High Voltage DC-DC Converter VANNER HBA (Hybrid Beltless Alternator)

High Voltage DC-DC Converter VANNER HBA    (Hybrid Beltless Alternator)
VANNER Incorporated
Owner’s Manual
High Voltage DC-DC Converter
HBA
(Hybrid Beltless Alternator)
Table of Contents
Introduction………………………………………………….………………… 3
Specifications…………………………………………………….………….… 4
Operation……………...………………………………………………………. 6
Installation Instructions…………………………...…………….……………. 8
Testing and Troubleshooting………………………………………………… 15
Vann-Bus Battery Management………....………..………………………… 20
Dual HBA System…………………………………..………………………… 24
CAN Bus Specification……………………………..………………………… 27
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Notes
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Owner’s Manual
Introduction
Thank you for purchasing Vanner’s High Voltage DC-DC Converter. We are confident that you will be
very pleased with its performance because Vanner products are designed and manufactured by skilled
professionals using the highest standards in workmanship. With minimum maintenance and care, you can
be assured of many years of trouble free service.
General Description
The Vanner High Voltage DC-DC Converter (commonly referred to as HBA in this document) is an
efficient and highly reliable method of converting high dc voltage present in hybrid drive systems to low dc
voltage (24V) for auxiliary batteries and loads. The converter is designed to be a direct replacement for a
belt driven alternator to increase reliability and reduce maintenance costs.
The converter is J1939 CAN (Controller Area Network) enabled and is fully configurable and controllable
over a J1939 compliant network but is also capable of autonomous operation. The converter is designed
to monitor and report the status of several critical functions and provides real-time fault signals over the
CAN bus to the vehicle electrical system controller.
A typical system includes a high voltage energy source (500 – 780VDC), a Vanner HBA and a low
voltage battery bank for auxiliary loads. The HBA is provisioned with a two pin sealed connector for
integration into the vehicle’s high voltage interlock system and a fourteen pin sealed circular connector for
CAN and vehicle I/O.
Paralleling: The outputs of two HBA's may be connected in parallel to double the output capacity of the
24V charging system. Please contact Vanner engineering and/or sales for the appropriate HBA model
number for your dual application.
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Specifications
High Voltage DC-DC Converter
Model Numbers
HBA400-*
HBA500-*
Single HBA Current Rating
250A
300A
Dual HBA Current Rating
500A
600A
Input Voltage Range (VDC)
Input Voltage (VDC) – Full Power Out
Input Under-Voltage Range (VDC)
Under-Voltage Current Limit Range (A)
Efficiency (At Maximum Power)
Max Input Current (AMPS)
Output Voltage Range (VDC)
Max Output Current (AMPS)
Max Ripple Voltage (mV)
Standby Current (Milliamps)
Cooling Method
High Voltage Discharge
Operating Temp.
Storage Temp.
550
600
See graph below
See graph below
91%
15
17
24 - 30
250
300
<100mV RMS
<20mA
Forced Air
Upon removal of high voltage power source or terminal access cover, caps
will discharge to 50 VDC or less within 30 seconds.
-40°C to +60°C
Full Power Output
80°C - Half Power Output
-40°C to +85°C (-40°F to 185°F)
Internal components to be serviced by Vanner personnel only.
Fan filter/finger guard to be removed and cleaned of dirt/debris quarterly.
Serviceable
Environmental Considerations
IP55 Rated
Mounting Location
Weight (lbs.)
500 – 780
Plated sheet steel enclosure provides protection against salt, fungus, dust,
water, fuel vapors and all fluids associated with commercial and offhighway vehicle operations.
Mount on a flat surface (horizontal or vertical) close to the high voltage
batteries to allow short cable runs.
75 (34kG)
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Dimensional Specifications
(All Dimensions are in Inches)
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Operation
Converter Start Up/Normal Operation
In order for the HBA to start successfully, the following conditions must be met;
1. The low voltage battery shall be between 16 – 32 VDC.
2. The high voltage battery shall be between 500 – 800 VDC.
3. The converter must receive a +24V enable signal on Pin A of the circular I/O connector.
a. For vehicles with pre MY2013 engines, the wakeup signal may come from the engine oil
pressure switch.
b. For vehicles with MY2013 engines or newer, the wakeup signal originates from the hybrid
drive train transmission control module. Contact Vanner engineering for details.
