- Metric Mind Corporation
Contents
1. 12CMisc Misc n Clear Freeze Status Baud 19200 Port 4 Open Spyl f Disconnect DE va FRE Software Flow Control RxD 2 hee ae OR Receive Xon Char 17 Hae s 2 rd 2 bits Hardware Flow Control m Transmit Xoff Char 19 DCD 1 6 bits None RTS CTS PARER DSR 6 Space C 5bits DTRADSR RS48541ts an Ring 9 i Telnet _ BREAK Error Char Count 2646 ICPS 0 Port 4 19200 8N1 None Below is capture of the main status page displaying major running parameters updated every 1s RealTerm Serial Capture Program 2 0 0 70 Display Port Capture Pins Send Echo Port 120 120 2 12CMisc Misc Mn Clear Freeze gt Baud 19200 Port E Open Spl A Change Software Flow Contro Data Bits Stop Bits ae A 117 Site oh k rte Receive Xon Char E e 7 bits Hardware Flow Contro Transmit aff Char T T E bits None ATSCTS Bbits DTRVDSR C RS485 ts RE Ring 9 f Telnet _ BREAK Error Char Count 26176 CPS 0 Port 419200 861 None METRIC MIND CORPORATION To upgrade heater firmware choose Setup from the main window and then choose Firmware download Navigate to the directory containing firmware file and click Send File button RealTerm Serial Capture Program 2 0 0 70 Display Port Capture Pins Send Echo Port 120 120 2 12CMisc Misc An Clear Freeze gt2. page 7 METRIC MIND CORPORATION A A A A C rectifying AC mains power and will require external radiator as a heat exchanger The MMC400 fluid heater CANNOT be used in open loop application such as on demand residential or commercial running water heaters where hot liquid is not returned to the inlet of heater The following absolute limits are set for the operation of the MMC4000 heater Operating outside these limits can lead to shut down or damage to the heater amp Max DC input voltage 500 VDC for LV version and 900 VDC for HV version gt Max AUX supply voltage 32 VDC amp Max temp control DC voltage 5VDC amp Max Enable control voltage lt AUX supply voltage amp Maximum pressure cooling water system 1 0 bar 8 Technical specifications MMCAO00HVK J Uni V Max input voltage PWR 500 7 w VDC O Y DC DC DC DC DC g g DC m m m V V ee A Vy Max temp control voltage analog input FEe Max DC input power adjustable 4000 kbps Power control isolation resistance min GOhm initial 32 5 1 Reverse polarity HV power protection Yes fuse Dry Weight LV and HV version Dry Weight LVP and HVP version CAN 2b 11 bit identifier comm speed default 125 250 500 1000 Overtemperature protection ves Insufficient fluid flow protection Yes optional pe W k 1 0 k es ional V protection a o Power inet over Veltage protection 2 v parameter does not apply to LVP or H
3. pressure controller circuit may get damaged Rapid temperature increase due to this condition will be detected and stored in memory for service and troubleshooting purposes and damaged heating elements or control circuit due to insufficient fluid flow or absence of fluid is not covered by warranty For this reason running heater with its flow sensor disabled is not recommended regardless whether internal or external water pump is used If a flow sensor is disables or not present the MMC4000 will work in any position However care must be taken to ensure sufficient fluid flow Keep in mind that in case of clogged or kinked tubes or loss of liquid and no external means to disable heater due to insufficient flow rate the heating elements may burn out 12 2 Using USB Fiber Optic Cable interface dongle to configure the heater Because heater is installednear hot liquid to avoid corrosion of the serial interface contacts used very rarely and increase safety by complete galvanic isolation the heater is equipped with fiber optic interface to a PC To upgrade heater s firmware in the field you can use any serial terminal utility allowing sending external ASCII files such as RealTerm also available from MMC web site 13 Serial communication The MMC4000 is equipped with serial port for diagnostics and field upgrades of the firmware To prevent contact corrosion in close proximity to hot corrosive liquid assure absolute electrical safety and
