Lyra Electronics
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1. o M d w ka e o D S S T H a u tL Q o b e ea CI KI eS TT CN 1158 L uogisod dr Und VEGA3 ECU USER MANUAL KI U ENE o gg um Digital Inputs pull up down resistors By default all the inputs have resistors fitted as pull ups They can be moved to be pull downs as The locations of the pull up resistors are shown below for each of the digital inputs shown 2 9 8 CHANGING DIGITAL INPUT PULL UPS www Lvrakblectronics com LITEA VEGA3 ECU USER MANUAL 2 10 DIGITAL OUTPUTS The twenty low side and four high side digital outputs are simpler than the digital inputs having little in the way of configurable hardware They provide pulse width modulation PWM of outputs as well as simple on off switching 2 10 1 MPC563 DIGITAL OUTPUTS ASSIGNMENT Connector Pin Digital MPC563 Configuration If applicable Channel Output 30 B1 30 B2 30 B3 30 C1 30 C2 30 C3 30 D1 30 D2 30 D3 30 E1 30 E2 30 E3 30 F 1 30 F2 30 F3 30 G1 30 G2 30 G3 DIGO DIG1 DIG2 DIG3 DIG4 DIG5 DIG6 DIG DIG8 DIG9 DIG10 DIG11 DIG 12 DIG 13 DIG 14 DIG 15 DIG 16 DIG17 TPUBA TPUBS TPUB6 TPUB7 TPUB8 TPUB9 TPUB10 TPUB11 TPUB12 TPUB13 Move jumper R199 for PWMO Move Jumper R213 for PWM1 Move jumper R192 for PWM2 Move jumper R195 for PWM3 Move jumper JP1 for PWM4 Move jumper JP3 for PWM5 Move jumper JP2 for PWM6 Move jumper JP4 for PWM7 30 H1 AIN7 DIG18 MDA8 30 H2. A The low side drive outputs pins are shared with the digital inputs The digital inputs have 10k pull up resistors fitted as default between the input and the internal 5V supply If the load is very light a single LED or no load at all for example then the 7V you see is the difference between your 12V external supply and the 5V internal supply Solution For a relay coil or a lamp this will present no problem as the load impedance is much lower than the 10k pull up For light loads remove the 10k pull up from the shared digital input altogether If you absolutely need both consider connecting your load between a 5V supply and the low side drive rather than from 12V Q Why do the outputs briefly pulse on during power up A Because the processor has internal pull ups and pull downs that are invoked during reset Check that the PULL SEL resistor R239 on the underside of the board is in its pull down configuration i e pin R26 of the processor is connected to ground to prevent this www LyraElectronics com 23 of 23
3. EEEE Eep E en PIC CAN monitor LUISCLIS TTTTTTESTTITITO SIS SC E CES wl t www LyraElectronics com 21 of 23 LY TEA VEGA3 ECU USER MANUAL The second processor the PIC can also be connected any of the three main CAN buses by shorting the appropriate jumper pair This is shown below E These jumpers also allow hardware loopback of one CAN bus to another You could link CAN A to CAN C for instance allowing physical connection of two buses at the Vega3 connector rather than harness splices 2 13 USB INTERFACES The MPC365 USB interface is implemented with an FTDI USB to serial IC connected to the MPC563 with TXD1 and RXD1 Serial data transmitted by the connected host will appear at the MPC563 as if it were connected via RS232 The PIC32 USB interface is a true USB port configured as a device connected directly to the processor 2 14 RS232 LIN INTERFACE Both the RS232 port and the LIN interface use the same TXD2 amp RXD2 pins of the MPC563 The RS232 receive pin is directly connected to pin 18 F2 but the RS232 transmit pin and the LIN line share pin 18 F1 By default the RS232 TX is connected to the pin and the LIN bus is not Move jumper R116 to select the LIN interface WWW LyraElectronics com 22 of 23 LITEA VEGA3 ECU USER MANUAL Frequently Asked Questions Q With a low side drive off I still get 7V across my load With the low side drive on get the full 12V Why
