ETAS ES1392.1 User manual

ES1392.1 High Current Switch Board
User’s Guide

ES1392.1 High Current Switch Board2
Copyright
The data in this document may not be altered or amended without special
notification from ETAS GmbH. ETAS GmbH undertakes no further obligation in
relation to this document. The software described in it can only be used if the
customer is in possession of a general license agreement or single license.
Using and copying is only allowed in concurrence with the specifications stip-
ulated in the contract.
Under no circumstances may any part of this document be copied, repro-
duced, transmitted, stored in a retrieval system or translated into another lan-
guage without the express written permission of ETAS GmbH.
© Copyright 2003-2018 ETAS GmbH, Stuttgart
The names and designations used inthis document are trademarks or brands
belonging to the respective owners.
R02 EN - 12.2018 TTN F 00K 102 735

Contents 3
Contents
1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Configuring Battery Node 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Controlling the Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Overcurrent Protection with the Status Output . . . . . . . . . . . . . . . . . . . . 13
2.5 EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Battery Voltage at the "CTRL" Connector . . . . . . . . . . . . . . . . . . . . . . . . 14
2.7 MRC Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8 Reverse-Connect Protection of the Battery Node Switches . . . . . . . . . . . . 14
2.9 Parallel Switching of Several Battery Nodes . . . . . . . . . . . . . . . . . . . . . . . 15
2.10 Potential Difference between Ground and -UBatt . . . . . . . . . . . . . . . . . . 15
2.11 Battery Voltage at the "BATTERY NODES" Connector . . . . . . . . . . . . . . . 15
2.12 Protective Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.12.1 +UBatt and -UBatt at "BATTERY NODES" . . . . . . . . . . . . . . . . . 16
2.12.2 +UBatt and -UBatt at "CTRL". . . . . . . . . . . . . . . . . . . . . . . . . . 17

Contents4
2.12.3 MRC Signal between "BATTERY NODES" and "CTRL" . . . . . . . 17
2.12.4 Supply Voltages at "SUPPLY" . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3Pin Assignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 "BATTERY NODES" Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 "BATTERY INPUT" Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.3 "CTRL" Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.4 "SUPPLY" Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1.1 Cable CBAV300.1-2: Connection between ES1392.1 and Power
Supply (Battery Voltages) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1.2 Cable CBV300.1-0.5: Connection between ES1391 and ES139226
5Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6ETAS Contact Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Introduction 5
1Introduction
This section contains information about the basic features and applications of
the ES1392.1 High Current Switch Board. A block diagram is also included
here to show the schematic layout of the board.
1.1 Applications
The ES1392.1 High Current Switch Board is used to switch five high current
battery nodes to +UBatt (five nodes) or -UBatt (one node).
The ES1391.1 Power Supply Controller Board is used to control the ES1392.1
High Current Switch Board with TTL signals. An ES1391.1 Power Supply Con-
troller Board can control up to two ES1392.1 High Current Switch Boards and
at the same time up to two battery voltage power supplies.
Five battery nodes can be switched per voltage when two ES1392.1 High Cur-
rent Switch Boards and two power supplies (for example 12 V and 42 V) are
used.
An example of this kind of scenario is shown in Fig. 1-1.
note
Some components of the ES1392.1 High Current Switch Board may be damaged
or destroyed by electrostatic discharges. Please keep the board in its storage
package until it is installed.
The ES1392.1 High Current Switch Board should only be taken from its package,
configured and installed at a working place that is protected against static dis-
charge.
note
The components, connectors and conductors of the ES1392.1 High Current
Switch Board may carry dangerous voltages.
These voltages may even exist when the ES1392.1 is not installed in the ES4100
or ES4300 or the ES4100 or ES4300 is powered off.
Make sure that the ES1392.1 is protected against contact during operation. Dis-
connect all connections to the ES1392.1 before removing the board.