4. Name Function _ Fault out LED CL31 AUX power return GND CL15 AUX power input CANL CAN Low CANH CAN High 6 EN Heater ENABLE Analog control input 8 POT Potentiometer bias 10 3 Description of interface signals and functions Pin 1 FLT Diagnostic and visual indication interface configured as 10mA current sink Connect cathode of external LED to this output Connect anode of the LED to C15 AUX power Pin 2 CL31 Connect to the vehicle chassis neg of AUX power Pin 3 CL15 Connect to AUX power source 12 24VDC typically after ignition key Pin 4 CANL Connect to CAN low of controlling CAN bus Pin 5 CANH Connect to CAN high of controlling CAN bus Pin 6 EN Connect normally open switch to this input Connect the other terminal of the switch to CL15 Pin 7 ANA Connect to external control voltage 0 5V corresponds to 0 100 of output power Pin 8 POT Connect external 5k pot to this input Connect other side of the pot to ANA 0 5k resistance corresponds to 100 0 of the output power If a particular control function is not used leave corresponding interface pins unconnected 10 4 Vehicle interface internal circuits 10 4 1 Enable signal EN 100 10mA CL31 The MMC4000 is enabled by connecting EN to 12 24 VDC auxiliary vehicle net Leaving EN unconnected or connecting EN to CL31 disables the MMC4000 MMC4000 Series Fluid heater User Manual page 10 METRIC MIND CORP
5. PWM npn CL31 Analog input circuit 10 4 3 CAN control MMC4000 Series Fluid heater User Manual page 11 METRIC MIND CORPORATION A A A A C When MMC4000 is configured for CAN control no other interface signal need to be connected You only need to apply 12 24V power to the heater and connect the CAN bus CAN interface is isolated from the HV To avoid high voltage spikes on the transceiver input and output make sure CL31 is connected to the vehicle chassis otherwise overvoltage suppressors will not function for high common mode noise 5 VDG 5 VDC internal to CPU CL31 2xX2TV The CAN transceiver is not internally terminated by default allowing MMC4000 to be a middle node on the CAN bus However there is provision on the PCB for the node termination If the MMC4000 is last node on the bus used must short two SMT pads on the PCB labeled CAN TERM 10 5 CAN interface specifications 2 CAN 2 0B comm protocol 11 bit identifier CANyspeed default is preset to 125kbps and can be user set to 125 250 500 1000 kbps amp No bus termination installed 10 5 1 CAN Messaging RR s RR ho DEN Control request 7C2h DLC 6 Temp Ana PWR computed PWR computed HV computed HV computed Vars computed Req Acces 7C3h E S Model Main MFG MFG Fixed DES counte type version Fuse Week Year SME UDE r Status Limits 0 7C4H MMC4000 Series Fluid heater User Manual page 12 METRIC
6. or a boat or a hybridvehicle boat equipped with standard heater core The MMC4000 will replace your engine as a source of heat It can also be used in semi stationary applications such as space heaters in RVs or ground camps It is especially usable in electric or hybrid vehicles converted from conventional gasoline or diesel powered ones so that all internal heating system air ducts blowers and controls can remain unchanged and only source of hot liquid replaced For instance one such application is heating of the cabin ofdong haul trucks using on board DC battery as tighter environmental regulations prohibit idling large diesel engines overnight or during long stay Also increasing numbers of ocean ports and cargo docs prohibit fossil fuel powered trucks and other vehicles to enter their premises all together and only electric powered ones are allowed to operate within certain radius of the port Using MMC4000 in such vehicles solves cabin heating issues In a typical installation the MMC4000 is plumbed to the same fittings on a firewall the coolant hoses from the engine used to be connected to This is by far the simplest modification unlike major system redesign if ceramic elements or heat pumps are deployed Though not optimized the MMC4000 can be used as portable space heater in buildings or garages However note that the MMC4000 cannot accept AC power or pulsating DC power resulting from direct MMC4000 Series Fluid heater User Manual
7. ri send Numbers Send ASCII jz T Send Numbers Send ASCII After MM E m Repeats fi zl Bliss mire SMBUS amp Dump File to Por S SERISLFH ENC ae Send File X stop Delays 0 SIE Ring 9 ere __ BREAK Repeats i om p __ Error _ DSR 6 Ctrl Tab to step through tab ees Cher Count 55658 cPs 585 Port 419200 8N1None Selectfile Send file 14 Changing internalfuse There are no user serviceable parts inside heater other than HV fuse and CAN termination jumper The fuse will blow in case of excessive power consumption or connecting HV in reverse Always replace fuse with the same type and ratings If fuse blows it indicates internal problem and increasing fuse rating will not make problem go away and will only cause further damage to the power connector HV wiring and external power source or components Contact the manufacturer for assistance if such situation will occur Location of the power fuse is shown on the photo below Fuse rating depends on the model it is 25A for LV version and 10A HV version The fuse rated for 1000VDC Direct Current operation DO NOT install AC rated fuse METRIC MIND CORPORATION A A A A C SP Ifyou attempt to replace internal fuse without taking heater out of the vehicle ALWAYS physically unplug main power connector before performing this step DO NOT rely on the power electronics such as relays or contactors to keep high voltage away in case of softw
