Vector BRICK UPS 200 User manual

Vector
Brand
Vector
Model
BRICK UPS 200
Type
User manual
BRICK UPS 200
Manual
Version: 2.1
Imprint
Vector Informatik GmbH
Ingersheimer Straße 24
D-70499 Stuttgart
The information and data given in this user manual can be changed without prior notice. No part of this
manual may be reproduced in any form or by any means without the written permission of the
publisher, regardless of which method or which instruments, electronic or mechanical, are used. All
technical information, drafts, etc. are liable to law of copyright protection.
© Copyright 2019, Vector Informatik GmbH. All rights reserved.
Contents
1 General Information .......................................................................................................................... 6
Important instructions .............................................................................................................. 6
Warranty and liability ............................................................................................................... 6
Trademarks .............................................................................................................................. 7
Used symbols and their meanings .......................................................................................... 7
2 Safety ............................................................................................................................................... 8
Proper Use and Intended Purpose .......................................................................................... 8
Hazards ................................................................................................................................... 8
Battery notice ........................................................................................................................... 8
Electrostatically Sensitive Components (ESD) ........................................................................ 9
Grounding practices............................................................................................................. 9
Warning of hot surface ............................................................................................................ 9
Disclaimer ................................................................................................................................ 9
3 System Configuration ..................................................................................................................... 10
BRICK UPS Configuration ..................................................................................................... 10
4 Accessories .................................................................................................................................... 11
Power Supply and Cable ....................................................................................................... 11
5 Product Identification ...................................................................................................................... 11
Scope of delivery ................................................................................................................... 11
Type plate .............................................................................................................................. 12
6 Functional description .................................................................................................................... 13
Overview ................................................................................................................................ 13
Signal description .................................................................................................................. 13
7 Technical Specification ................................................................................................................... 14
Base specification .................................................................................................................. 14
Electrical characteristics ........................................................................................................ 16
Mechanical details ................................................................................................................. 17
8 Product Description ........................................................................................................................ 18
BRICK UPS front view ........................................................................................................... 18
BRICK UPS rear view ............................................................................................................ 18
9 Interfaces, Control Elements and Indicators .................................................................................. 19
100 MbE MGMT .................................................................................................................... 19
HMI Battery status ................................................................................................................. 19
HMI System status................................................................................................................. 20
Power Switch ......................................................................................................................... 20
CARCTRL .............................................................................................................................. 21
CTRL Switch .......................................................................................................................... 21
SYSCTRL .............................................................................................................................. 22
GPIO ...................................................................................................................................... 22
HMI POWER OUT ................................................................................................................. 23
HMI POWER IN ..................................................................................................................... 23
10 Functional Description ............................................................................................................... 24
Failure Analysis ..................................................................................................................... 25
Battery Operation Behavior ................................................................................................... 25
11 Configuration options ................................................................................................................. 27
Ignition Mode ......................................................................................................................... 27
Master/Slave Operation ......................................................................................................... 28
12 BRICK UPS Status Management .............................................................................................. 29
Web Interface Overview ........................................................................................................ 29
Web Interface description ...................................................................................................... 31
13 Commissioning and Maintenance ............................................................................................. 34
Initial Commissioning Insert Battery Pack ............................................................................. 35