4. Emm mp removal tool 5810118920 664 7270 1282214 The supplier part numbers are correct at the time of issue of this document but may change WWW LyraElectronics com LITEA VEGA3 ECU USER MANUAL 2 7 OVERVIEW OF PCB The PCB is designed to be customisable by the end user All pull up pull down gain and hysteresis components are the larger 0805 size surface mount components to simplify rework Most of these components are on the top side of the board for the same reason Spice simulations are provided of the customisable interfaces to verify the intended operation before changing real components please see the LTSpice Simulations folder on the installation disk The top side of the board is arranged like this Power Supplies E S 3 er High Side rivers MIPCS5S3 Pla oer Side Drivers Digtal Inputs L S _ K Res Bes H H W NN UE W 4 AR A HN Be VA y www LyraElectronics com 10 of 23 LITEA VEGA3 ECU USER MANUAL 2 8 DIGITAL INPUTS AND OUTPUTS There are 20 pins on the Vega3 that are shared between digital inputs and digital outputs although they are distinctly separate to the processor LC GD x Ee implified The 20 digital outputs are permanently connected to the 20 digital inputs at the connector pins This allows independent monitoring of the state of any driven digital outputs If a digital pin is required to be an input the digi
5. VEGA3 DEVELOPMENT ECU ISSUE DRAFT 05 DATE 03 May 2013 AUTHOR Mike Evans Address USER MANUAL Lyra Electroncs Ltd Web www lyraelectronics com The Venture Centre email admin lyraelectronics com Sir William Lyons Road Phone 0121 667 9832 Coventry CV4 7EZ LITEA VEGA3 ECU USER MANUAL Table of contents KAES 3 E a E AA GA Ga a AG ATA GG 3 2 1 vii ete GS AAAH NAY 4 ra ane HE kad Lapu AA AA e E BO ak al BEE 5 AA AA 6 SEENEN 8 C uiii ENEE 8 2 6 ACCessorles NCTTCNNDNPRORCICPK 9 2 Overview of HBC AAA 10 ZEE SCELUS REI I omm 11 Ge E 12 Ate 12 2 9 2 MPUSDS Digital Mpu Assignment eege Ee see 13 ST e leie Doala FUD EES 14 PLUS o ReKe 15 2 10 1 MPESSS DIAL Guipuls elt EE 15 2 10 2 Low scx BI 16 e drives 2 10 2 een len EE 17 2 10 3 lerpal EE brani RETE 17 El IMS ee 18 2 11 1 PCB Lay ut aaa Cal PAA 19 2 11 2 Internal Analogue Channels o 0 04000 0000000 40004004804480488 4080480040 0488408 4084840848 408400400a0anaawg 19 2 11 3 MP E563 Digital Outputs e ul EE 20 PA PAGAN CLA AA 21 bg BE erter 22 2 14 RS232 LIN Interface 22 WWW LyraElectronics com LITEA VEGA3 ECU USER MANUAL 1 INTRODUCTION The Vega3 Electronic Control Unit ECU is a module for developing real time control applications It has been designed for the electric vehicle market although it c
6. A AN55 Internal Temperature ADC12 A AN56 Accel X ADC13 A AN57 Accel Y ADC14 A AN58 Accel Z ADC15 A AN5 www LyraElectronics com 19 of 23 LITEA VEGA3 ECU USER MANUAL 2 11 3 MPC563 DIGITAL OUTPUTS ASSIGNMENT Digital Channel MPC563 Output Configuration E Lm 0 82 DIG p48 30 88 DIG2 X TPUBO OF 30 C1 X DIG3 TPUB7 CT 30 C2 IG 4 XLTPUBB 30 98 DIG5 TPUB 30 D1 Deg JTPUBIO 30 D2 DIG7 TPUBA TO CT 30 D3 DIG8 TPUBI2 oo 30 E1 Deg TPUB13 30 Ht IG 18 MDA 30 H2 DIG19 MDAR _ _ CT T www LyraElectronics com il 20 of 23 LITEA VEGA3 ECU USER MANUAL 2 12_CAN INTERFACES Termination Every CAN bus requires a 120R termination resistor at each end of the CAN bus pair Due to the many places the termination resistors can be fitted the default configuration of the Vega3 is to have empty pads where termination resistors can be added This schematic shows the termination configuration of the three main CAN buses to MPC563 to MPC563 to MPC563 It shows two 60R resistors in series with an optional 10nF capacitor from the centre point to ground The resistors are 0805 components so they re easy to solder The PCB plots show where the components are physically on the board E LE MN KSC KE sde m F ELI o AA gg i N Pl s RIR e IER mm