8. A A A C 1 Foreword Dear Customer You have acquired one of the most capable and sophisticated hardware capable to fulfill your performance demands Please keep in mind that its operation involves high temperatures near water boiling point 100 C poisonous liquids ethylene glycol aka antifreeze and high voltages your traction battery voltage Therefore it is critical to observe safety and warning instructions and have this product installed and serviced by qualified personnel The MMC4000 is NOT a consumer product and thussit is not designed to be consumer friendly It this is specialized OEM sub system meant to be part of electric or a hybrid vehicle conventional vehicles usually commercial trucks requiring running heating Subsystem but restricted in idling its engine just for that purpose or a stationary infrastructure Please read and understand this manual Contact Metric Mind Corporation technical support if you have any questions not addressed in this manual 2 List of Abbreviations Throughout this manual some specific technical abbreviations are used Their meaning is shown in the table below Auxiliary Battery Management System Controller Area Network Electromagnetic Interference Ground High Voltage Low Voltage Throughout thismanual the term HV or high voltage is used to refer to the voltage applied to the power connector whether heater model is low voltage range 200 500 VDC or hig
9. MIND CORPORATION A A A A C IGBT status Ba LAS pot status Limitation status pro P sensor status HV limits Bt2 M limits Limits 2 or 1 byte 2 Bit 7 7 Bit7 crow bar source Fluid flow CANdb database is available for download from the MMC web site 10 5 2 Changing the CAN Parameters Options MMC4000 Series Fluid heater User Manual page 13 METRIC MIND CORPORATION A A A A 11 Block Diagram of the MMC4000 TX RX Heating elements Fuse HV ee 7 HV power Heater Vehicle interface 3 Fault Brushless Voltage DC motor regulator 12 Dimensions dnd Installation Information For installati n of the heater the following points must be strictly adhered to All models featuring fluid flow sensor must be installed in correct orientation according to the arrows molded on the enclosure Installing heater at wrong angle will prevent sensor from detecting the flow and disable the heater amp The air cooled version must be installed so that a constant fresh air supply is guaranteed This has a direct influence on the power of the device de rating amp The mechanical fixings must be arranged so that the device is fitted firmly and in a way that is as vibration proof as possible amp The cable feeds and cooling water tubes should have sufficient space for routing and plumbing and may under no circumstances sit in contact with sharp edged components MMC4000 Series Fluid heate
10. are used in this manual to indicate danger warning and caution conditions Paying attention observing and following safety rules is sole responsibility of the user General Prohibition A General Warning 4 Do Not urn On A Warning High Voltage Disconnect or Turn Off A Warning Magnetic Field Do Not Touch High Voltage LA Warning hot liquids MMC4000 Series Fluid heater User Manual page 2 METRIC MIND CORPORATION A A A A C TABLE OF CONTENTS T m0 SN 6 Ce eee ee eee ee eee eee 4 PE COPA DB BREV al ONS LE ee ee ne ee eee Oe eee eee ee eee 4 dE and Warming MMe SUNN CUO Sec Ei eae ee T 4 3 1 Safety Instructions for Electrical Systems AR 5 3 2 Safety instructions for fluid heating systems RM 6 MOSS AC 6 a ee a D RR 6 So Scope Of DONS ns a dune dans ci oc Re E 7 6 Manufacturer Contact Information for Ordering spare parts 4h M 7 7 Proper Intended Use sr RER 1 dd 7 8 Technical SD CICAIONSSE 2 en rr re RE suse 8 8 1 Special features and options erne Sae Oy ooe Prececcussarsssccessuesensas 8 9 Major mechanical and interface COMPONENMS ccc ceccecceeeceeeeeeceeeeeadecsahseecneeDUbteceseeceeeseeseeeseeeseeseeeees 9 ROIS CORSA ee ie ey Hun BE VERNE ne ie eer een 9 10 1 HV connector Pin Assignment if present JR MMM ss 9 10 2 Signal Interface Connector Pin Assignment 4 ss 9 10 3 Description of interface signals and functions 6