14 Installation .................................................................................................................................. 37
Typical Application ................................................................................................................. 37
Example Setup with a BRICK CORE COM ........................................................................... 38
Handling of internal components ........................................................................................... 39
15 Valid for: ..................................................................................................................................... 40
List of Figures
Figure 1: BRICK UPS Type plate (example) ......................................................................................... 12
Figure 2: BRICK UPS Mechanical Dimensions ..................................................................................... 17
Figure 3: BRICK UPS front view............................................................................................................ 18
Figure 4: BRICK UPS rear view ............................................................................................................ 18
Figure 5: Pin assignment 100 MbE MGMT connector .......................................................................... 19
Figure 6: HMI Battery status .................................................................................................................. 19
Figure 7: HMI System status ................................................................................................................. 20
Figure 8: Power Switch .......................................................................................................................... 20
Figure 9: Pin assignment CAR CTRL connector ................................................................................... 21
Figure 10: Control Dip-Switch ................................................................................................................ 21
Figure 11: Pin assignment SYS CTRL connector ................................................................................. 22
Figure 12: Pin assignment GPIO connector .......................................................................................... 22
Figure 13: Pin assignment HMI POWER OUT connector ..................................................................... 23
Figure 14: Pin assignment HMI POWER IN connector ......................................................................... 23
Figure 15: One BRICK UPS stand alone .............................................................................................. 28
Figure 16: Two BRICK UPS parallel-connected.................................................................................... 28
Figure 17: Three BRICK UPS parallel-connected ................................................................................. 28
Figure 18: Integrated Web Interface ...................................................................................................... 29
Figure 19: Web interface configuration tab ........................................................................................... 30
Figure 20: Web interface acknowledge ................................................................................................. 30
Figure 21: BRICK UPS battery slots ..................................................................................................... 35
Figure 22: BRICK UPS Power In connector .......................................................................................... 36
Figure 23: BRICK UPS CARCTRL connector ....................................................................................... 36
Figure 24: BRICK UPS Power Out connector ....................................................................................... 36
Figure 25: BRICK UPS Power switch .................................................................................................... 36
Figure 26: BRICK UPS typical application ............................................................................................ 37
Figure 27: Example Setup with BRICK CORE COM ............................................................................ 38
1 General Information
1
Important instructions
Prior to use of the unit it is essential to comply with the following instructions. As stipulated by law, we
are providing important safety information and advice how you can avoid damage to the device and
other fittings.
▪ Connection to the power supply must be carried out with correct polarity. Polarity reversal could
cause irreparable damages.
▪ The correct supply voltage is 12V or 24V DC
▪ Operation of the device is allowed only in circuits with safety low voltage within the admissible limit
values (SELV standard EN60950). This applies to all connections to the unit.
▪ The use of a power supply outside the limits defined above could cause damage or even
destruction of the device.
▪ It is forbidden to directly connect the unit to the 230 V mains voltage!
▪ Please avoid mechanical stresses when the device is installed.
▪ The unit has undergone a comprehensive final check to guarantee that it has left the facility in a
perfect condition. Prior to initial operation, the unit has to be examined for damage caused by
transport or inappropriate storage. If there is any damage to the unit it must not be taken into
service.
▪ The unit must not be operated with defective safety equipment or with incorrectly mounted or
inoperable safety/protection devices.
▪ Prior to initial operation, please check the suitability of the unit for the specific application. Please
take special note of the admissible environmental and operating conditions specified in the data
sheet.
▪ Any removal of identification numbers, repair work by yourself or modification of the unit is
forbidden.
▪ Prior to initial operation carefully read this user manual containing notes and warnings in order to
ensure safe operation.
▪ Unless specified differently, all technical data apply to an environmental temperature of 25°C. The
specified values are subject to the usual fluctuations.
▪ Stresses due to extreme environmental conditions (e.g. heat or cold) over a longer period of time
may influence reliability. Even under normal conditions of use within the admissible limits service
life may be reduced by permanent operation at the limits. Tolerance of the extreme values is
subject to the usual fluctuations.
Warranty and liability
We reserve the right to change the contents of the documentation and the software without notice.
Vector Informatik GmbH assumes no liability for correct contents or damages which are resulted from
the usage of the documentation. We are grateful for references to mistakes or for suggestions for
improvement to be able to offer you even more efficient products in the future.
Trademarks
All trademarks mentioned in this documentation and if necessary third party registered are absolutely
subject to the conditions of each valid label right and the rights of particular registered proprietor. All
trademarks, trade names or company names are or can be trademarks or registered trademarks of their
particular pro- prietors. All rights which are not expressly allowed are reserved. If an explicit label of
trademarks, which are used in this documentation, fails, should not mean that a name is free of third party
rights.
Used symbols and their meanings
Symbol
Meaning
Warning of general hazard. The kind of hazard is specified by the text next to the
symbol.
