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OBR PCM2, Installation And User Manual

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OBR PCM2 Installation And User Manual Download Page 8

 

  Control Systems

 

 

OBR Control Systems Inc 

 

OBR Control Systems Inc

 

Telephone : +1 (248) 672-3339 

[email protected]

 

32233 West 8 Mile Road

 

 

www.obrcontrolsystems.com 

Livonia, Michigan 48152 

 

 

USA

 

8 / 92

 

 

 2   Hardware 

 
The PCM2 enclosure is CNC machined to the highest standards.  
The two parts of the casing are sealed by an O-ring, located in a recess in the main half. A lip in 
the lid presses on the O-ring and assures a water tight sealing. The connectors are individually 
sealed. 
 
Connector #1 is a Deutsch Autosport Heavy Duty single pin connector, type ASHD0 14-1 PN. 
This is a specially developed connector, designed to conduct very high currents with very low 
losses and to withstand high temperatures. 
We recommend using a 35 sq.mm heavy duty battery cable as the main power supply. 
The mating connector on the wiring loom must be ASHD6 14-1 SN C35. 
 
Connector #2 is a Deutsch Autosport connector, type AS2 20-16 SN. This connector has 16 size 
AWG 16 contacts and each contact is designed to handle a maximum current of 20 A.  
The mating connector on the wiring loom must be a Deutsch AS6 20-16 PN or a Souriau 8STA6 
20-16 PN. 
 
Connector #3 is a Deutsch Autosport connector, type AS2 20-39 SA. It has a different keyway to 
connector 2, preventing incorrect mating of connectors. 
This connector has 37 size AWG 20 contacts and 2 size AWG 16 contacts. Each AWG 20 contact 
is designed to handle max 8 A current.  
The two size AWG 16 contacts (pins m and r) in this connector are power ground connections and 
must be connected to earth. 
The mating connector on the wiring loom must be Deutsch AS6 20-39 PA or a Souriau 8STA6 20-
39 PA (yellow coding). 
 
Connector #4 is a Deutsch Autosport connector, type AS2 16-35 SN. This connector has 55 size 
AWG 22 contacts and is used for signal, sensor supplies and data connections. 
The mating connector on the wiring loom must be a Deutsch AS6 16-35 PN or a Souriau 8STA6 
16-55 SN. 
 
 

Summary of Contents for PCM2

Page 1: ...systems com Livonia Michigan 48152 USA 1 92 Power Control Module PCM2 The Next Generation Intelligent Power Distribution Module Installation and User Guide for PCM2 Firmware and Tool Version 1 47 With...

Page 2: ...Counters 11 4 3 11 Get Firmware Checksum 11 4 4 Interface 12 4 5 Options 12 4 5 1 Reset Display 12 4 5 2 Sync Time Automatically 12 4 6 User 12 4 7 Help 12 5 Functions 13 5 1 Overview 13 5 2 Units 13...

Page 3: ...ation Digital Inputs 27 8 2 Analogue Inputs 28 8 2 1 Pin Configuration Analogue Inputs 29 8 3 CAN Inputs 30 8 3 1 CAN Overview 30 8 3 2 CAN Channel Editing 30 8 3 3 CAN Row Counts 34 8 3 4 Pin Configu...

Page 4: ...t ON or OFF Status 61 OCL Output Current Low Byte 61 OCM Output Current Mid Byte 61 TO Output Tri State Voltage 62 OFL Output Fault Status LSB 62 VVL VVM Vehicle Battery Voltage 62 EVL EVH Event Statu...

Page 5: ...4 5 4 Panel Transmit 77 14 5 5 Panel Receive 77 14 6 CAN Bus Export 79 14 7 Miscellaneous Functions 81 14 8 CAN Bus Monitor 81 15 Steering Wheel Controller 83 16 PCM2 Pin Configuration 86 16 1 Connect...

Page 6: ...nnels From 50 mA on 4 low power channels not in current software release From 200 mA on all other channels Any of these channels can be controlled by various types and combinations of inputs 14 digita...

Page 7: ...tervals for each output channel A manual reset function of all channels in fault mode is also available The current draws and channel status can be exported via one of the available CAN bus PCM2 offer...

Page 8: ...Connector 2 is a Deutsch Autosport connector type AS2 20 16 SN This connector has 16 size AWG 16 contacts and each contact is designed to handle a maximum current of 20 A The mating connector on the w...