7. level positive feedback is introduced with R99 This resistor can be changed to vary the amount of hysteresis The supplied LTSpice simulation shows that the default switching threshold is around 1 5V Adjust R2 to change switching threshold Y Digitallnputs4k7 raw elt zs www LyraElectronics com 12 of 23 LITEA VEGA3 ECU USER MANUAL 2 9 2 MPC563 DIGITAL INPUTS ASSIGNMENT Each channel of the digital input circuitry is connected to a unique MPC563 pin given below Generally they map to TPUA channels but since there are only 16 channels per TPU the last four digital inputs are connected to TPUB inputs 30way Digital Channel MPC563 Input Connector Pin The TPU channels provide many options for processing digital inputs from simple discrete on or off to frequency measurements and timer capture operations TPU stands for Time Processor Unit stand alone modules within the MPC563 processor They are further explained in the software guide for the Vega3 Whilst all of the digital input pins are also connected to the digital outputs as previously explained pins H1 and H2 of the 30 way connector also double up as the last two analogue input pins It is important to check the input signal conditioning circuitry of these analogue inputs will not affect the digital input voltage thresholds and vice versa when using these pins for analogue inputs www LyraElectronics com 13 of 23 uonisod uwmoq Ing Y tu
8. 2 AIN6 DIG19 MDA9 Jumpers JP1 2 3 and 4 are dual jumpers i e DPDT which also control the High Side Drive control signals as shown below This allows the MDA or PWM signal to be used for either outputs www LyraElectronics com 15 of 23 LITEA VEGA3 ECU USER MANUAL 2 10 2 LOW SIDE DRIVES In their simplest form low side drives are used to switch electrical loads such as external relays or lamps For example consider digital output O DIGO By turning on TBUBA of the processor the low side switch is energised and the external relay is connected to ground switching it on If using the Vega3 blockset this is simplified further just select the connector pin to be used from the drop down menu All Vega3 low side digital outputs have built in protection diodes to prevent inductive loads such as relays damaging the low side switch at switch off The switching MOSFET on each channel is fully protected against over current over temperature and short circuit It has an Rps o of 120m4 and the device current limits at 3 5A The outputs are also able to be PWM controlled via software allowing brightness control of lamps or speed control of small DC motors Some outputs DIG10 to DIG17 may need configuration changes to achieve this please refer to the table in section 2 10 1 WWW LyraElectronics com 16 of 23 LITEA VEGA3 ECU USER MANUAL 2 10 1 HIGH SIDE DRIVES The high side outputs are contro
9. an be used in any application that requires a rugged compact and powerful ECU By carefully considering the functional requirements and combining this with a case that is cost effective yet completely waterproof the Vega3 is rugged practical affordable but extremely capable ASIL D applications can be considered due to the two microprocessors from different manufacturers that can self monitor or monitor each others operation Since the module is suitable for high volume applications development costs are reduced as the same module can be used to develop the system as will be used in the final application This has the added benefit of not having to re code for a production intent module and removes the risk of errors being introduced both software bugs and hardware incompatibilities Code once Demonstrate on a small scale Deploy on a large scale 2 HARDWARE This section describes the Vega3 ECU from an electronics hardware perspective ERSE MINAR DRAR www LyraElectronics com LY TEA VEGA3 ECU USER MANUAL 2 1 FUNCTIONAL DESCRIPTION The Vega3 is a general purpose ECU designed to automotive specifications It has two microprocessors both 32bit high end specification with an interconnecting SPI bus and a NMI reset line from the PIC32 to the MPC563 This allows software to be written that complies to an ASIL rating for safety Flexible routing of CAN buses allow the PIC32 to monitor connect to any of