4. The converter must receive a CAN message to turn on.
a. For vehicles with pre MY2013 engines; the HBA must receive an engine RPM signal via
CAN message. The engine speed must be equal to or greater than 400 RPM for 0.1
second. (After start up, the HBA will shut down if the engine speed is less than 350 RPM
for 4.0 seconds.)
b. For vehicles with MY2013 engines or newer; the HBA On/Off controls are handled via
CAN message from the hybrid drive train controller. Note: Contact Vanner engineering
for the latest version of the HBA CAN Messages Specification.
Normal Operation
The HBA can provide up to full rated output (250 or 300 amps) of continuous current and maintain 29
volts out across a DC input range of 550 – 800 volts. It can maintain this output in ambient
temperature conditions of -40° to +60°C.
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. (See chart on page 4.) 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. (See chart on page 4.) 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.
LV Battery Conditions
The low voltage battery must be greater than 16V but less than 32V for the HBA to start.
If the low voltage battery drops below 15V or goes above 32V, the HBA will perform a soft shutdown.
The converter will restart automatically if the voltage returns to the normal operating range of 16 –
32V.
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Overload Condition
The HBA is current limited to its rated output current (250 or 300 amps). If the 24V load exceeds the
HBA's rated output current, it will continue to provide its rated output current until the battery voltage
falls below 20V. If the battery voltage falls below 20V the HBA will current limit at 90 amps. If the
battery voltage falls below 16V the HBA will shut down.
Output Short Circuit Protection
There are three ways that the output of the HBA is protected from short circuits.
1. The output current increment is monitored and if the rate is above 10A / 100µs, the HBA will
perform a soft shutdown.
2. A comparator will generate an over-current signal if the current in the high voltage side of the
transformer exceeds 70A. The HBA software will detect this signal and the HBA will perform
a soft shutdown.
3. Hardware will detect an over current condition. Once the current in the high voltage side of
the transformer reaches 90A, the HBA will perform a soft shutdown.
The HBA will automatically restart upon removal of the fault condition.
Thermal Protection
The temperatures of critical components within the HBA are continuously monitored. The highest
temperature of these components will be used for temperature control.
During light load conditions (less than 80% of the nominal current rating) the cooling fan will be turned
on at 75°C and turned off at 70°C.
During high load conditions (greater than 80% of the nominal current rating) the cooling fan will be
turned on at 70°C and turned off at 65°C.
The HBA will shut down if any of the following conditions exist:
 temperature on the low voltage power stage reaches 82°C, or
 * temperature on the high voltage power stage reaches 98°C, or
 * temperature on the control board reaches 98°C
The HBA will restart automatically if all of the following conditions exist:
 temperature on the low voltage power stage drops below 78°C, and
 temperature on the high voltage power stage drops below 92°C, and
 temperature on the control board drops below 92°C

The output of the HBA will current limit if the temperature on the high voltage power stage and
control board is below 98°C but above 92 degree C. The output current will be incrementally
reduced to avoid thermal shutdown conditions.
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Installation Instructions
These symbols are used to note procedures that if not closely followed could lead to loss of life or
damage to equipment or property due to electrocution.
Electrocution hazard exists
Fire hazard exists
A potentially dangerous condition
Explosive hazard exists
Corrosive hazard exists
Do not exceed the specified torque of 100 lb-in when connecting cables to the 5/16-18
terminal posts (±24 and ±600V) during installation of the HBA. Torque values higher than specified may
damage the product, reduce performance, and/or create hazardous conditions. Products damaged by
improper torque are not covered by the warranty.
Do not connect more than one conductor per terminal post on Vanner HBA. Multiple wires
and cables may overstress internal components, resulting in poor performance or creating hazardous
conditions. Products damaged by the installation of multiple conductors per post are not covered by the
warranty.
Fault protection devices must be installed between the HBA and the power
source (battery). A fault protection device would be any fuse or circuit breaker properly rated for the
maximum DC current obtainable. This advisory is in accordance with SAE, NEC and UL, for mobile power
applications. Install per applicable codes or within 18” of the battery. See Wire and Fuse Sizing Chart on
page 13 of this manual or contact Vanner at 1-800-227-6937 or [email protected] if assistance is
needed in sizing fault protection devices.
Caution: This equipment tends to produce arcs and sparks during
installation. To prevent fire or explosion, compartments containing batteries or flammable materials must
be properly ventilated. Safety goggles should always be worn when working near batteries.
Mounting Location –The HBA must be mounted on a flat horizontal or vertical surface suitable
for support during application. The HBA must be mounted under a cover to protect it from direct exposure
to the elements, i.e., rain, sun, sleet/snow. Do not mount in a zero-clearance compartment that may
result in overheating. Care should also be taken when selecting a mounting location to ensure the fan
inlet and outlet locations are not blocked. A minimum of four inches should be allowed at fan inlet and
outlet. Locate the HBA so that contact by unauthorized personnel is unlikely.
