter
Overview
Environmental Conditions
Electrical Performance
Protection and Control Functions
Safety Regulations and EMC Characteristics
Structure and Interface Description
Recommendations and Precautions
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THUNDERSTRUCK MOTORS TSM-HV DC-DC Converter

THUNDERSTRUCK-MOTORS-TSM-HV DC-DC-Converter-

Overview

The TSM HV DCDC converter adopts advanced high-frequency power electronic conversion technology. It is a high-performance vehicle-mounted DCDC converter specially developed for electric vehicles with high voltage traction systems. Following are the main features:

Input and output are completely electrically isolated, safe and reliable
The highest conversion efficiency exceeds 95%
High power density and small volume
Uses multi-stage power conversion technology, compatible with a wide input voltage range
Uses soft switching technology to reduce power device losses and greatly improved EMC performance of the product
Air cooled IP67 rated aluminum case with mounting points
Utilizes dual controller digital architecture, with automatic protection and fault diagnosis functions
High peak power and strong overload capacity, meeting the usage requirements of impact loads
Includes optional CAN communication, BootLoader function, low voltage enable control, high voltage sleep and designated CAN message sleep function
Non-CAN operation is accomplished by connecting as shown in the diagram below

Environmental Conditions

Item	Parameter	Value	Unit	Remarks
1	Working Temperature	-40 to +85	℃
2	Ambient Storage Temperature	-40 to +105	℃
3	Relative Humidity	5 – 95	%	Non-condensing
4	Cooling Method	Air-cooled	–	Outside the Shell
5	Protection Class	IP67	–	Shell Part
6	Working Noise	＜60	dBA	Air Cooling System
7	Anti-vibration Leve	GB 413-2002 3.12	–	Requirements for Non- engine

Parts

Electrical Performance

Input and Output Characteristics

Item	Parameter	Value	Unit	Remarks
1	Input Voltage range	280-450	Vdc	200~450
2	Input Current	6.8	A
3	Input Inrush Current	8.2	A	Capacitance spikes in

0.5 ms not Counted

4| Input current in standby| < 2| ma| with 12v disconnected
Item| Parameter| Value| Unit| Remarks
---|---|---|---|---
1| Rated Output Voltage| 13.8±0.2| Vdc| Can be adjusted according to system requirements, the adjustment range is 10.8~15V
2| Rated Output Power| 1500| W| @Rated Input Voltage
3| Peak output power| 1800| W| @Rated Input Voltage
4| Voltage Regulation| ＜±1| %| Regulation Accuracy
5| Load Regulation| ＜±1| %
6| Current Reporting Error| ＜1| A| ＜5A| Report Error
＜0.5| >5A
7| Voltage Reporting Error| ＜0．2| V|
8| Current Control Error| ＜1| A| Control Precision
9| Voltage Control Accuracy| ＜0．2| V
10| Work Efficiency| ＞94.5| %| 40%~70% Load

(Warm Up 2mi)

---|---|---|---|---
＞94.0| 70%~100% Load

(Warm Up 2min)

＞95.0| Highest Efficiency
11| Output current| 130±2| A|
12| Output Ripple and Noise| ＜240| mVp

-p

| 20Mhz bandwidth, output connected to 10uF electrolytic

capacitor and 0.1uF ceramic capacitor

13| Transient Response| Overshoot

amplitude

| ＜5| %| 30% -80% -30% load

step change, amplitude 100A/ms

Recovery Time| ＜500| µs
14| Output current while in stand by| ≤1| mA| Secondary-side MCU enables sleep and wake-up through hard wire to ensure current at the output while

standby

Protection and Control Functions

Item	Parameter	Value	Unit	Remark
1	Hard-wired Enable Control	Signal voltage	9-16	Vdc

enable signal is input to the DC-DC, the DC-DC is

turned on (default sleep); when the signal is floating or grounded, the DC-DC is

turned off (default sleep).