10. e and Marine ECU Power Supply Operating voltage range Max total LSD load Max total HSD load Nominal operational current Standby quiescent current Shut down SW controlled The MPC563 can hold power on after Key On has been released to enable a graceful system shut down without an external HK EL XE J d relay Microcontroller Freescale MPC563 supporting double precision floating point operations Clock Frequency nternal Flash External Flash MRAM EEPROM Internal SRAM External SRAM Microcontroller Clock Frequenc Internal Flash Digital Inputs 20 digital inputs each individually configurable to be used as switch inputs sensor logic inputs or voltage threshold inputs Automatic independent monitoring of digital outputs All capable of frequency and timing measurements Analogue Inputs 8 external inputs 8 from an internal header 4 x oversampled 10 bits single ended with configurable input divider and gain 4 of these are also measured by PIC32 3 sensors Internal box temperature measured by MPC563 Output drives and MPC563 temperature measured by PIC32 Power supply monitors Vbat 5V sensor Supply Key On voltage and 2v6 supply measured by MPC563 Vbat sensor 5v 2v6 independently monitored by PIC32 Accelerometers 3 axis sensor with X Y Z signals on separate ADC channels GE P a N N N N N Switch inputs Frequency Inputs Monitoring digital outputs Inte
11. inch part 5991111611 In an emergency the case can be separated by using many small screwdrivers inserted into key points but it is easy to damage the plastic locking points and ruin the seal The Cinch tool is recommended Details of the Cinch case mating connectors crimps and tools can be found at http www cinch com products modular integrated connector enclosure modice se le These parts are stocked by most major electronics distributors RS Farnell Digikey etc 2 5 PINOUT grim DRAFT WWW LyraElectronics com LITEA VEGA3 ECU USER MANUAL 2 6 ACCESSORIES The full list of Cinch parts are listed below together with part numbers for popular suppliers Not all of these parts may be needed it is possible to use the Vega3 as a CAN gateway for instance with only the one 18 way connector Although both crimp sizes and tools are listed the smaller 0 5 to 0 8mm wire should be suitable for most applications of the Vega3 Cinch Partt RSPart Farnell Part 18 way mating 5810118023 664 7254 1282205 connector 30 way mating a 5810130029 664 7267 1282208 connector alternate keywa Crimp terminal for 4250000872 664 7260 1282209 0 5 0 8mm wire ry 20 to 18 AWG P AMEN Sealing plug for 5810000011 664 7295 1282218 unused crimp positions Crimp tool for O 5991111615 664 7273 1282211 0 8mm terminals l 20 to 18 AWG Cinch case al 5991111611 664 7282 1282216 disassembly tool
12. lled by the following MPC563 pins Digital Channel MPC563 Output Configuration Jumper 18 C2 HSDO PWMA MDA4 JP1 pair 30 A3 HSD1 PWM5 MDA5 JP3 pair 30 A2 HSD2 PWM6 MDA6 JP2 pair 30 A1 HSD3 PWM7 MDA7 JP4 pair The outputs are controlled by a single solid state relay capable of supplying four outputs of 3A Note that there is a limit of 10A per pin before temperature de rating see section 2 2 1 and that this applies to the Vbat input pin from which these high side outputs are supplied 2 10 2 SENSOR SUPPLY The 5V output on Pin 18 C3 is switched off by default It can be switched on with MPIOS or selecting 5V Sensor supply from