Introduction6
Fig. 1-1 Use of Two ES1392.1 High Current Switch Boards to Switch Two
Battery Voltages
The ES1392.1 High Current Switch Board does not have a VMEbus interface -
it is controlled by TTL signals which have to be connected to a front-facing
connector. In the LabCar environment, these TTL signals are generated by the
ES1391.1 Power Supply Controller Board which communicates with the back-
plane of the ES4100 or ES4300 Signal Box via a VMEbus interface.
1.2 Features
The ES1392.1 High Current Switch Board has the following features:
• Two high current switches for currents of up to 20 A
– Switch 0 switches to +UBatt or -UBatt
– Switch 1 switches to +UBatt
• Three high current switches for currents of up to 12 A
– Switches 2 - 4 switch to +UBatt
I
O
EX - 750L2
EXTENDED RANGE DC POWER SUPPLY
0-60V / 0-50A, 750W
8888 V
8888 V
8888 A
VOLTAGE
CURRENT
OUTPUTOVPPRESET OCP
UBatt 1
Switch 0-4
ES1392.1 BATTERY
INPUT
BATTERY
NODES
CTRL
SUPPLY
<
ES1392.1 BATTERY
INPUT
BATTERY
NODES
CTRL
SUPPLY
<
ES1391.1
Switch 0-4
Switch 5-9
PWR-Ctrl 2
PWR-Ctrl 1
I
O
EX - 750L2
EXTENDED RANGE DC POWER SUPPLY
0-60V / 0-50A, 750W
8888 V
8888 V
8888 A
VOLTAGE
CURRENT
OUTPUTOVPPRESET OCP
UBatt 2
Switch 5-9
CBAV300.1-2 CBAV300.1-2
CBV300.1-0.5
CBV300.1-0.5

Introduction 7
• Maximum overall current of 40 A
• Input voltage range of 6 - 60 V
• Control connector on the front panel ("CTRL") (digital TTL signals)
• Power supply input on the front panel
• Overcurrent protection
• Overcurrent status is routed to the "CTRL" status output on the front panel
• Versioning information (version/type of board) available via front-facing
"CTRL" connector (1-Wire®)
• Supply voltages are routed to the front panel ("SUPPLY")
(+5 V (2 A), +12 V (1,5 A), -12 V (1,5 A))

Introduction8
The following figure shows the front panel of the ES1392.1 High Current
Switch Board.
Fig. 1-2 Front Panel of the ES1392.1 High Current Switch Board
ES1392.1 BATTERY
INPUT
BATTERY
NODES
CTRL
SUPPLY
<

Introduction 9
1.3 Block Diagram
Fig. 1-3 shows the block diagram of the ES1392.1 High Current Switch Board.
The battery voltages are supplied via "BATTERY INPUT". The battery nodes
connected via "BATTERY NODES" can be switched to these battery voltages
via the switches.
Fig. 1-3 Block Diagram of the ES1392.1 High Current Switch Board
-UBatt
+UBatt
3
BATTERY
NODES
BATTERY
INPUT
Overcurrrent
Protection
+5 V
+12 V
-12 V
Fuses
CTRL
Supply

Introduction10

Hardware 11
2 Hardware
This chapter contains the hardware descriptions of the ES1392.1 High Current
Switch Board. It consists of the following sections:
• "Functional Description" on page 11
• "Configuring Battery Node 0" on page 12
• "Controlling the Switches" on page 13
• "Overcurrent Protection with the Status Output" on page 13
• "EEPROM" on page 13
• "Battery Voltage at the "CTRL" Connector" on page 14
• "MRC Signal" on page 14
• "Reverse-Connect Protection of the Battery Node Switches" on page 14
• "Parallel Switching of Several Battery Nodes" on page 15
• "Potential Difference between Ground and -UBatt" on page 15
• "Battery Voltage at the "BATTERY NODES" Connector" on page 15
• "Protective Measures" on page 15
2.1 Functional Description
The ES1392.1 High Current Switch Board has two groups of switch channels
which differ in terms of their maximum current rating. Battery node 0 can be
switched to either +UBatt or -UBatt whereas the other battery nodes can only
be switched to +UBatt (see Tab. 2-1).
Tab. 2 - 1 Switching Possibilities and Permissible Currents
Battery Node
Switch to
Permissible
Current
+UBatt -UBatt
0YesYes20A
1Yes No 20 A
2 Yes No 12 A
3Yes No 12 A
4 Yes No 12 A