Warning of hazardous electrical voltage and the effects thereof.
This symbol refers to a hot surface that should not be touched without appropriate
precautions. There is danger of burning!
Warning of damages by electrostatic discharge
ESD (Electrostatically Sensitive Device) warning symbol
This symbol refers to general information about device and user manual.
This symbol introduces diverse details as to product configurations.
This symbol indicates that, in the case of non-observance of the warning, the device
or parts thereof could be damaged.
This symbol refers to instructions and recommendations for the connection of
external peripherals and their wiring.
2 Safety
In order to avoid personal injuries and damage to property, you have to read and understand the
following safety instructions and hazard warnings prior to installation and use of this hardware. Keep
this documentation (manual) always near the hardware.
Please observe the notes in chapter 1 in addition to this chapter.
Proper Use and Intended Purpose
The hardware may only be operated (i) according to the instructions and descriptions of this manual;
(ii) with the electric power supply designed for the hardware, e.g. USB-powered power supply; and (iii)
with accessories manufactured or approved by Vector.
The hardware is exclusively designed for use by skilled personnel as its operation may result in
serious personal injuries and damage to property. Therefore, only those persons may operate the
hardware who (i) have understood the possible effects of the actions which may be caused by the
hardware; (ii) are specifically trained in the handling with the hardware, bus systems and the system
intended to be influenced; and (iii) have sufficient experience in using the hardware safely.
The knowledge necessary for the operation of the hardware can be acquired in workshops and
internal or external seminars offered by Vector. Additional and hardware specific information, such as
„Known Issues“, are available in the „Vector KnowledgeBase“ on Vector´s website at www.vector.com.
Please consult the „Vector KnowledgeBase“ for updated information prior to the operation of the
hardware.
Hazards
The hardware may control and/or otherwise influence the behavior of control systems and electronic
control units. Serious hazards for life, body and property may arise, in particular, without limitation, by
interventions in safety relevant systems (e.g. by deactivating or otherwise manipulating the engine
management, steering, airbag and/or braking system) and/or if the hardware is operated in public
areas (e.g. public traffic, airspace). Therefore, you must always ensure that the hardware is used in a
safe manner. This includes, inter alia, the ability to put the system in which the hardware is used into a
safe state at any time (e.g. by „emergency shutdown“), in particular, without limitation, in the event of
errors or hazards.
Comply with all safety standards and public regulations which are relevant for the operation of the
system. Before you operate the system in public areas, it should be tested on a site which is not
accessible to the public and specifically prepared for performing test drives in order to reduce hazards.
Battery notice
CAUTION!
There is a risk of explosion if the battery is replaced incorrectly. Replace only with
the same or equivalent type recommended by the manufacturer. Discard used
batteries according to the manufacturer’s instructions.
Please also see the battery supplementary sheet!
Valid only for devices containing a battery.
Electrostatically Sensitive Components (ESD)
A sudden electrostatic discharge could destroy sensitive components. Therefore, proper packaging
and grounding prescriptions must be observed. Please always observe the following safety advices.
1. Plug-in cards always have to be transported in electrostatically safe containers or bags.
2. Please leave electrostatically sensitive components in their containers until they have reached the
electrostatically safe assembly site.
3. Take care that you are correctly grounded if you touch electrostatically sensitive components.
4. Make sure that electrostatically sensitive components are stored in protective packages or on
antistatic mats.
Grounding practices
By observing the following measures, electrostatic damage to the device can be avoided.
1. Lay out antistatic mats at the work place. Wear a grounding strap which is connected to the work
place and the working tools.
2. Use antistatic foot mats, foot grounding equipment or air ionizers to provide additional safety.
3. Only touch sensitive components, plug-in cards and units on the housing or at the outer edges of
the plug-in cards.
4. Avoid contact with pins, wires and conductor tracks.
5. Make sure that all voltage and signal sources are switched off before establishing or
disconnecting electric connections or connecting testing devices.
6. Avoid non-conductive materials such as usual mounting accessories made of plastics or
polystyrene at the work place.