the Vega Blockset The sensor supply output pin is monitored through a 2 1 voltage divider with ADCO9 This supply output is also used as an alternate reference voltage for the ADCs i e the MPC563 ALTREF input 2 10 3 INTERNAL PERIPHERAL CONTROL Several MPIO lines control the Vega 3 peripherals MPC563 Output Peripheral Notes MPIO1 Hold On Holds power on to the Vega3 regardless of KeyOn state MPIO1 LIN Output Enable Active high MPIO2 LIN Wake Active High MPIO3 FLASH R B Input MPIO4 RS232 FTDI pin CBUS3 MPIO5 5V Sensor Supply Output Enable Active high MPIOG Accelerometer Self test Active high At revision B of the Vega3 PCB this line is erroneously connected to both the LIN Enable and the Hold On control line This line sho
13. rnal nitors Temperature www LyraElectronics com LITEA VEGA3 ECU US Medium Current Drivers 3A Sensor Supplies CAN 2 0B Outputs Communications RS232 LIN Operating temperature range Construction IP rating Connector Contact resistance Insulation resistance ESD protection Vibration Shock Salt spra Temperature Humidity Cycling Fluid resistance www LyraElectronics com ER MANUAL 20 low side drives with PWM capability 4 high side drives with PWM capability 5V 250mA output software switchable with ADC measurement of output voltage to detect overloads shorts selectable to PIC32 processor 4 transceivers Full USB COM port emulation with FT232R Internal USB mini port from PIC32 host or device a WC P L H EE o0g s 320 hours 40x8hr cycles 40 to 85 C 85 RH to 125 C Most industrial fluids Ce 0 llb BI E E WE LITEA VEGA3 ECU USER MANUAL 2 4 MECHANICAL ASSEMBLY The Vega3 is supplied with the outer case not mated to the connector i e the PCB can be withdrawn from the housing This is to allow for modifications to be made to suit the application e g for pull up resistors to be added and to allow the PIC32 processor to be programmed if required Since the assembled Vega3 unit is completely waterproof once the connector is mated with the outer case a special tool is required to separate them again The release tool is C
14. s share a connector pin with digital inputs Ain6 is connected to Dig19 and Ain7 to Dig18 It is possible to use both simultaneously but care needs to be taken with pull up and pull down resistor configuration to prevent interaction From a software perspective the channels are split in half between A ANO 1 2 3 and A AN48 49 50 51 See the table in the next section for more information www LyraElectronics com 18 of 23 LY TEA VEGA3 ECU USER MANUAL 2 11 1 PCB LAYOUT OF ANALOGUE INPUTS 715225 ua EEE o RS JI 15227 a EEN o WIER PI NE 15 95 R2900 O GT M ecc expl M u o e 321386 EI e Cipa R211 3 P P n n n z EA aS UI FOE IE GET AE er Rn 2st Let 32 Hast E34 LE LE LE i B gu 8 bois H ke R Schaz E d H Sch R len qm uro cm ns cm unco vm m Sm e com as oum ns sm m zo 4 cb E BE Ub a b EP obs P cb BO BM H Wb H NE HON NUT H NOE H NE Nu H Ne CONZ BAGA CRAT Re c pdH Camp R199 792120 c R228 1533578223 oy Ain7 Ain6 Ain5 Ain4 Ain3 Ain2 Aint Ain0 2 11 2 INTERNAL ANALOGUE CHANNELS In addition to the 8 external inputs there are several analogue inputs that monitor internal voltages temperatures and acceleration VEGAS3 Function VEGA3 Channel Name MPC563 PIN NAME External ADCO to 3 ADCO to ADC3 A ANO 3 External ADC4 to 7 ADCA to ADC7 A AN48 51 Vbat Voltage ADC8 A AN52 5V Sensor Supply Mon ADC9 A AN53 KeyOn Voltage ADC10 A ANDA 2V 6 Monitor ADC11
