vanner hba overview 9-7-11

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.


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)


Dimensional Specifications(Dimensions are in inches)


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


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


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


Installation Photos

HV Battery

HBA

DPIM

Unit Installed on Roof of Bus (Fiberglass Cowling Removed)



Installation Photos Cont’d

Components Covered by Fiberglass Cowling

HBA LOCATION


HV Input Cable

HV Interlock Cable

HV Lug Box

HV Lug Box

Cover Removed

High Voltage Input



Fuse Panel

LV Cables

from Converter

I/O and CAN Connector

LV Output Terminals

and Cables

Low Voltage Output


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’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’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.



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



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.


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.


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 hba overview 9-7-11

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