7. Use conductive tools (e.g. ESD screwdrivers) when working on electrostatically sensitive units
and components.
8. Always put plug-in cards and drives on the antistatic mat with the component side downwards.
Warning of hot surface
The BRICK UPS can become very hot during operation and should not be touched
without appropriate precautions. There is danger of burning!
Disclaimer
Claims based on defects and liability claims against Vector are excluded to the extent damages or
errors are caused by improper use of the hardware or use not according to its intended purpose. The
same applies to damages or errors arising from insufficient training or lack of experience of personnel
using the hardware.
3 System Configuration
BRICK UPS Configuration
For the BRICK UPS, the following HW equipment features are available for the respective device
configuration:
Supply
Voltage
Temperature
Performance
100Mbe
MGMT
SYS CTRL
CAR CTRL
GPIO
12V DC / 24V D
C
-20 ~ 60
°C
-20 ~ 60°C (limited current <0°C)
Capacity
[Wh] @ nominal voltage
Max Current
[A]
Max Current
[A] @ -20°C
Nominal voltage
[V]
RJ45 100Mbe Ethernet
K15/Ignition Output
BRICK System Com. Interface
K15/Ignition Input
CAR System Com. Interface
4xGPI
4xGPO
BRICK UPS 200
✓
✓
-
2x77
2x9
2x9
10,8
✓
✓
✓
✓
✓
✓
✓
- = not available
✓ = available
4 Accessories
Power Supply and Cable
Designation
Description
BRICK PowerCable
BRICK PWR Cable, red-black, pigtail, 4qmm, 1,5m
BRICK GPIO Cable
BRICK GPIO Cable, pigtail, 8x weiß FLRY 0,75 qmm, 1,5m
BRICK UPS CARCTRL Cable
BRICK UPS CARCTRL Cable IGN, LOAD, 0,75 qmm, 1,5m
BRICK UPS B2B POWER Cable
Cable Bridge to connect Power from UPS to BRICK, 4qmm, 35cm
BRICK UPS B2B CTRL Cable
Cable Bridge to connect CTRL from UPS to BRICK, 3pol to 4pol, 0,75 qmm, 35cm
5 Product Identification
Scope of delivery
The scope of delivery depends on the ordered system or set configuration. Please check the scope of
delivery according to the survey printed below.
BRICK UPS SB200NI2
BRICK UPS device
BRICK UPS 200
✓
Battery pack
2x NI3020HD
✓
Accessories
BRICK Power Cable
✓
BRICK GPIO Cable
✓
BRICK UPS CARCTRL Cable
✓
BRICK UPS B2B POWER Cable
✓
BRICK UPS B2B CTRL Cable
✓
Documentation
Manual BRICK UPS
online
Safety supplement
✓
- = not available
✓ = available
Type plate
Figure 1: BRICK UPS Type plate (example)
A type plate like this is located on the bottom of the
device. The example data used here refer to the
BRICK UPS 200.
Symbol
Meaning
Legal notice regarding the disposal of used appliances (WEEE)
CE label
6 Functional description
Overview
The BRICK UPS is designed to bridge gaps in any kind of automotive supply systems. It uses two Li-
Ion smart batteries to provide the needed energy during voltage drops or even breakouts on board
supply. There is the opportunity to control the switching between operation from the board net and the
batteries with an additional signal called “LOAD”. This feature can be used to reduce the board nets
load. Furthermore, the BRICK UPS provides secondary functions like a management interface, two
CAN interfaces and several GPIOs.
Signal description
The BRICK UPS uses the following external Signals
Name
I/O
Description
VIN+
I
Positive potential of the supply voltage
VIN-
I
Negative potential of the supply voltage
VOUT+
O
Positive potential of the output voltage
VOUT-
O
Negative potential of the output voltage
IGN_IN
I
Ignition input, this signal is logically connected to IGN_OUT
IGN_OUT
O
Ignition output, this signal is logically connected to IGN_IN
LOAD
I
LOAD high allows the BRICK UPS to supply the load from the input voltage.