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Mounting Dimensions
(Bottom View – Dimensions are in Inches)
23.1
10.5
12.2
.406 x .750 OBROUND, TYP 4 PL
Environmental Protection
Although your HBA has been designed to an IP55 rating, it must be mounted under a cover to protect
it from direct exposure to environmental elements such as sun, rain, sleet and snow. The converter
has also been designed for exposure to direct pressure spray, but continual exposure to direct
pressure spray may reduce the serviceable life. Any damage due to water contamination is covered
by Vanner only through the terms of the factory warranty.
Wiring Sequence
High Voltage Input: The HBA's high voltage input is internally protected for reverse polarity.
24V Output: The HBA’s 24V output is not reverse polarity protected. The HBA will be damaged if the
24V battery is connected to the HBA with the positive and negative reversed. To protect the positive
cable, it shall be fused as close to the battery as practical.
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Wiring Input/Output Definitions
CAN and Ignition I/O
See Wiring Diagram
for Pin Designations
5/16-18 Low Voltage
Output Terminals.
Terminating hardware
provided by Vanner.
High Voltage Lug Box
Low Voltage Output Terminal
Designations
LUG INSTALLATION DETAIL
FLAT WASHER
CONICAL
WASHERS
+
NUT
STUD
TORQUE = 100LB-IN
120LB-IN MAX.
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LUG
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High Voltage Input and Interlock Designations
5/16-18 High Voltage
Input Terminals.
Terminating hardware
provided by Vanner.
High Voltage Lug Box Provisioned
with a 1.85" Diameter Hole for a
Threaded Connector, PG-36 Size Threads
+
-
HVIL HVIL
Connector
(High Voltage Interlock)
Connector
Molex Panel
Mounted
Plug, Part #19429-0033
Molex
#194290033
Mates with Molex Receptacle, Part #19418-0007
and MolexFor
14-16
AWG
Socket, Part
mating
connector
use #19420-0009
Molex #19418-0007 (14 - 16 AWG)
or Molex #19418-0008 (18 - 22 AWG)
Limit Switch for HVIL,
Detects When Cover
has Been Removed
For terminals use
Molex #19420-0009 (14 - 16 AWG)
or Molex #19420-0010 (18 - 22 AWG)
HIGH VOLTAGE LUG
INSTALLATION DETAIL
FLAT WASHER
SPRING
WASHER
NUT
TORQUE = 100LB-IN
120LB-IN MAX.
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STUD
LUG
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HBA Wiring Diagram w/Vanner 70 Series Equalizer
High
Voltage
Battery
F3
F2
High
Voltage
Interlock
Vanner
70 Series
Equalizer
12V Battery B
+24V
+12V
F1
Vanner High
Voltage DC-DC
Converter
GND
24V Loads
A
B
C
D
E through P
+24V Enable
CAN - Shield
P
E
CAN - High
TBD
A
G
M
C
L
B
H
12V Loads
N
D
F
CAN - Low
12V Battery A
J
K
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I/O Definitions and Functionality (Pins E through P are Optional)
A. +24V Enable Input
This input “wakes up” the HBA and must be present for the HBA to turn on.
B. CAN Shield
This connection is used to make the shield on the CAN cable common. This is required for
electrical noise considerations in vehicle electrical systems.
C. CAN Low
This is the low signal connection for the vehicle’s CAN bus. The HBA will communicate faults to
the vehicle’s electrical system controller via the CAN bus.
D. CAN High
This is the high signal connection for the vehicle’s CAN bus. The HBA will communicate faults to
the vehicle’s electrical system controller via the CAN bus.
E through L - TBD
M. For DUAL HBA Installations only. (See wiring diagram on page 24.)
Installing a jumper between Pins M and N designates the HBA as the PRIMARY unit.
N. For DUAL HBA Installations only. (See wiring diagram on page 24.)
Installing a jumper between Pins M and N designates the HBA as the PRIMARY unit.
Installing a jumper between Pins N and A designates the HBA as the SECONDARY unit.
P. TBD
Note: The HBA I/O connector is a panel mounted Deutsch receptacle P/N: HDP24-18-14PN. A typical
mating connector is Deutsch plug P/N: HDP26-18-14SN provisioned with Deutsch socket contacts
P/N: 1062-16-0622. The Deutsch part numbers for the mating plug and contacts will vary depending on
the wire gauge, insulation type and back-shell used. Select the proper sealing ring option for the wire
insulation diameter to ensure proper sealing.
