TECHNICAL PRODUCT INFORMATION FLUID HEATERS Type RM 3/4 February 2008 MES DEA s.a. – Service - Copying of this document and giving it to others and the use or communication of the contents thereof are forbidden without express authority. Offenders are liable to the payment of damages. All rights reserved in the event of grant of a patent or the registration of utility model or designDoc. No. UM-Fluid Heater RM3 RM4 1.7-GEN_en Rev. 1.7 Page 1 di 13 TECHNICAL PRODUCT INFORMATION Table of contents 1 2 RM3/4 Wiring..............................................................................................................................3 Signals description:.....................................................................................................................3 2.1 GND.....................................................................................................................................................3 2.2 HEATER_EN (10 mA @ 12 V)..........................................................................................................4 2.3 FAULT_OUT......................................................................................................................................4 2.4 PLUS_POWER(+)..............................................................................................................................4 2.5 MINUS_POWER(-)............................................................................................................................4 3 Block Diagram Description:.......................................................................................................4 3.1 Semiconductor Fuse...........................................................................................................................4 3.2 Secondary HV Power Supply (SPS)..................................................................................................5 3.3 Thermal Bimetallic Switch (TBSW).................................................................................................5 3.4 Power Current Elevator (PCE).........................................................................................................5 3.5 HV Power Supply...............................................................................................................................5 3.6 Microprocessor...................................................................................................................................5 3.7 Power Switching Module (PSM).......................................................................................................5 3.8 Fluid Semiconductor Temperature Sensor......................................................................................5 3.9 Opto Isolation.....................................................................................................................................6 4 Functional Description:..............................................................................................................8 4.1 Mounting Considerations..................................................................................................................8 4.2 Constant Power Control....................................................................................................................8 4.3 Fluid Flow Interruption Control.......................................................................................................8 4.4 Liquid Absence Detection..................................................................................................................8 4.5 General Considerations......................................................................................................................8 5 6 7 8 9 Mechanical Dimension RM3: (3D CAD on request)................................................................9 Mechanical Dimension RM4: (3D CAD on request)..............................................................10 RM3/RM4 pressure drop..........................................................................................................11 Circulation Pump MR600.........................................................................................................12 Maintenance and