Vector BRICK UPS 200 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.

 
 
 
 
 
 
 
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

Smart Battery

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

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.

0

Gateway

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

OUT,NET

Output voltage when supplied from board net

14,1

14,8

15,5

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

GPI,HIGH

GPI High voltage

4,5

4,6

4,7

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

LOAD,HIGH

LOAD Input High voltage

4,5

4,6

4,7

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

IGN_IN,HIGH

IGN_IN Input High voltage

4,5

4,6

4,7

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

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

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.

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 BRICK UPS 200 User manual

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