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Wire Size and Temperature Rating
Cables connecting the HBA to the 24V batteries must be sufficiently sized to prevent unwanted voltage
drop. The temperature rating of the wire should be a minimum of 90ºC.
Vanner recommends the following wire and fuse sizes for the 250A and 300A HBA's. To protect the
positive cable, it shall be fused as close to the 24V battery as practical.
HBA Low Voltage Output Wire and Fuse Size Chart
Wire
Ring Terminal
Size
Fuse F3
Panduit
AWG
#4/0
*LCD4_0-56000-CUST
400 amp
* The Panduit part number listed is recommended, not required, by Vanner. Equivalent substitutes may
be used. Contact Vanner engineering for a drawing of the Panduit ring terminal.
The recommended terminal is a right angle lug that enables the installer to route the 4/0 cables along the
side of the HBA. Factory installed tie wrap bases are present on the side of the HBA for strain relief.
Crimp the ring terminals using Panduit CT-930 manual/hydraulic crimping tool.
Use Panduit die CD-920-4/0 die. (Purple P54).
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Testing and Troubleshooting
CAUTION
Servicing of electrical systems should only be performed by trained and qualified technical personnel.
Equipment Required
Required: A laptop provisioned with Vanner's Dashboard software, supporting hardware and
interface cables.
Note: There are kits available for purchase that include Vanner's Dashboard software, a USB to CAN
adapter module and a harness to connect to the vehicle's CAN network. Please contact Vanner's
inside sales department for the appropriate kit part number for your application.
Optional:
Volt Meter having 0.01 volt resolution. (Fluke Model 87 Multimeter recommended).
Clamp-on current meter (Fluke Model 36 Clamp-on Meter recommended).
Test Procedure for HBA
The HBA is working properly if:
1. The 24 volt DC loads are being operated continuously and are within the rated capacity of the HBA
and;
2. The power drawn from the hybrid drive train system is within its rated capacity.
HBA Test Procedure:
1. Field-test the HBA while fully connected to the vehicles high and low voltage batteries.

The 24V battery must measure between 16 and 32 volts. If the 24V battery is below 16 volts,
apply a 24 volt battery charger to the batteries.

The high voltage battery must measure between 500 and 780 volts for the HBA to start properly.
2. Start the vehicle normally while monitoring the HBA status with a laptop provisioned with Vanner’s
Dashboard software. The laptop must be connected to the vehicle CAN Bus utilizing a USB to CAN
adapter and harness.

The HBA will turn on automatically upon receiving the engine RPM signal or CAN On/Off
command via CAN bus and a +24V enable signal.

Upon normal system startup, the output voltage will increase to 28.5 volts and the output current
will increase indicating charging of the 24V batteries and providing power for the 24V auxiliary
loads.
3. The Vanner Dashboard software monitors the following data which can be observed on the laptop;
High Input Voltage
High Input Current
Engine RPM
Heartbeat
CAN On/Off Command Message Status
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Low Output Voltage
Low Output Current
Power Stage Temps. Control Board Temp
Converter Status and Faults
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Dashboard screenshot of a system under normal operating conditions
4. If the Vanner Dashboard software isn’t utilized or available, proper start up can be validated by
measuring the 24V output terminals with a Volt Meter. Upon start up, the voltage will increase from
the 24V battery nominal value up to ≈ 28.5 volts. Note: The measurement is dependent on the
voltage drop in the cables/bolted connections between the HBA output terminals and the 24V
battery terminals.
5. A clamp on style current meter can also be used to validate the output current of the HBA.
6. Important: The high voltage terminals are inaccessible for measurement. A high voltage interlock
circuit is implemented for safety purposes to prevent an accidental and potentially lethal shock to
personnel. The high voltage input to the HBA can only be read via the Dashboard software.
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Trouble Shooting an HBA No-Start Situation
In the event the Vanner HBA does not start, the following need to be reviewed/validated;
1. Is the high voltage battery within the acceptable input range? 550 - 780VDC
2. Is the 24V battery within the acceptable range? 20 – 32VDC
3. Is 24V battery voltage present at the output terminals of the HBA upon closing the battery disconnect
switch?
4. If not, verify the fuse between the 24V battery and the HBA is installed and hasn’t cleared.
5. Upon startup of the engine, does the 24V battery remain within the acceptable range? If the health of
the 24V batteries is questionable, the voltage may collapse below 20 volts before the HBA starts.