11. 0 6 icc dt cece eccc ete ecceece secu eeseeseeceeeseeseeeseeseeeaeeeaes 10 10 4 Vehicle interface internal circuits ete Res Pe eecaecceeceeeseeceeseeceeseeseeesseeseesaeeees 10 104 1 Enable SION D re es EEr EE eres 10 10 4 2 Analog PWM control Ni sener er ker knn enker kreeret rkk renere 11 10 4 3 CAN CONFORT eme onto cent 11 10 5 CAN interface specifications 1 eee NOMS occcecceccuscecceccussurserssseoscceccucceesuusentenrsessansass 12 10 5 1 CAN Messaging CR ieineserernen 12 10 5 2 Changing the CAN Parameters Options 2 4 iii 13 11 Block Diagram of the MMC4000 0 2 0 eee ccc cakes ccc eeeceeeeeeceeeeeeeeeceeeseeseeeseeceeeseeeeeeseeeseeseesseeseeeseeegeees 14 12 Dimensions and Installation Information 2 A ccc ccc ec cece eecc eee e cece iii 14 12 1 Installing and Connecting the Heater Vs 15 12 2 Using USB Fiber Optic Cable interface dongle to configure the heater cccccecceeeceeeeeeeeeeees 15 13 Serial COMMUNICATION MM cece ceed ees eeceeeceeceeeeeeceeeseeceeeseeseeeseeseeeseeseeeseeseeeseeseeeseeeeeesseeseeeeeseesaeees 15 14 Changing internal fuse ms MA cccccceccceccneeceeeeeeceeeeeeceeeeeeceeeseeseeeseeseeeseeseeeseeteeeseeeeeesseeseeeeeseesgeess 17 15 Warranty 222 2 E enerenerneneneenenenecnnencenceeseeneenseeneenneeneennene 18 16 Liability waver and legal disclaimer se 18 MMC4000 Series Fluid heater User Manual page 3 METRIC MIND CORPORATION A
12. METRIC MIND CORPORATION A i N A C MMQ4000LV MMC4000HV EV Fluid Heater User Manual Version 0 9 Preliminary MMC4000 Series Fluid heater User Manual page 1 METRIC MIND CORPORATION Metric Mind Corporation 10117 SE Sunnyside Rd Clackamas OR 97015 USA 1 503 477 6071 www metricmind com tech support metricmind com 1999 2015 Metric Mind Corporation All rights reserved Copyright Distributing or copying this document whole in part or using excerpts of its content without written permission of its owner Metric Mind Corporation MMC is prohibited Violators are liable for damages resulted from failure to comply with applicable copyright laws changes will be documented in the revisions section of this manual Updates MMC reserves right to periodically update user manual with new information or error corrections All Disclaimer The hardware described in this manual is not a consumer product It is OEM part meambfor installation and service by qualified personnel Operation involves high temperature poisonous liquid and lethal voltages UNDER NO CIRCUMATANCES EXPRESSED OR IMPLIED MMC WILL BE HELD LIABLE FOR ANY DIRECT OR CONSEQUENTIAL DAMAGES TO LIFE PROPERTY OR HARDWARE OR LOSS OF BUSINESS OR PROFITS RESULTING FROM USAGE OF THIS PRODUCT USER ASSUMES ALL THE RISK ASSOCIATED WITH USE OF THIS PRODUCT REVISIONS DATE NAME COMMENT Warning and Caution Jabeling The following internationally recognized icons
13. ON AGENCIES IT IS OEM HARDWARE SUBSYSTEM MEANT TO BE INSTALLED AND SERVICES ONLY BY QUALIFIED MMC4000 Series Fluid heater User Manual page 18 METRIC MIND CORPORATION A A A A C PERSONNEL MMC HAS NO WAY TO ASSESS QUALIFICATIONS OF THE END USER THUS MMC ACCEPTS NO LIABILITY FOR PERSONAL INJURY DEATH OR PROPERTY DAMAGE RESULTING FROM INCORRECT OR IMPROPER HANDLING OF THE MMC4000 FLUID HEATER BY PURCHASING THIS HARDWARE ORIGINAL PURCHASER AGREES WITH THIS LIABILITY WAVER AND ACCEPTS RESPONSIBILITY AND ALL THE RISKS ASSOCIATED WITH USING THIS DEVICE THIS WAVER IS SUPPLIED TO THE ORIGINAL PURCHASER TOGETHER WITH THE HARDWARE IN CASE THE HARDWARE IS RE SOLD IT IS RESPONSIBILITY OF THE SELLER TO PROVIDE THIS USER MANUAL TO THE NEW USER OR RESPONSIBILITY OF THE NEW USER TO OBTAIN THIS MANUAL BY DOWNLOADING IT FROM THE MMC WEB SITE LIKE FOR THE ORIGINAL PURCHASER BY PURCHASING USED OR SECOND HAND UNIT NEW USER AGREES NOT TO HOLD MANUFACTURER LIABLE FOR ANY PERSONAL INJURY DEATH OR PROPERTY DAMAGE RESULTING FROM INCORRECT OR IMPROPER HANDLING OF THE MM4000 FLUID HEATER MMC4000 Series Fluid heater User Manual page 19