LOAD low forces to supply from the batteries
CAR_CAN
I/O
CAN interface with general purpose
SYS_CAN
I/O
CAN interface for in-system communication
Digital Input 1-4
I
General purpose inputs
Digital Output 1-4
O
General purpose outputs
7 Technical Specification
Base specification
Features
Details
Supply voltage
Typ. 12V DC / 24 DC, wide range 10V to 32V
Maximum Power Consumption
250W including battery charge current
Switch to USV mode
Vin < 10V
Energy Storage
2x Li-Ion Smart Batteries
Output Voltage
Ext. supply mode
14.8V ±5%
UPS mode
depending on used battery packs, see table UPS Configuration
Delivery Power
200W max
Network interfaces
1x 100Mbe (Management Interface)
Default network configuration
IP address
192.
168.
10.
3
Subnet mask
255.
255.
255.
0
Gateway
0.
0.
0.
0
DHCP
off
GPIO
4xGPI
4xGPO, highside switching
On/Off control
Power Switch, please note,
CAR system control interface
1x CAN, termination resistor switchable, 1x Digital Input
BRICK system control interface
1x CAN, termination resistor switchable, 1x Digital Output
Housing dimensions
320 x 22 x 250 (B x H x T) mm
Cooling
Passive
Weight
approx. 3kg
Maximum Battery Charge Current
4A
Characteristics
Details
Operating temperature device
-25°C to +70°C
Storage temperature device
-40°C to +75°C
Storage temperature incl. battery
-20°C to 60°C, 80%RH
Operating temperature
battery discharge
SB200NI
0°C to +60°C (limited current <0°C)
SB200NI2
-20°C to +60°C
Operating temperature
battery charge,
controlled by battery
SB200NI
0°C to +50°C
SB200NI2
0°C to +50°C
Air humidity device
90% non-condensing
Vibration and shock
EN 60068-2-64:2008 (10-1000Hz – 33,8 m/s²)
EN 60068-2-27:2009 (half sine, 11ms, 500 m/s²)
IP protection class
IP20
Electromagnetic compatibility (EMC)
EMV Directive 2014/30/EU
Electrical safety
Low-voltage directive (LVD) 2014/35/EU
RoHS II directive
2011/65/EU
European Union
EN 55032 (Class B) and EN 55024
EN 62368-1 Safety
USA / FCC
Part 15 Subpart B
Electrical characteristics
Symbol
Description
Value
Unit
Min
Typ
Max
V
IN,MIN
Input voltage
10
-
32
V
V
OUT,NET
Output voltage when supplied from board net
14,1
14,8
15,5
V
V
OUT,BATT
Output voltage when supplied from batteries
*
*
*
V
I
OUT,NET
Output current when supplied from board net
-
-
15**
A
I
OUT,BATT
Output current when supplied from batteries
*
*
*
A
V
GPI,LOW
GPI Low voltage
4,2
4,3
4,4
V
V
GPI,HIGH
GPI High voltage
4,5
4,6
4,7
V
V
GPI
GPI input voltage max
32
V
R
IN,GPI
GPI input resistance
12
kΩ
V
LOAD,LOW
LOAD Input Low voltage
4,2
4,3
4,4
V
V
LOAD,HIGH
LOAD Input High voltage
4,5
4,6
4,7
V
V
LOAD
LOAD input voltage max
32
V
R
IN,LOAD
LOAD input resistance
12
kΩ
V
IGN_IN,LOW
IGN_IN Input Low voltage
4,2
4,3
4,4
V
V
IGN_IN,HIGH
IGN_IN Input High voltage
4,5
4,6
4,7
V
V
IGN_IN
IGN_IN input voltage max
32
V
R
IN,IGN_IN
IGN_IN input resistance
12
kΩ
V
GPO,NET
GPO output voltage when supplied from board net
14,1
14,8
15,5
V
V
GPO,BATT
GPO output voltage when supplied from batteries
*
*
*
V
I
GPO,NET
GPO output current when supplied from board net
-
-
6**
A
I
GPO,BATT
GPO output current when supplied from batteries
-
-
6
A
V
IGN_OUT,NET
IGN_OUT output voltage when supplied from board net
14,1
14,8
15,5
V
V
IGN_OUT,BATT
IGN_OUT output voltage when supplied from batteries
*
*
*
V
I
IGN_OUT,NET
IGN_OUT output current when supplied from board net
-
-
1**
A
I
IGN_OUT,BATT
IGN_OUT output current when supplied from batteries
-
-
1
A
* Nominal voltage depending on used battery pack, see table in 3.1
** overall current is not allowed to exceed 15A (I
OUT
+I
GPO1
+I
GPO2
+I
GPO3
+I
GPO4
+I
IGN_OUT
≤ 15A)
Mechanical details
All dimensions are given in millimeters [mm].