There is an approximate 2 - 3 second delay from the time the engine starts to the start of the HBA.
6. Is the +24V enable signal present at the I/O connector?
7. If the +24V enable signal is present, is the wire in the proper location of the mating I/O connector?
8. For vehicles with pre MY2013 engines: Is the engine rpm data being transmitted properly via the
CAN Bus? PGN 61444 (0xF004)
9. If so, is the engine rpm greater than 400 rpm?
10. For vehicles with MY2013 engines or newer, is the "Converter Control" command message being
received? PGN 65498 (0xFFDA)
11. If the answers to 5 and 6 are yes, are the CAN signal wires (HI,LO and Shield) in the proper locations
of the mating connector?
HBA Status and Fault Indication Definitions
The HBA monitors several status and fault conditions. If any faults occur, they are reported via CAN
bus and can be observed with the Dashboard software. The HBA status and fault indications in the
lower left corner of the screenshot on page 16, are defined as follows;
DC/DC Converter ON: Green indication that HBA has turned on successfully
DC/DC Converter OFF: Red indication that HBA is off. If the reason is due to a fault, that condition
will be indicated by a red icon.
Engine RPM/ Low or CAN Data Loss: The HBA will perform a soft shutdown if the engine speed
drops below 350 RPM for four seconds or there is a loss of CAN communication. The HBA will
restart automatically when the engine speed exceeds 400 RPM for 0.1 seconds or CAN
communication is restored.
HVPS (High Voltage Power Stage) Imbalance Fault: Internal circuitry detects if the voltage
differential between the center point to negative and center point to positive is excessive, > 200V. If
an imbalance fault is detected, the HBA will "permanently" shut down. The unit will not restart
automatically if the imbalance condition clears, the ignition must be cycled off and on. See note
below.
Note: An imbalance fault can be caused by leakage current or a defective detection circuit within the
HBA. However, the HBA will also detect external leakage paths. The external leakage path could be
caused by water ingress in a high voltage cable assembly or junction box. It could also be caused by
damaged shielding on a high voltage cable assembly. If the high voltage imbalance fault does not
clear after cycling the ignition, Vanner recommends inspecting the high voltage cable assemblies for
leakage paths.
Over Temperature Fault: The HBA will perform a soft shutdown if any of the following conditions
exist: the temperature on the low voltage power stage reaches 82°C, or the temperature on the high
voltage power stage reaches 98°C, or temperature on the control board reaches 98°C. The HBA will
restart automatically if all of the following conditions exist: the temperature on the low voltage power
stage drops below 78°C, and the temperature on the high voltage power stage drops below 92°C,
and the temperature on the control board drops below 92°C.
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HBA Status and Fault Indications Cont'd
Input Overvoltage Fault: The HBA 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” shut down. The unit will not restart
automatically if the input voltage drops below 750V, the ignition switch must be cycled off and on.
Input Under Voltage Fault: The HBA will perform a soft shut down if the input voltage drops below
500V. Once the input voltage is equal to or greater than 550V, the converter will restart
automatically.
Output Overvoltage Fault: The HBA will perform a soft shutdown if the low voltage battery exceeds
32V. The HBA will restart automatically if the voltage returns to the normal operating range of 16 32V.
Output Under Voltage Fault: If the low voltage battery drops below 15V, the HBA will perform a soft
shutdown. The converter will restart automatically if the voltage returns to the normal operating range
of 16 – 32V.
Output Overload Fault: The HBA is current limited to 250A or 300A. If the load is above 250A or
300A, the unit will begin current limiting and gradually reduce the output voltage. Once the HBA
output voltage decreases to a value less than or equal to the battery voltage, the batteries will begin
to assist in supporting the load. If the load continues to increase and the output voltage drops to 20V,
the output current will begin to fold back. If the output or battery voltage is reduced to 16V, the HBA
will turn off. The HBA will restart automatically if the loads are reduced and the battery voltage
returns to the normal operating range of 16 - 32V.
Over Maximum Current Fault: The HBA will perform a soft shutdown if the current flowing through
an internal power stage current transformer exceeds 90A. The HBA will restart automatically if the
current returns to a value below 90A.
+12V Power Supply Failure Fault: The HBA will perform a permanent shutdown in the event of a
+12V power supply failure. The unit should be replaced and the failed unit returned to Vanner for
evaluation.
LV Gate Drive +12V Failure: The HBA will perform a permanent shutdown in the event of a LV Gate
Drive +12V power supply failure. The unit should be replaced and the failed unit returned to Vanner
for evaluation.