14. ORATION A A A A e In CAN mode EN signal is not monitored and CAN control takes priority You can leave EN unconnected if the MMC4000 is configured for CAN control 10 4 2 Analog PWM control Analog power control is accomplished by applying analog voltage to Ana PWM input This can be implemented two ways if your vehicle controlled has DAC output with 0 5 VDC output voltage range you can directly apply it to the MMC4000 Ana PWM input 0 5VDC corresponds to 0 100 of preconfigured max power To improve noise immunity there are 70 7V dead zones designed to the analog control circuitry e g MMC4000 will not will start outputting power when analog voltage reach 0 7 VDC and will output 100 power when analog voltage is at 74 3 VDC or above If you don t have any analog voltage source there is special output POT to bias external 5k variable resistor You can use any linear potentiometer by connecting one fixed end to the bias power and viper to the ANA input Leave the other fixed end of the potentiometer unconnected Reducing resistance from 5k to Ok with some dead Zone margins increases MMC4000 power from 0 to 100 This way in case of broken control pot connection output power is reduced to zero ANA input can also receive 0 5 VDC PWM signal within 150 5000 Hz frequency range The low pass RC filter on the input has 3dB cutoff frequency of 130 Hz 12 24 VDC Internal power Control pot bias supply Linear Ana
15. UX chassis Potential Damage tothe MMV4000 amp Make sure maximum voltage applied to power input of heater does not exceed specification amp Make sure AUX power and control voltages are within specified limits Exceeding absolute maximum limitwill damage heater control electronics There are no user serviceable parts inside other than power fuse In case software monitor reports error contact MMC tech support Most of these errors can be cleared and issues resolved remotely amp f your device is equipped with flow sensor DO NOT defeat its operation Doing so may leave heating elements powered up while there is insufficient fluid flow which may lead to elements burning out before stalled liquid will trigger overtemperature protection amp The MMC4000 is internally fused Under no circumstances should you bypass upgrade or replace fuse with higher current rating If power fuse keeps blowing you must determine root cause of malfunction The fuse is sized with enough margin not to blow under any normal working condition In the even of fuse blow the heater software takes a snapshot of the fault condition and stores it in non volatile memory This information is user accessible read only and helps to determine root cause of the failure Mere replacing fuse will not fixing underlying problem and the same blow will likely reoccur MMC4000 Series Fluid heater User Manual page 5 METRIC MIND CORPORATION A A A A C A CAUTION O
16. VP version Fluid flow rate 8 1 Special features and options amp Fiber Optic cable isolation between a PC and heater circuit MMC4000 Series Fluid heater User Manual page 8 METRIC MIND CORPORATION A A N i C amp Field upgradeable firmware via fiber optic interface hardware included amp External output for diagnostic LED No internal fluid pump option No flow sensor option amp Vibration resistant construction for automotive use amp Reverse HV polarity protected internal fuse amp 5 way controllable user programmable modes By simple ON OFF via ENABLE input MES RM3 4 series compatible mode By external analog voltage By external potentiometer By external PWM signal By CAN from external control unit 9 Major mechanical and interface components 1 Cooling water inlet 19 mm or 3 4 2 Cooling water outlet 19 mm or 3 4 3 HV battery power connector input 4 Interface connector input output 5 Fiber optic interface transmit port 6 Fiber optic interface receive port 10 Electrical interface Electrical interface and pinout of connectors is the same regardless of the model 10 1 HV connector Pin Assignment if present High voltage power input positive always RED wire High voltage power input negative always BLUE wire 10 2 Signal Interface Connector Pin Assignment MMC4000 Series Fluid heater User Manual page 9 METRIC MIND CORPORATION A A A A C Pin Name Function Pin
17. are glitch or external interference such components might unexpectedly engage DC voltage above 36V is considered dangerous and in right circumstances such as wet hands of the person subjected to it can be lethal Traction battery voltage is typically 10 20 times higher than this thus there is proportionally higher probability that a person subjected to such a high voltage will be killed Lethality is virtually guaranteed if electric current passes from one hand to the other through the heart Note that only 5mA is enough to stop heart of average person Thus we are stressing again that the user must unplug main power connector before servicing the MMC4000 If the traction battery service disconnect is removed instead make sure power inverter s capacitors that may still be connected to DC bus and thus to the heater power input do not store charge that can still present danger to the user 15 Warranty MMC warrants propernoperation of the heater for 24 month from the sale date Warranty repair or replacement wilkbe provided if uniquely verifiable material and or assembly workmanship defects are discovered Warranty is void if the seal on the housing is damaged or missing or internal diagnostic reveals tampering with the device or its software Warranty is not transferable 16 Liability waver and legal disclaimer THE MMC400 IS NOT A CONSUMER PRODUCT AND AS SUCH IS NOT A SUBJECT TO LAWS AND REGULATIONS APPLIED AND ENFORCED BY A CONSUMER PROTECTI