Page 9: ...w features visible in the new tool will not functioning if used in conjunction with old firmware versions It is strongly recommended always to use the latest software releases and always make sure you...

Page 10: ...es by selecting the function COMPARE WITH Please refer to section 6 Click on EXIT to close the PCM2 tool Use F7 as a hot key to close the programme 4 2 Product This tool supports two versions from the...

Page 11: ...are deactivated and no automatic or programmed switching is possible Instead it is only possible to switch each single output ON and OFF using the PC tool Go to section OUTPUTS for further information...

Page 12: ...n CAN communication OK 4 5 Options 4 5 1 Reset Display When disconnecting from PCM2 all display screens in the PC tool would normally be reset when disconnecting from the PCM2 Tick this option to reta...

Page 13: ...is section see Configuration Utility Version 5 2 Units Use this section to assign a unit to analogue and CAN channels These settings can be applied in INPUTS sections Analogue Inputs and CAN Inputs 5...

Page 14: ...Input A Input B Output 0 0 0 0 1 0 1 0 0 1 1 1 Select the output to trigger Select NONE if this is a conditional event only 5 3 1 4 OR gate The OR gate combines up to five events to set switching cond...

Page 15: ...d in section 5 6 This event will generate a count each time the event it is linked to changes from false to true The sequence in which it counts is defined in section 5 6 Counters Use this event withi...

Page 16: ...1 15 Always ON Use this event to switch the event to true once power is applied to the PCM2 for example when the master switch is ON 5 3 1 16 Tri state output The tri state outputs are used as trigger...

Page 17: ...1 Fault Status To detect a failed PCM2 output create an event for each output Select Event Type as Input Follow Name the event for example Fault LP01 Select the input as the Fault for the actual outpu...

Page 18: ...ded to use an interval of app 2 5 times the message update rate For example if the update interval is 100 msec it is recommended to set the time interval to 250 msec During this time interval the syst...

Page 19: ...en selected events becomes true This switch status overrides normal event handling as it has the highest applied priority It is possible to select up to 8 individual events controlling the special fun...

Page 20: ...3 1 11 and 5 3 1 12 Counters count up or down in steps of 1 5 6 1 Increment Action It is possible to set a maximum number of counts This can be any number between 0 and 255 The maximum number of coun...

Page 21: ...igh Analogue channels displays sensor input voltage PCM2 on board temperature measurement in degrees Celsius on signal and power boards CAN channels displays decimal channel values Counters are not ye...

Page 22: ...gnostics can also display a combination of errors 5 8 Events Monitor This section displays the status of PCM2 events Green resembles a TRUE event Blue resembles a FALSE event Events not assigned are c...

Page 23: ...ue of 1 the channel is switched on If you see a value of 8 the channel is switched off and has no load connected to it Error status codes are normally shown as a combination of numbers If you see a va...

Page 24: ...llow To view the differences click on a section marked in yellow Shown in the example there are differences in Inputs in section Analogue Inputs Move the cursor over channel 06 in the column Name A wi...

Page 25: ...t to Read Only and the user must select the desired access level and key in the correct password if known 7 1 1 1 Default Passwords It is strongly recommended to define personalised passwords to avoid...

Page 26: ...ithin the configuration file folder 7 1 2 1 Import and Export of User Access Rights It is possible to store user settings on disc and these settings can be imported and programmed into other PCM2 s Su...

Page 27: ...en circuit connecting to battery voltage any combination of these in a single switch Configuration of switch condition is set within the event handling Latching or momentary switches can be used Confi...

Page 28: ...nded for use with NTC temperature sensors Pull up to VREF through a 47 kOhm resistor allows detection of broken sensor wires Floating input preferred selection for all sensors except NTC temperature s...

Page 29: ...ation table is left blank Analogue channel values are exported as scaled values when the calibration table is used Please note that the analogue inputs are disabled in the instant when power to the PC...

Page 30: ...settings 16 channels displayed on each of the 4 pages Num Click to open the graphic visualisation see section 10 Name CAN input channel name max 15 characters Address Identifier in HEX the lower the...

Page 31: ...ntifiers each plus the PC tool CAN identifiers can be individually selected and they do not have to be arranged in special groups The lower the address number the higher the data priority CAN channels...