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Testing an HBA for an Isolation Fault
In the event the vehicle is experiencing an isolation fault, the HBA should be eliminated as the cause of
the fault prior to replacing any hybrid drive components. The isolation resistance of an HBA can be
tested using an Amprobe AMB-45 Megohmmeter, commonly referred to as a "megger".
WARNING! The Vanner HBA uses potentially lethal voltages for operation. DO NOT attempt to test
the HBA unless you have been trained to work with the Allison H 40/50 EP system.
1. Before beginning, reference Allison Transmission's "Electrical Disconnect Verification Procedure" for
the H 40/50 EP product family. It contains important steps that are not covered in these instructions.
2. High Voltage Personal Protective Equipment (PPE) must be worn for this procedure.
3. Assure that the vehicle ignition switch is in the OFF position.
4. Assure that the vehicle master battery disconnect switch is in the OFF position. Use lockout devices
to assure the switch cannot be moved to the ON position until the test procedure is complete.
5. Disconnect the high voltage positive and negative cables from the HBA input studs.
6. Insulate the ring terminals.
7. Do not disconnect the 24V positive and negative cables, 14 pin Deutsch connector, and chassis GND
8.
9.
10.
11.
12.
13.
from the HBA. Note: If bench testing, connect HBA 24V negative to HBA chassis.
Set the AMB-45 to the 250V scale.
Connect AMB-45 negative to HBA chassis.
Connect AMB-45 positive to HBA high voltage positive stud. Measure and record resistance.
Connect AMB-45 positive to HBA high voltage negative stud. Measure and record resistance.
See table below for proper resistance readings.
If either resistance reading is significantly lower than specified, the HBA may be defective and should
be returned to Vanner for repair.
HBA Serial Number
Positive to Chassis Negative to Chassis Actual Measurement
Pos to Chassis:
Prior to 13246-250093
810kΩ ±10%
Neg to Chassis:
Pos to Chassis:
After 13246-250093
2.8MΩ ±10%
Neg to Chassis:
Vanner Repair Service
Vanner offers a quick turnaround factory repair service. Send the unit to the address on last page
with a note instructing us to repair it. Include your name, phone number, shipping address (not a
P.O. Box Number), and your purchase order number.
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Vann-Bus Battery Management
Vanner 80 Series Equalizer and Sensors
A vehicle with 12 and 24 volt loads may be provisioned with the following Vanner parts to permit
dynamic voltage regulation of the HBA.
1. 80 Series Equalizer
When connected to the I/O of the current and voltage/temperature sensors listed below, the 80 series
equalizer utilizes Vanner's MBBM (Model Based Battery Monitoring) algorithm to determine the SOH
(State of Health) and SOC (State of Charge) of the 12 and 24 volt batteries.
The equalizer will communicate the appropriate voltage requirement, based on the battery
manufacturers data, to the HBA which will adjust its output accordingly. The voltage requirement
communicated to the HBA is based on the voltage at the battery terminals, therefore, voltage drop
contributed by the cables and bolted connections is taken into consideration.
Note: The appropriate battery model must be loaded in the equalizer for maximum accuracy of the
SOH and SOC calculations. Please contact Vanner for a library of batteries that are modeled to
ensure the proper equalizer part number is ordered or the proper battery profile is loaded in memory.
2. Dual Current Sensor (80A/600A)
The dual current sensor, VSS-C80/600, monitors the current flowing into and out of the 24V battery.
3. Single Current Sensor (80A)
The single current sensor, VSS-C80, monitors the current flowing into and out of the 12V battery.
4. Voltage and Temperature Sensor
The voltage and temperature sensor, VSS-VT, monitors the 12V battery voltage as well as the
temperature. It is mounted to the positive terminal of the 12V battery.
See page 21 for the HBA/Equalizer wiring diagram with the addition of the sensors and their pinout
definitions.
Operational Theory
There are two operating modes for the HBA, standalone and battery management. If battery
management is turned off or CAN messages from the equalizer/battery monitor are not received, the
HBA defaults to standalone mode and regulates the output voltage locally at a fixed value. Note: the
factory default is 28.5V but is user configurable via the dashboard interface.
In battery management mode, the output voltage reference is adjusted to regulate the output voltage
remotely at the battery. The reference is adjusted at a rate of 0.1V/second. The upper limit of the
reference voltage is 1.0V above the standalone output voltage.