Hardware12
2.2 Configuring Battery Node 0
Battery node 0 can be configured to be switched to either +UBatt or -UBatt.
Once the configuration has been changed, both switches remain open until,
after a delay, the new configuration becomes active. This makes it impossible
to use battery node 0 as a half bridge for fast signals.
Battery node 0 can be configured using jumpers or via the "configuration
switch 0" control signal of the "CTRL" connector (see Tab. 3-3 on page 22).
Please consult Tab. 2-2 for more details on the jumper configuration or the
control signal for the relevant configuration
Tab. 2 - 2 Jumper Configuration and Control Signals for Configuring Bat-
tery Node 0
The position of the jumpers on the board is shown in Fig. 2-1.
Fig. 2-1 Position of Jumpers JP1 and JP2
JP1 JP2 Control Signal Configuration
1 0 Any +UBatt
0 1 Any -UBatt
1 1 L/open +UBatt
1 1 H -UBatt
JP1
JP2

Hardware 13
2.3 Controlling the Switches
The switches are controlled using the "control signal switch n" control signals
(see Section 3.3 on page 21).
Tab. 2 - 3 Control Signal and Switch Position
2.4 Overcurrent Protection with the Status Output
If an overcurrent is detected on one of the battery nodes, the relevant switch
is opened. After a delay of max. 800 ms, the switch is automatically closed
again to check whether the error has been recovered. If the overcurrent can
still be detected, the switch is opened again immediately. This is repeated until
there is no longer an overcurrent.
The user is made aware of one of the switches being switched off because of
an overcurrent by the "signal switch error" status signal at the "CTRL" connec-
tor (see Fig. 3-3 on page 21).
Tab. 2 - 4 Status Signal for Overcurrent Errors
For more details on protective measures, please refer to Section 2.12
on page 15.
2.5 EEPROM
The type of board (ES1392.1) and the version is stored in an EEPROM and can
be read out via a 1-Wire®interface on the "CTRL" connector by the ES1391.1
Power Supply Controller Board.
Control Signal Switch
L/open Open
HClosed
note
The cyclical current impulses which occur with an overcurrent may overstrain the
current limitation of some power supplies. In this case, the battery voltage should
be buffered with a large capacitor at the output of the power supply or a low-
impedance power resistor should be added to the battery voltage line to limit the
current.
Overcurrent Status Signal
Normal operation L
Error H

Hardware14
2.6 Battery Voltage at the "CTRL" Connector
-UBatt and +UBatt are available at the "CTRL" connector. Both voltages are
protected (see Section 2.12.2 on page 17).
2.7 MRC Signal
To keep the wiring harnesses as simple as possible, the main relay control sig-
nal (MRC signal) is routed from the "BATTERY NODES" connector to the
"CTRL" connector. The signal is protected (see section 2.12.3 on page 17).
It is not used for any other purpose on the ES1392.1 High Current Switch
Board.
2.8 Reverse-Connect Protection of the Battery Node Switches
The switches to +UBatt are protected against voltages at the battery node
which are above the battery voltage.
This may occur, for example, in a system with two battery voltages (12 V/42 V)
if a short occurs between battery nodes of the two different battery voltages.
Fig. 2-2 Reverse-Connect Protection
Without this protection, the MOS-FET switches would still conduct current
with this kind of error without being able to be switched off. This could result
in the lower battery voltage being increased and connected consumers being
destroyed; alternatively the switch itself could be destroyed because of an
overcurrent.
The protective circuit acts as a diode (as shown in Fig. 2-2 on page 14) without
actually causing the voltage drop of a diode. The low resistance values of the
switches (including reverse-connect protection) listed in the chapter "Technical
Data" on page 29 illustrate this.
ES1392
ES1392
+UBatt_A = +12 V
+UBatt_B = +42 V
Battery Node
Battery Node

Hardware 15
2.9 Parallel Switching of Several Battery Nodes
To increase the maximum current of the battery nodes, the two 20-A battery
nodes, BN0 and BN1, can be switched in parallel. The overcurrent protection
of the switches to +UBatt of these two battery nodes is synchronized, i.e. they
are both switched off (simultaneously) when an overcurrent is detected and
then are both switched on again simultaneously.
To increase the maximum current of the battery nodes, two or all of the 12-A
battery nodes, BN2, BN3 and BN4, can be switched in parallel. The overcurrent
protection of the switches to +UBatt of these three battery nodes is synchro-
nized, i.e. they are all switched off (simultaneously) when an overcurrent is
detected and then are all switched on again simultaneously.
2.10 Potential Difference between Ground and -UBatt
The potential difference between ground and -UBatt must not exceed ±2 V.
Otherwise the functionality of the board can no longer be guaranteed and the
board may even be damaged.
2.11 Battery Voltage at the "BATTERY NODES" Connector
-UBatt and +UBatt are available at the "BATTERY NODES" connector. Both
voltages are protected.
2.12 Protective Measures
The battery voltages +UBatt and -UBatt supplied by the power supply to "BAT-
TERY INPUT" are protected by fuses in their individual current paths.
The battery node switches themselves are protected electronically against over-
current. The battery voltages, supply voltages and the MRC signal at the front-
facing connectors are protected by fuses.
There is no fuse protection of the overall current of +UBatt. The overall current
of +UBatt must not exceed 40 A.
note
Only the same type of battery node can be switched in parallel. 20-A and 12-A
channels cannot be combined.
The maximum overall current of 40 A must not be exceeded.