Page 32: ...PER on the value of the byte changes to 2 32 34 Switching the fan on too the byte value will now be 2 8 32 42 A CAN input for a dedicated switch can be configured to display 0 or 1 when toggling betwe...

Page 33: ...Now tick the box Bit Selection OR Byte Selection Click on the sixth bit window 5 and select 37 Deselect reading of data from bits 0 1 2 3 4 6 and 7 by selecting the option from the scroll down menu fo...

Page 34: ...e same position bytes 2 and 3 in identifier 0x300 PCM2 will read Shift Pressure from this location when the row count value is 0 it will read Oil Pressure from this location when the row count value i...

Page 35: ...Very high power outputs ON OFF switches The tri state analogue outputs cannot be used as power supplies they can only be used as trigger signals It is possible to connect two or more identical power...

Page 36: ...referred selection for lift pumps for example The driver stages can deliver significantly more current but it is important to avoid overloading the wiring and contacts in the connector Once an output...

Page 37: ...utput channel after is has been shut down caused by a short circuit or an overload It is strongly recommended not to exaggerate the number of retries select a number 10 In Retry ms set the time interv...

Page 38: ...AS2 20 39 SA h 10 25 13 AS2 20 39 SA T 11 25 13 AS2 20 39 SA i 12 25 13 AS2 20 39 SA U 13 25 13 AS2 20 39 SA d 14 25 13 AS2 20 39 SA K 15 25 13 AS2 20 39 SA n 16 25 13 AS2 20 39 SA L 17 25 13 AS2 20 3...

Page 39: ...PWM output in parallel with any other output 9 3 1 Half Bridge Full Bridge These PWM outputs are true half bridge drivers having a top and bottom transistor Contrary to conventional outputs the PWM ou...

Page 40: ...wed to exceed the OCS fuse level Time intervals are selectable from 25 ms to 250 ms In column NORM mA key in the steady state fuse level required This value must be lower than the maximum fuse level O...

Page 41: ...single axis calibration select the X or Y axis as the input reference using only the first row or column of the other axis The map can be imported and exported to Excel An easy way to create a duty cy...

Page 42: ...N button for each individual channel to switch the output ON Click the ON button again to switch the output OFF Clicking on Trigger will open the main event controlling this output A warning may appea...

Page 43: ...16 connector Current draw can be measured on all outputs The driver stages can deliver significantly more current but it is important to avoid overloading the wiring and contacts in the connector Onc...

Page 44: ...time interval in milliseconds during which the current draw is allowed to exceed the OCS fuse level Time intervals are selectable from 25 ms to 250 ms In Retry set the maximum number of automatic re a...

Page 45: ...WARNING Do NOT connect any PWM output in parallel with any other output 9 5 1 Half Bridge Full Bridge These PWM outputs are true half bridge drivers having a top and bottom transistor Contrary to con...

Page 46: ...threshold the output will be switched off In column NORM mA key in the steady state fuse level required This value must be lower than the maximum fuse level OCL Maximum current threshold is 26 000 mA...

Page 47: ...y table Mark the table and copy Return to the tool and click past Set frequency in Hz minimum applied value is 30 Hz maximum value is 15 kHz HP PWM1 and HP PWM2 must use the same frequency The Status...

Page 48: ...ntrolsystems com Livonia Michigan 48152 USA 48 92 Clicking on Trigger will open the main event controlling this output A warning may appear if several events are used to control it 9 5 3 Pin Configura...

Page 49: ...16 connector Current draw can be measured on all outputs The driver stages can deliver significantly more current but it is important to avoid overloading the wiring and contacts in the connector Once...

Page 50: ...NORM mA key in the steady state fuse level required This value must be lower than the maximum fuse level OCL Maximum current threshold is 26 000 mA If the current draw on an output exceeds the NORM fu...

Page 51: ...when used on a wet screen Once an output is turned on the current draw depends on the attached load If this load is a resistive load there will hardly be any inrush current If the output drives a mot...

Page 52: ...e level Time intervals are selectable from 25 ms to 250 ms In Retry set the maximum number of automatic re activation of an output channel after is has been shut down caused by a short circuit or an o...

Page 53: ...hannel switches 5 0 volts ON maximum current draw is 1 0 A 9 10 Fault Reset You can reset all output channels in error status by briefly connecting the selected reset channel to ground A reset channel...