Signal Current| 2| mA
2| Input undervoltage protection| Protection point| 272±2| Vdc| Instant protection, automatic recovery
Recovery point| 278±2| Vdc| Instant protection, automatic

recovery

3| Input Overvoltage Protection| Protection point| 458±2| Vdc| Instant protection,

automatic recovery

---|---|---|---|---|---
Recovery point| 452±2| Vdc| Instant protection, automatic

recovery

4| Output Undervoltage Protection| Protection point| 7.0±1| Vdc| Instant protection, automatic

recovery

Recovery point| 9.0±1| Vdc| Instant protection, automatic

recovery

5| Output Overvoltage Protection| Protection point| 16.0±0.5| Vdc| If greater than protection point, turn off

output

Recovery point| 15.5±0.5| Vdc| If less than

recovery point, works normally

6| Output Current Limit Protection| 130±2| A| When the output current increases to the current limit protection point, it enters the constant current voltage

limit mode

7| Output Short Circuit Protection| | –| Instant protection, automatic

recovery

8| Input Reverse Connection Protection| DC-DC input does not start after reverse

connection

| –|
9| Overheat Protection| Power attenuation| 100（Primary）/112（ Secondary）| ℃| When the temperature reaches the attenuation point, the module limits the power output; the power is attenuated at 8% / ℃

with, derated output.

---|---|---|---|---|---
Protection shutdown| 110（Primary）/118（

Secondary）

| ℃| If met, turn off the output

voltage

Protection Recovery| 95（Primary）/90（

Secondary）

| ℃| If all met, work properly
10| CAN communication function| 1. With BootLoader function, software can be updated by CAN communication;

2. Can report DC-DC working status, input voltage, output voltage, output current, hardware failure, communication failure and other information;

3. Support hard-wired and arbitrarily formulated message sleep and wake-up.

Logical function| If the customer has no special logic requirements, the default is:

1. Enable hard-line control of DCDC converter on / off, high level start;

2. Enable hard-wired control for DCDC sleep and wake up, high level wake up.

Safety Regulations and EMC Characteristics

Item	Parameter	Value	Unit	Remarks
1	Withstand voltage	Input to Output	2120	Vdc

≤5mA, 1min, No breakdown, no flashover, basic insulation

Input to Earth| 2120| Vdc
2| Insulation resistance| Input to Output| ≥50| MΩ| Test Voltage 500Vdc
Input to Earth| ≥50| MΩ
3| EMI| RE| GB / T 18655-2010,

Chapter 6.4, CLASS 3 standard

| –|
CE
4| EMS| Radiation Immunity| GB/T 6113.1| –|
High Current Injection| ISO 11452-4: 2005

Article 7, 100mA

RF Immunity| ISO 11452-9
Conducted Immunity| ISO 7637-2: 2004 Article

5

Transient Conducted Immunity| ISO 7637-3: 2007 Article

3.4.2

Electrostatic Discharge| ISO 10650-2008

Structure and Interface Description

Structure size diagram

Interface definition

Connector Pinouts

Note: the top left- hand pin is #1, increasing to the right, when viewing the low voltage receiving plug on the DCDC.

---|---|---|---|---
CANL| 6
Enable| 3
Output Ground| 1

Recommendations and Precautions

Ensure that the input voltage is within the allowable input voltage range of the DC-DC converter.
The converter is not equipped with an HV input fuse. It is recommended that the module be equipped with 15A / 600V fuse at the HV battery when using the module.
Ensure that the input polarity is correct before connecting to the HV battery.
Ensure that the output polarity is correct before connecting to the 12V auxiliary battery.
The output side of the DCDC converter must be connected to a 12V auxiliary battery in order to operate.
Do not mix or reverse the input and output wires.
Avoid hot plugging the HV connector to avoid arcing. Due to the high power, make sure that the HV input connector is firmly connected before turning on the main power switch or contactor on the high-voltage side.
Recommended to disconnect 12v positive output from the 12V auxiliary battery when DCDC is powered down. Options include use of a KSI or other relay of adequate current.