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
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
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
Connector schematic| Name| Pin definition| Specifications
****| High Voltage Input connector| Input+| 1| REM-Z2PA-2.5-A
Input—| 2
| DC Output Connector| Output+| NA| ACTB142-C-N
M8 screw hole| Output-| Case| M8 bolt
| Signal Connector| CANH| 5| MOLEX 477259010
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.