Page 54: ...up and down the PC arrow keys or the wheel on the mouse Press and hold the shift key and use the mouse scroll wheel to move the display left and right A Navigate button gives access to these features...

Page 55: ...is opened by clicking the visualisation button found in the lower right hand corner of the event configuration window The event input box displays Event name Event number Event type Event conditions f...

Page 56: ...there is traffic on the CAN bus If a CAN bus fails for example after a short circuit PCM2 will automatically reset the CAN stream 11 1 1 CAN Bus Name Each CAN bus can be labelled individually to ease...

Page 57: ...can be individually terminated By ticking the box a 120 Ohm resistor within PCM2 is connected between CAN H and CAN L on the selected CAN bus Please note that a CAN connection should not exceed 16 met...

Page 58: ...52 USA 58 92 11 1 4 2 Incorrectly Terminated CAN Bus If the CAN bus is incorrectly terminated having NO termination resistors the data transfer will be instable Please note the shift in voltage level...

Page 59: ...y then do NOT tick this option 11 1 6 CAN Bus Identity Set the base send and receive identifiers for each CAN bus This must be set for each individual CAN bus 11 2 CAN Monitor A CAN bus analysing tool...

Page 60: ...ex Transmission time interval Code for information sent in each byte displayed from byte 7 byte 0 from left to right 11 3 1 Configuration of Export Channels It is possible to export the following info...

Page 61: ...Status is displayed as 0 off 1 switched low 2 switched open 3 switched high AL Analogue Input LSB Any analogue input channel can be exported on a CAN bus The LSB channel can export values between 0 25...

Page 62: ...hannel is switched on Displaying a value of 8 the channel is switched off and has no load connected to it Error status codes are normally shown as a combination of numbers Displaying a value of 17 PCM...

Page 63: ...SB Byte PCM2 exports currents between 0 131 070 mA OCL4 Output Current LSB Byte mA 4 Current draw from each of the 48 power outputs can be measured This byte export current draws between 0 1 023 mA OC...

Page 64: ...el can be exported on a CAN bus The MSB channel can export values between 256 65 535 Combining export of the LSB and MSB channels values between 0 65 535 can be exported These channels can be arranged...

Page 65: ...e byte to use as row count for example Byte 0 In Byte Format select Constant Value In Value select number any value will do for example 0 For all remaining bytes select which channels to export Second...

Page 66: ...ecifically control the Bosch WDA wiper motor This section will concentrate on the settings required for this wiper motor to function correctly In this example we have used digital inputs to control th...

Page 67: ...Road www obrcontrolsystems com Livonia Michigan 48152 USA 67 92 Configuration of byte 1 Configuration of byte 2 3 4 5 6 and 7 The wiper motor has a 4 way connector Pin 1 LIN bus signal connect to PCM...

Page 68: ...ns from connector 4 this way Pin 17 in connector 4 RS232 TX to pin 2 in the serial DB9 connector Pin 18 in connector 4 RS232 RX to pin 3 in the serial DB9 connector Pin 33 in connector 4 RS232 ground...

Page 69: ...switch Each key can be assigned to several CAN addresses Up to 10 independent definition of CAN identifiers Adjustable EL backlight and LED intensity 14 1 Software installation There is no software to...

Page 70: ...Panel user name Click on Write or press F9 to send a configuration file to the MSP The panel will reset and use the new configuration Click on Reset or press F10 to reset the controller manually 14 3...

Page 71: ...11 13 14 15 14 4 2 Switch name Key in the name of each switch A maximum of 15 characters including spaces can be used 14 4 3 Mode Select the key mode as latching or momentary In latching mode the key...

Page 72: ...when the car has dual PCM2 s 14 4 10 Extra Group In addition to the regular CAN export the panel may perform a secondary CAN export It is possible to define up to 8 additional CAN export packages each...

Page 73: ...3 Switch 9 transmits on byte 6 bit 0 absolute bit number 48 Switch 10 transmits on byte 6 bit 1 absolute bit number 49 Switch 11 transmits on byte 6 bit 2 absolute bit number 50 Switch 12 transmits on...

Page 74: ...nnel will display 0 when switch 1 is not activated and it will display 1 when the switch is activated Repeat the configuration for the other MSP keys replacing the absolute bit value in bit position 0...