18. d to boil 4 Model Identification MMC 4000 HV PF P no integrated water pump F novinternal flow sensor LV Low voltage HV High Voltage 4000 max power watts Manufacturer identifier The MMC4000 can be ordered without integrated fluid pump P version and or without internal flow sensor F version or without both PF version If external water pump is used make sure the flow rate does not exceed max 10 l min to avoid damage to the flow sensor Reversing direction of fluid flow will not damage but will disable the MMC4000 This does not apply to MMC4000xx PF version MMC4000 Series Fluid heater User Manual page 6 METRIC MIND CORPORATION A A A A C 5 Scope of Delivery Representative ep o e MMC4000 series heater fluid heater MMC optic fiber to USB serial interface converter 8 circuits Ampseal interface plug Ampseal crimp terminals e Py Fiber Optic cable 1 5m 2 Cy Optionally items 2 5 can be ordered from the manufacturer as spare parts 6 Manufacturer Contact Information for ordering spareyparts METRIC MIND CORPORATION 10117 SE Sunnyside Rd STE F1211 Clackamas OR 97015 USA Phone 1 503 477 6071 Email tech support metricmind com Web www metricmind com 7 Proper Intended Use The MMC4000 fluid heaters are designed to maintain set liquid temperature closed circulation loop using a DC power source In general MMC4000 is meant to be installed in a battery or fuel cell powered electric vehicle
19. h voltage range 450 900 VDC This is often referred to as traction battery voltage Unless specifically mentioned low voltage range is still considered high voltage as far as safety context in contrast with auxiliary 12VDC or 24VDC voltages powering internal control logic which is referred to as AUX the same voltage running lights wipers radio and other such subsystems 3 Safety and Warning Instructions In this chapter you will find safety instructions which apply to this device and refer to assembly start up and running operation in the vehicle These instructions mostly apply to stationary application as well Always read and observe them in order to maintain personal safety and avoid damage to the device and other property The following generally applicable safety measures have been developed based on the knowledge MMC4000 Series Fluid heater User Manual page 4 METRIC MIND CORPORATION A A A A of the manufacturer They are not complete they can be supplemented by local and or country specific safety instructions and guidelines for accident prevention The system integrator and or distributor of the device must therefore supplement the present general safety instructions by country specific and local guidelines 3 1 Safety Instructions for Electrical Systems A High voltage Danger to life amp Do not touch any HV wiring unless you re assured there is no high voltage applied to the heater a
20. immunity to EMI no physical connectors or any metal parts are present and communication is implemented via fiber optic cables Operation is transparent to the user as special supplied USB optical transceiver dongle converts serial transmitted data to modulated optical transmission which is demodulated on the receiving end For full duplex operation two fiber optic cables are used MMC4000 Series Fluid heater User Manual page 15 METRIC MIND CORPORATION The firmware is supplied as ASCII file and the latest revision along with comments specifying changes is always available for download from the MMC web site Any serial terminal utitily capable of sending and receiving external ASCII files can be used to communicate with heater controller Examples below depict one of such utilities free terminal program RealTerm for PC provided by Sourceforge sourceforge net Supplied serial to optical converter has USB interface It is recognized by operating system as serial port and automatically installs appropriate virtual port driver The port number assigned to the adapter by windows when USB connector is plugged in has to be selected in the terminal utility On the screen capture below the port number is set to COM4 Other communication parameters are 19200 Baud rate 8 data bits no parity 1 stop bit no flow control RealTerm Serial Capture Program 2 0 0 70 Display Port Capture Pins Send Echo Port 12C 12C 2