Hardware16
The position of the fuses on the board is shown in Fig. 2-3 on page 16 - their
specifications can be found in the following sections.
Fig. 2-3 Position of the Fuses (Component Side)
2.12.1 +UBatt and -UBatt at "BATTERY NODES"
The battery voltages output at the front-facing "BATTERY NODES" connector
are protected as follows:
Tab. 2 - 5 Fuse Protection of Battery Voltages +UBatt and -UBatt
Fuse Specification Ty p e Manufacturer/Order No.
FU201 20 A 80V Blade Fuse Link Pudenz / 166.7000.520
FU202 20 A 80V Blade Fuse Link Pudenz / 166.7000.520
FU 222
FU 220
FU 221
FU 270
FU 272
FU 271
FU 201 FU 202

Hardware 17
2.12.2 +UBatt and -UBatt at "CTRL"
The battery voltages output at the front-facing "CTRL" connector are pro-
tected as follows:
Tab. 2 - 6 Fuse Protection of +UBatt and -UBatt at "CTRL"
2.12.3 MRC Signal between "BATTERY NODES" and "CTRL"
The MRC signal fed-through between the front-facing connectors "BATTERY
NODES" and "CTRL" is protected as follows:
Tab. 2 - 7 Fuse Protection of the MRC Signal
2.12.4 Supply Voltages at "SUPPLY"
The supply voltages routed from the backplane to the front-facing "SUPPLY"
connector are protected as follows:
Tab. 2 - 8 Fuse Protection of the +5 V Supply Voltage
Tab. 2 - 9 FuseProtection of the -12 VSupply Voltage
Fuse Specification Ty p e Manufacturer/Order No.
FU220 1 A, slow-
blowing
NANO2 SMD Fuse Littelfuse 154.001T
FU221 1A,slow-
blowing
NANO2 SMD Fuse Littelfuse 154.001T
Fuse Specification Ty p e Manufacturer/Order No.
FU222 1 A, slow-
blowing
NANO2 SMD Fuse Littelfuse 154.001T
Fuse Specification Ty p e Manufacturer/Order No.
FU271 2 A NANO2 SMD Fuse Littelfuse 154.002T
Fuse Specification Ty p e Manufacturer/Order No.
FU270 1.5 A NANO2 SMD Fuse Littelfuse 154.01.5T

Hardware18
Tab.2-10 Fuse Protection of the +12 VSupply Voltage
Fuse Specification Ty p e Manufacturer/Order No.
FU272 1.5 A NANO2 SMD Fuse Littelfuse 154.01.5T

Pin Assignment 19
3PinAssignment
This chapter explains the pin assignment of the connectors of the ES1392.1
High Current Switch Board.
These are:
• ""BATTERY NODES" Connector" on page 19
• ""BATTERY INPUT" Connector" on page 21
• ""CTRL" Connector" on page 21
• ""SUPPLY" Connector" on page 22
3.1 "BATTERY NODES" Connector
Type: ITT Cannon CA02COM-E20A-48SB
Fig. 3-1 shows the pin assignment of the jack (view from the front).
Fig. 3-1 "BATTERY NODES" Connector
A
B
C
D
E
F
M
G
H
J
K
L
N
P
RS
T
U
V

Pin Assignment20
Tab. 3 - 1 "BATTERY NODES" Pin Assignment
The counterpart connector is an" ITT Cannon CA06COM-E20A-48PB".
Pin Signal
A -UBatt
B-UBatt
CMRCsignalin
D+UBatt
E +UBatt
FCH4 out
G CH4 out
HCH3 out
J CH2 out
KCH1 out
L CH0 out
MCH0 out
N -UBatt
PNot assigned
R +UBatt
SCH3 out
T CH2 out
UCH1 out
V Not assigned