Page 75: ...it identifier Select 11 or 29 bit identifier used Select update interval in milliseconds Click in byte 0 and select Constant Value select 10 Click on byte 3 and select Output On Off as byte format For...

Page 76: ...old for detecting no fault to 2 Click Save In PCM2 use the CAN Export to configure transmission of the output switch status to the membrane panel Name the package Select CAN bus on which the MSP is co...

Page 77: ...AN mode in parallel with the advanced mode Please see section 11 5 for a description of the two strategies 14 5 4 Panel Transmit Use this section to define the addresses in which the panel sends comma...

Page 78: ...D2 is used for communication with a secondary PCM2 in advanced CAN mode If the box Use with old PCM is ticked MSP will transmit data using the standard protocol too Leg ID1 is used for communication w...

Page 79: ...CAN export using one or two bytes Switch value LSB Select to send switch data having values between 0 and 255 Switch value MSB Select to send switch data having values between 256 and 65535 In Value s...

Page 80: ...alue LSB Select to send 0 255 bits of the 1024 bits representing 5 000 mV sensor data Analogue value MSB Select to send 256 1023 bits of the 1024 bits representing 5 000 mV sensor data In Value select...

Page 81: ...tomatically when pressing one of the membrane switches typically the light switch This way the brightness will be dimmed when lights are turned on for night driving In addition with MSP2 it is also po...

Page 82: ...on the actual CAN bus The monitor is only active once the Monitor On box is ticked Tick the box Monitor On to display the data detected on the bus The analyser displays all traffic on the bus it is co...

Page 83: ...ng and terminating is done via the CAN link and it can be programmed to communicate on any address It is fitted to the steering wheel by 2 x M3 screws and has a total thickness of 13 mm The steering w...

Page 84: ...ess the switch once to turn ON press the switch again to turn OFF Using this setup the diodes shown in the diagram are not required Some installations are done by using conventional toggle switches Th...

Page 85: ...nce and LED indicators J26 5V 5V Reference and LED indicators J27 LED 18 SWITCH 18 LED J28 LED 20 SWITCH 20 LED J29 CAN H CAN Bus High signal J30 CAN L CAN Bus Low signal J31 GND Ground connection for...

Page 86: ...igh Power 26 100 B Channel 2 Very High Power 26 300 C Channel 1 Very High Power 26 300 D Channel 9 High Power 26 100 E Channel 1 High Power 26 100 F Channel 5 High Power 26 100 G Channel 1 High Power...

Page 87: ...nel 4 13 75 R 15 Channel 6 13 75 S 16 Channel 8 13 75 T 17 Channel 10 13 75 U 18 Channel 12 13 75 V 19 Channel 2 PWM 13 25 0 100 DC W 20 Channel 4 PWM 13 25 0 100 DC X 21 Channel Wiper 1 8 75 Y 22 Tri...

Page 88: ...232 RX 19 Digital Input 14 Trig High Low Open 20 Digital Input 10 Trig High Low Open 21 CAN 4L 22 CAN 3L 23 CAN 1L 24 CAN 1H 25 LIN bus LIN_MST Connect to 26 to set as MASTER 26 LIN bus LIN_BUS 27 Eth...

Page 89: ...Michigan 48152 USA 89 92 Pin Used for Comments 49 Analogue Input 2 12 bit Pull up 0 3 16k 47k 50 Analogue Input 6 12 bit Pull up 0 3 16k 47k 51 Analogue Input 9 12 bit Pull up 0 3 16k 47k 52 Analogue...

Page 90: ...outputs 12 Maximum inrush peak current each output 150 A Maximum continuously current draw per output 50 A Maximum recommended current draw 26 A 17 2 3 High power PWM channels Number of individual out...

Page 91: ...nded inrush current 1 000 A peak current 17 4 Temperatures Maximum operating temperature 85 deg C continuous internal temperature Typical temperature rise over ambient 30 deg C 140 A 30 minutes 17 5 C...

Page 92: ...trol Systems Inc Telephone 1 248 672 3339 ole buhl obrcontrolsystems com 32233 West 8 Mile Road www obrcontrolsystems com Livonia Michigan 48152 USA 92 92 17 7 Dimensions Length x Width x Height 197 x...

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