services.........................................................................................................13 Doc. No. UM-Fluid Heater RM3 RM4 1.7-GEN_en Rev. 1.7 Page 2 di 13 TECHNICAL PRODUCT INFORMATION 1 RM3/4 Wiring Sig Nr. 1 2 3 Function Vehicle Ground Heater Enable Fault Output Plus Power Minus Power Cable colour RM3/4-Signal Diameter (IN/OUT/POWER) [mm²/AWG Number] Black [0,518/20] Brown [0,518/20] Blue [0,518/20] Red [6,63/9] Black [6,63/9] PLUS_POWER(+) (POWER) MINUS_POWER(-) (POWER) FAULT_OUT (OUT) HEATHER_EN (IN) GND 2 Signals description: 2.1 GND Vehicle Ground (minus pole of the onboard battery) - - Physically isolated from MINUS_POWER(-) Isolation Resistance > 2G Ω @ 1000V between PLUS_POWER or MINUS_POWER and any other Low Voltage Input or Output Doc. No. UM-Fluid Heater RM3 RM4 1.7-GEN_en Rev. 1.7 Page 3 di 13 TECHNICAL PRODUCT INFORMATION 2.2 HEATER_EN (10 mA @ 12 V) To enable the heater: - The Heater will be enabled with HEATER_EN input to 12 V (Min 8V , Max 18V) - The Heater will be disabled with HEATER_EN input floating or to GND - Available 24V version 2.3 FAULT_OUT Fault output (Open Collector:MAX 10 mA, 50 V), in case of: - - - - - Overvoltage Overtemperature, T >= 80°C Fluid flow interruption (Temperature Gradient based algorithm) Fluid absence detected (Temperature Gradient based algorithm) Intermittent when the temperature is in the right range after (2-3-4) fault condition: the normal operating will automatically reestablish 2.4 PLUS_POWER(+) Plus pole from traction net - - Maximal current from the net: Imax = 40 Amp RMS with 100 V , 4000Watt Heater Isolation Resistance > 2G Ω @ 1000V between PLUS_POWER or MINUS_POWER and any other Low Voltage Input or Output 2.5 MINUS_POWER(-) Minus pole from traction net - Physically isolated from Vehicle Ground - Isolation Resistance > 2G Ω @ 1000V between PLUS_POWER or MINUS_POWER and any other Low Voltage Input or Output 3 Block Diagram Description: 3.1 Semiconductor Fuse The semiconductor fuse is responsible for Heater safety. Its short clearing time ( about 20 µs) , guarantees an high safety level during heater operation. The semiconductor fuse is cleared by the heater control under the following conditions: - - Doc. No. UM-Fluid Heater RM3 RM4 1.7-GEN_en Fluid temperature > 95°C Power Switching Module Hardware problems (short-circuit) Rev. 1.7 Page 4 di 13 TECHNICAL PRODUCT INFORMATION 3.2 Secondary HV Power Supply (SPS) In case of hardware fault the secondary HV Power Supply is charged to clear the fuse. - The SPS module activate the Power Current Elevator in case of Tfluid > 95°C 3.3 Thermal Bimetallic Switch (TBSW) The Thermal Bimetallic Switch is a component independent from the control circuit. If the liquid temperature would rise above 95°C , the TBSW will activate the Power Current elevator to clear the fuse , disabling the heater. 3.4 Power Current Elevator (PCE) The Power Current Elevator is an important part of the safety system, and is charged to clear the fuse under the following conditions: - - Fluid temperature > 95°C Power Switching Module Hardware problems (short-circuit) The clearance of the fuse is obtained by increasing the current. This is the task of the PCE 3.5 HV Power Supply The control circuit is supplied from the traction net. The internal DC/DC need Ubat >= 40V in order to operate properly. 3.6 Microprocessor The microprocessor is the arithmetic/logic unit of the control board. Beside, safety function which are independents , all the other function are implemented in the firmware. 3.7 Power Switching Module (PSM) The PSM control the heating resistors current , as well as the constant heating power control. 3.8 Fluid Semiconductor Temperature Sensor The fluid sensor is dip in the fluid. The measurement allows the controller to keep the fluid temperature at nominal value with an hysteresis of 4°C. Doc. No. UM-Fluid Heater RM3 RM4 1.7-GEN_en Rev. 1.7 Page 5 di 13 TECHNICAL PRODUCT INFORMATION 3.9 Opto Isolation Heater signal inputs and outputs are galvanically insulated from HV potentials coming from traction net. Isolation Resistance > 2G Ω @ 1000V between PLUS_POWER or MINUS_POWER and any other Low Voltage Input or Output Doc. No. UM-Fluid Heater RM3 RM4 1.7-GEN_en Rev. 1.7 Page 6 di 13 TECHNICAL PRODUCT INFORMATION Block Diagram Safety parts