21. mp The device may only be connected by a qualified electrician A Potential Damage to the traction battery or power source amp Make sure the battery or other power source supplying heater fuel cell solar panel generator and such has enough power and current capability to sustain prolonged operation While the heater has low voltage lockout feature it will not prevent your battery from overdischarging if left unattended amp You must make sure that the battery voltage is within working voltage range of chosen device If your battery voltage falls in overlapping range 450VDC to 500VDC LV or HV model can be used with identical outcome Potential Damage to infrastructure amp Only use compatible and high quality power cable and connector amp Make sure the power leads are of sufficient cross section area to continuously carry max working current amp Make sure crimp terminals in power connector are secured loose crimp will cause local overheating and arcing resulting in meltingneanby plastic parts and potentially causing fire 2 Make sure to protect optical interface parts in case heater is washed from outside Avoid direct contact with road debris salt or corrosive liquids amp The heater features galvanic isolation between AUX voltage and HV Connecting traction battery to device s Ground terminal will not damage the MMC4000 but may destroy other control circuits in the vehicle relying on the isolation between HV and A
22. r User Manual page 14 METRIC MIND CORPORATION A A A A C 12 1 Installing and Connecting the Heater The MMC4000 heater is intended to be installed on a firewall in the engine compartment but can be installed on any vertical surface or supporting brackets providing upright position Tilt up to 15 in any direction is allowed A The MMC4000xx heaters are equipped with flow rate sensor which is operational only if the heater is installed in correct vertical position Heater should not be installed in horizontal or any other orientation than vertical It is allowed to install MMC4000xx heater in any position if the fluid flow rate sensor is disabled in the software In such configuration is a responsibility of the user to make sure fluid chamber is always filled with fluid and there is sufficient fluid flow while heater is electrically enabled Note that integrated fluid pump is not self priming Make sure the air is removed from the coolant loop before operating heater A Be aware that in case of loss of liquid heating elements expOsed to the air will burn up within a few seconds With liquid present but not moving heater may protect itself from burning out but depending on the ethylene glycol and water mixture ratio the fluid might boil before temp protection kicks in this will cause rapid pressure increase and unless expansion tank is usedburst of hot liquid damage to the seals and water pump In case of internal leak due to increased vapor
23. verheating of the cables Fire hazard amp Heater enclosure is sealed Unauthorized opening or attempted repairs will void warranty Generic rules when servicing any HV hardware amp Physically unplug system power Do not rely on relays or contactors still under software control as any microcontroller glitch may cause inadvertent closure of power relays Turn off the ignition and remove key If equipped remove service disconnect or main power fuse amp Make sure the system cannot re apply HV power due to software glitch or unauthorized access amp When practical do HV measurements with one hand connect disconnect test leads using spring loaded hooks or alligator clips Remember the current path from one hand to another lies through your heart while from any one hand to your feet the heart will be bypassed 3 2 Safety instructions for fluid heating systems amp Make sure fittings are tight and fluid hoses are in good condition amp Make sure retaining clips are used to secure hoses onto the fittings as high temperature liquid increases pressure of vapors and insecure hoses may slip off fitting during maintenance or inspection Causing severe burns by hot ethylene glycol or water Disassemble service or open expansion tank for refill only when liquid is cold amp Use of expansion tank for safety is required Aside of convenient point to fill up the system with fluid it will allow vapor to escape in case of malfunction causing flui
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