If the battery SOC is 100% or the battery status is quiescent (quiescent is defined as when there is
less than 5 amps going into or out of the batteries), the remote voltage is set to the float voltage
value. Otherwise it is set to the absorption voltage value. The float voltage and absorption voltage
are adjusted automatically with temperature according to a pre-defined curve.
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Enabling Battery Management
Battery management is enabled through Vanner's dashboard interface. At the HBA startup screen,
verify the "Battery Management" status is "On". If it is off, select the "Set Output Voltage" icon to turn
it on.
Note: The default factory setting is "On". Battery Management only works if an 80 series equalizer
and sensors are installed.
Note the low voltage battery status information displayed in the lower right corner of the screenshot
below. The battery terminal voltage, state of health (SOH), state of charge (SOC) are all displayed as
well as the charging modes, Charge/Quiescent/Discharge. Also note the difference in the battery
voltage (27.8) and HBA voltage (28.3). This difference (0.5V) reflects the voltage drop in the
cable/bolted connections between the HBA output terminals and the battery terminals at the indicated
load of 125.9 amps.
Screenshot of HBA Dashboard with Battery Management "ON"
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HBA Wiring Diagram w/Addition of Vann-Bus Sensors
High
Voltage
Battery
F3
F2
Current Sensor
VSS-C80/600
High
Voltage
Interlock
Vanner
80 Series
Equalizer
12V Battery B
+24V
+12V
F1
Vanner High
Voltage DC-DC
Converter
Volt/Temp Sensor
VSS-VT
Current Sensor
VSS-C80
GND
24V Loads
A
B
C
D
E through P
+24V Enable
CAN - Shield
P
E
CAN - High
TBD
A
G
M
C
L
B
H
12V Loads
N
D
F
CAN - Low
12V Battery A
J
K
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Pinouts for 80 Series Equalizer and Vann-Bus Sensors
Sensor +5V Supply
+24V Ignition Input
CAN Shield
CAN Low
N
P
E
D
M
Vanner
80 Series
Equalizer
CAN High
L
F
G
B
K
J
Spare
Dual Curr Sensor, High
A
C
H
Sensor Ground
Dual Curr Sensor, Low
Single Curr Sensor
Temperature Sensor
+24V Remote Sense
+12V Remote Sense
Ground Remote Sense
Voltage/Temperature Sensor Pinouts (VSS-VT)
Sensor Pin #
Description
Equalizer Pin Letter
1
+5V Input
A
2
Ground
H
3
Temperature Sense
L
4
Fused +12V (From Bus Bar)
N
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Voltage/Temp
Sensor
80A Single Current Sensor Pinouts (VSS-C80)
Sensor Pin #
Description
Equalizer Pin Letter
1
+5V Input
A
2
Ground
H
3
Current Sense
K
4
Spare
-
Dual and Single
Current Sensor
80/600A Dual Current Sensor Pinouts (VSS-C80/600)
Sensor Pin #
Description
Equalizer Pin Letter
1
+5V Input
A
2
Ground
H
3
Current Sense, Low
J
4
Current Sense, High
G
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Dual HBA's - General Description
Paralleling Two HBA's
Two versions of HBA's, HBA400-28-CAN-DUAL and HBA500-28-CAN-DUAL, have been developed to
load share when the outputs are connected in parallel. Two HBA400-28-CAN-DUAL HBA's connected in
parallel provide 500A of 28V charging current and two HBA500-28-CAN-DUAL HBA's connected in
parallel provide 600A of 28V charging current.
When connected in parallel, one unit is designated as the "Primary" (Master) unit and the other as
"Secondary" (Slave) by installing external jumpers in the circular I/O connector. To designate a unit as
the Primary, install a jumper between pins "M" and "N". To designate a unit as the Secondary, install a
jumper between pins "A" and "N". (See wiring diagram on next page.)
The two units communicate with each other via the vehicle CAN network with the Primary unit providing
voltage and control loop logic information for the Secondary unit. Any imbalances introduced to the
system, i.e. rapid load changes, are automatically compensated for to ensure equal load sharing.
System Response to Vann-Bus Dynamic Voltage Regulation
If the 28V batteries are in a discharged state, the output voltage of the Primary unit will increase to a
value prescribed by the battery monitoring software. Since its reference voltage will be higher than the
Secondary unit, it will provide the majority of the load. The Primary unit will request a higher output
voltage from the Secondary unit causing its output voltage to increase at a rate of 10mV/s. Once the
voltage differential between the two units is approximately ≤ 0.5V, the Secondary unit will begin to provide
more current. Once the voltage differential is approximately ≤ 0.1V, the units will load share evenly.