Figure 2: BRICK UPS Mechanical Dimensions
8 Product Description
BRICK UPS front view
Figure 3: BRICK UPS front view
Pos.
Designation
Description
1
Battery slide-in cover
2
100 MbE MGMT
100Mb Ethernet Port for Management issues
3
HMI Battery status
User LEDs to indicate the battery status
4
HMI System status
User LEDs to indicate the system status
5
Power Switch
Turns the device on/off
6
Mounting holes with inner thread M4 (depth approx. 11.5mm)
BRICK UPS rear view
Figure 4: BRICK UPS rear view
Pos.
Designation
Description
1
CARCTRL
Car System control connector
2
CTRL SW
DIP-Switch for CAN termination for the SYSCTRL and CARCTRL connectors
3
SYSCTRL
BRICK System control connector
4
GPIO
4 GPI and 4 GPO
5
POWER IN
Power Input supply connector
6
POWER OUT
Power Output supply connector
7
Mounting holes with inner thread M4 (depth approx. 11.5mm)
❸
❹
❺
❻
❶
❷
❶
❷
❸
❹
❺
❻
❼
9 Interfaces, Control Elements and Indicators
100 MbE MGMT
This connector is designed as RJ45 sockets with integrated LEDs and corresponds to a 100BASE-T
Ethernet interface.
Pin
Signal
RJ45 Network socket
1
100MbE_TX+
Figure 5: Pin assignment 100 MbE MGMT connector
2
100MbE_TX-
3
100MbE_RX+
4
Connected to Pin 5, 75 Ω
termination
5
Connected to Pin 4, 75 Ω
termination
6
100MbE_RX-
7
Connected to Pin 8, 75 Ω
termination
8
Connected to Pin 7, 75 Ω
termination
Collision LED on the right (green)
State
Description
On
collision
Off
no collision
Link LED on the left (yellow)
State
Description
On
good link
Blink
activity
Off
no link
HMI Battery status
LED
Signal
LED array
1
Battery 1 charge status: ≥75%
Figure 6: HMI Battery status
2
Battery 1 charge status: ≥50%
3
Battery 1 charge status: ≥25%
4
Battery 1 charge status: <25%
5
Battery 2 charge status: ≥75%
6
Battery 2 charge status: ≥50%
7
Battery 2 charge status: ≥25%
8
Battery 2 charge status: <25%
Please note that blinking LEDs indicate the batteries are being charged.
Fast flashing LEDs No. 4 & 8 indicate very low charge status <9%.
Pin ❽
Pin ❶
❶
❷
❸
❹
❺
❻
❼
❽
HMI System status
LED
Signal
LED array
K15
IGN_IN on CARCTRL is high
Figure 7: HMI System status
IGN
IGN_OUT on SYSCTRL is on
LOAD
LOAD_IN on CARCTRL is high
OPT
reserved for internal use
VIN
Input voltage on POWER_IN is
present
DC
POWER_OUT is powered from
POWER_IN connector
BAT
POWER_OUT is powered by
Batteries
PWR
System is active
Power Switch
State
Signal
Switch
On
Device is turned on
Figure 8: Power Switch
Off
Device is turned off
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Vector BRICK UPS 200 User manual

Vector
Brand
Vector
Model
BRICK UPS 200
Type
User manual
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