Heater enable OPTO ISOLATION Fault Cap discharge Vehicle Ground Semiconductor FUSE (55A 660V) + traction Battery Secondary HV POWER SUPPLY HV POWER SUPPLY Heating resistor Enable clearing semiconductor fuse PWM control electronic from µC µC PIC + POWER SWITCHING MODULE POWER CURRENT ELEVATOR (to clearing semi-fuse) THERMAL BIMETALLIC SWITCH (Ton = 95°C) & ELECTRONIC Control loop Enable clearing semiconductor fuse Fluid semiconductor temperature sensor - traction Battery Doc. No. UM-Fluid Heater RM3 RM4 1.7-GEN_en Rev. 1.7 Page 7 di 13 TECHNICAL PRODUCT INFORMATION 4 Functional Description: 4.1 Mounting Considerations The Heater must be mounted vertically ,with a maximal inclination of 20 degrees. At 25 °C the fluid Level must be at least 6 cm below the top of the heater (RM4). 4.2 Constant Power Control The Heater is controlled by a PWM circuit which maintains the power constant over the voltage range. The total Power control error is lower than ± 5% of the nominal power 4.3 Fluid Flow Interruption Control The Heater can detect a fluid flow interruption (Temperature Gradient based algorithm), in this case FAULT_OUT is activated ( set to GND), and the heater is disabled. To reenabled the device , HEATER_EN must fall from HIGH to LOW state and then rise from LOW to HIGH again, or automatically after 1 min if the temperature return in the normal range. 4.4 Liquid Absence Detection The Heater can detect a fluid absence (Temperature Gradient based algorithm), in this case FAULT_OUT will be active (to GND), and the heater is disabled. To reenabled the device , HEATER_EN must fall from HIGH to LOW state and then rise from LOW to HIGH again, or automatically after 1 min if the temperature return in the normal range. 4.5 General Considerations The Heater does not accept reverse polarity (semiconductor fuse protected). The FAULT_OUT signal is intended for Heater monitoring only , and can not be used as logical command for other devices of the vehicle. This restriction is due to the delayed activation of FAULT_OUT, in case of detection of a fluid interruption or fluid absence. Doc. No. UM-Fluid Heater RM3 RM4 1.7-GEN_en Rev. 1.7 Page 8 di 13 TECHNICAL PRODUCT INFORMATION 5 Mechanical Dimension RM3: (3D CAD on request) α Max mounting angle α = 20 degrees Technical data RM3: - - - - - - Doc. No. UM-Fluid Heater RM3 RM4 1.7-GEN_en Temp regulation: 70°C +- 2°C Version: (Umin,Umax) Power +-5% 100/250V, 2000W 100/250V 3000W 100/250V 4000W 200/450V 2000W 200/450V 3000W 200/450V 4000W Weight: 1,7 Kg Diameter A: 16.5 – 18 – 20 mm Max mounting angle: 20 degrees Other versions on request Rev. 1.7 Page 9 di 13 TECHNICAL PRODUCT INFORMATION - 6 Mechanical Dimension RM4: (3D CAD on request) MR600 6 cm Max Fluid Level at 25°C α Max mounting angle α = 20 degrees Technical data RM4: - - - - - - - Temp regulation: 70°C +- 2°C Version: (Umin,Umax) Power +-5% 100/250V 2000W 100/250V 3000W 100/250V 4000W 200/450V 2000W 200/450V 3000W 200/450V 4000W Weight:: 2.8 Kg Diameter A : 16.5 – 18 – 20 mm Glycol thank: 2 liters Max mounting angle : 20 degrees Other versions on request Doc. No. UM-Fluid Heater RM3 RM4 1.7-GEN_en Rev. 1.7 Page 10 di 13 TECHNICAL PRODUCT INFORMATION - 7 RM3/RM4 pressure drop RM3 PRESSURE DROP30.0025.0020.0015.0010.005.000.000100200300400Q [l/h]500600700800900 RM4 PRESSURE DROP (without pump)∆P[mBar] 25.0020.00P [mBar]15.0010.005.000.000100200300400Q [l/h]500600700800900 Doc. No. UM-Fluid Heater RM3 RM4 1.7-GEN_en Rev. 1.7 Page 11 di 13 TECHNICAL PRODUCT INFORMATION 8 Circulation Pump MR600 Technical data MR600: - - - - - - - Nominal Voltage: 13 VDC Max. Pressure: 0.45 bar Max flow rate: 750 l/h Max. current: < 2.5 A Outlet diameter øA: 16.5 – 18 mm Type of service: continuous, life >10'000 h Note: a 3A fuse as to be used Doc. No. UM-Fluid Heater RM3 RM4 1.7-GEN_en Rev. 1.7 Page 12 di 13 TECHNICAL PRODUCT INFORMATION 9 Maintenance and services The fluid Heaters RM3/4 do not require regular maintenance. In case of a fault it is highly recommended to send the faulty unit together with a description of the fault and operating condition to S.A. attn. U. Cassani Via Laveggio, 15 CH – 6855 Stabio Switzerland for repair or replacement to be paid after expiration of warranty. Doc. No. UM-Fluid Heater RM3 RM4 1.7-GEN_en Rev. 1.7 Page 13 di 13