After the batteries reach a quiescent state, the output voltage of the Primary unit will reduce to a value
prescribed by the battery monitoring software. Since the reference voltage of the Secondary will be
higher, it will provide the majority of the current. The output voltage of the Secondary unit will begin to
reduce at a rate of 10mV/s. Once the voltage differential is approximately ≤ 0.1V, the units will load share
evenly.
Note: The maximum and minimum output voltages of the HBA's can be set via Vanner's Dashboard
Interface Software.
System Response to a Failed Converter, Fault Condition or Loss of +24V Enable Signal
If either unit shuts down due to a failure, fault condition or loss of +24V enable signal, the operational unit
will remain on and provide current up to 250A or 300A. If the load is above 250A or 300A, the operational
unit will begin current limiting and gradually reduce the output voltage. Once the HBA output voltage
decreases to a value less than or equal to the battery voltage, the batteries will begin to assist in
supporting the load. If the load continues to increase and the output voltage drops to 20V, the current will
begin to fold back. If the output voltage is reduced to 16V, the HBA will turn off.
If certain fault conditions clear or the +24V enable signal is restored, the HBA will restart automatically.
Note: Some fault conditions, once cleared, require cycling the ignition/+24V enable signal before the HBA
will restart.
System Response to Loss of CAN Communication
If either unit loses CAN communication both will continue to run, however, their voltage and current loop
controls will function independently of each other. Once CAN communication is restored, voltage and
control loop controls will be maintained by the Primary unit.
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Paralleling Two HBA's Cont'd
The Vanner Dashboard software permits viewing the operational status of both HBA's in a dual
application. See screenshots below and display definitions.
Screenshot of Primary HBA Dashboard in a dual application with battery management "ON"
Note that the output voltage is
reduced since the 24V batteries are
in a "Quiescent" state.
The LV Output Current displayed
here is the sum of the "Primary" and
"Secondary" HBA's.
"Secondary" unit status. Select the
"View Slave HBA Status" icon to
open the secondary unit dashboard.
Screenshot of Secondary HBA Dashboard in a dual application
Low voltage output current of
"Secondary" HBA. Note that it is 1/2
of total current indicating equal load
sharing.
The voltage displayed here is the
value the "Primary" unit is
requesting from the "Secondary"
unit.
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OWNER’S MANUAL
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ESS
DPIM
High
Voltage
Interlock
High
Voltage
Interlock
Vanner HBA
Primary
Vanner HBA
Secondary
INSTALL JUMPER IN EXTERNAL
HARNESS BETWEEN PINS "A"
AND "N" TO DESIGNATE UNIT
AS "SECONDARY"
A
B
C
D
E THROUGH L
M
+24V Enable
N
CAN - Shield
P
CAN - High
G
L
E
N
SPARE
P
F
J
CAN - Shield
CAN - Low
A
G
B
K
H
J
PRIMARY
ENABLE
+24V Enable
P
D
M
C
B
K
SPARE
F
A
C
L
N
E
D
M
CAN - Low
H
CAN - High
SPARE
SEC.
ENABLE
N
SPARE
P
INSTALL JUMPER IN EXTERNAL
HARNESS BETWEEN PINS "M"
AND "N" TO DESIGNATE UNIT AS
"PRIMARY"
F2
24V Distribution and Current Limit Protection
Current Sensor
VSS-C80/600
+24V
Vanner
80 Series
Equalizer
12V Battery B
Electrical Cooling
Package
Base Loads
HVAC Units
+12V
F1
Current Sensor
VSS-C80
GND
Volt/Temp Sensor
VSS-VT
12V Loads
12V Battery A
Vanner High Voltage DC-DC Converter
26
A
B
C
D
E through M
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VANNER Incorporated
OWNER’S MANUAL
CAN Bus Specification
High Voltage DC/DC Converter CAN Communication Specification
A comprehensive CAN communication specification is available for the HBA. Please contact Vanner's
engineering department to ensure you have the latest revision.
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OWNER’S MANUAL
VANNER Incorporated
OWNER’S MANUAL
Vanner Incorporated
4282 Reynolds Drive
Hilliard, Ohio 43026
1-800-AC POWER
(1-800-227-6937)
Tel: 614-771-2718
Fax: 614-771-4904
www.vanner.com
e-mail: [email protected]
Part Number D914892-F
May 26, 2015
Printed in U.S.A.
Vanner High Voltage DC-DC Converter
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OWNER’S MANUAL
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