15. tal output should not be driven Be aware that the digital output protection diode shown below may affect readings if the input is floating i e with no pull ups or weak pull downs due to the unavoidable small leakage current through this diode It is recommended that digital inputs are pulled high and switched to ground where possible Vbat Se 5V Not Fitted Lod B i Lt Digital Pin N v MPC563_TPUA Lt rh iN Lu T T Vbat D d as 3 MPC563 TPUB The last two digital I O pins DIG18 and DIG19 are further shared with analogue inputs 6 and 7 which also have provision for pull up and pull down resistors WWW LyraElectronics com 11 of 23 LITEA VEGA3 ECU USER MANUAL 2 9 DIGITAL INPUTS At their simplest the Vega3 digital inputs are used to detect when external devices e g switches are on or off or to measure a frequency or period that an input is oscillating at 2 9 1 HARDWARE There are 20 digital input circuits each identical to the one shown below Figure 1 Digital Input Schematic For DigO shown above the threshold voltage at which the digital input switches from 1 to O can be set by adjusting R118 and R100 designators will be different for each channel R314 and R317 can be used as a potential divider if larger input voltages are to be used with R314 moved to its pull down position To prevent oscillations as slowly moving inputs pass through the trigger
16. the three CAN buses B o O a m agram PRELIMINARY DRAF WWW LyraElectronics com LITEA VEGA3 ECU USER MANUAL 2 2_ ABSOLUTE MAXIMUM RATINGS e Maximum supply voltage beyond which damage may occur 36V e Maximum external fuse rating 20A e Maximum total high side load Limited by Vbat pin rating of 10A e Maximum total low side load Limited by two GND pins total rating of 20A The Vega3 ECU is protected from over voltage by a 33V stand off 5kW transient voltage suppression TVS diode It begins to conduct at 37V clamping the voltage to the Vega3 and dissipating the over voltage energy as heat It is designed to protect against voltage spikes and commonly experienced automotive transient over voltages but no device will survive continuous over voltage External fusing of the Vega3 is important EP N az APY M RA rrent bu correctly The BUL era Ad connected 2 2 1 CONNECTOR PIN DE RATING The Cinch connector pins are nominally rated at 10A per pin but this value should be de rated with increasing temperature Maximum Current AMP Ambient Temperature 9C At the upper limit of the Vega3 temperature range of 85 C 5A would be a conservative limit As a comparison the low side drives can sink a maximum of 3 5A before current limiting WWW LyraElectronics com LITEA VEGA3 ECU USER MANUAL 2 3 HARDWARE SUMMARY Vega 3 Electric Hybrid Vehicl
17. uld always be taken low during a controlled shut down www LyraElectronics com 17 of 23 LITEA VEGA3 ECU USER MANUAL 2 11 ANALOGUE INPUTS There are 8 identical analogue input buffer circuits each as shown below The default configuration is as a buffer with a gain of 1 A 10k resistor and 100nF capacitor form a low pass filter with a cut off frequency of 160Hz There is a weak pull down resistor to discharge the filter capacitor and a Schottky diode pair clamps any voltage below 0 3V and above 5 3V to the 5V supply rails Since the analogue inputs to the MPC563 processor are 0 to 5V the default unity gain setting limits the external voltages that can be measured to 5V also If a larger voltage needs to be measured the 1MO pull down can be replaced with a lower value to create a potential divider i e replacing 1MO with 10k0 allows up to 10V to be measured Note that this potential divider forms the input resistance of the analogue input it may be necessary to increase the 10k series resistor to prevent loading of the voltage being measured A not fitted pull up at the input pin can be fitted when an external potentiometer to ground is required effectively supplying the high side of the potentiometer Physically the channels are arranged from right to left on the PCB Each of the components is clearly marked and the relative positions are identical from one channel to the next Note that the last two channel
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