OBR PCM2 User manual

Control Systems OBR Control Systems Inc
OBR Control Systems Inc Telephone : [phone] [e-mail]
32233 West 8 Mile Road www.obrcontrolsystems.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 Membrane Switch Panel and
Steering Wheel Controller Version 2.9
Version 2.71 – October 2018
Copyright © OBR Control Systems Inc 2011-2018. All rights reserved.

Control Systems OBR Control Systems Inc
OBR Control Systems Inc Telephone : [phone] [e-mail]
32233 West 8 Mile Road www.obrcontrolsystems.com
Livonia, Michigan 48152
USA 2 / 92
1 Introduction ................................................................................................................................................. 6
2 Hardware .................................................................................................................................................... 8
3 Software installation ................................................................................................................................... 9
3.1 Software installation from web-download ........................................................................................... 9
3.2 PC Software and Firmware Releases ................................................................................................ 9
3.3 Connection to system ......................................................................................................................... 9
3.4 Wiring Harness ................................................................................................................................... 9
4 Main Menu ................................................................................................................................................ 10
4.1 File .................................................................................................................................................... 10
4.2 Product ............................................................................................................................................. 10
4.3 Device............................................................................................................................................... 10
4.3.1 Read ............................................................................................................................................ 10
4.3.2 Write ............................................................................................................................................ 10
4.3.3 Reset ........................................................................................................................................... 11
4.3.4 Firmware ..................................................................................................................................... 11
4.3.5 Manual Output Mode ................................................................................................................... 11
4.3.6 Automatic Output Mode .............................................................................................................. 11
4.3.7 Manual Output Mode, Keep Current States ................................................................................ 11
4.3.8 Get Time ...................................................................................................................................... 11
4.3.9 Set Time ...................................................................................................................................... 11
4.3.10 Reset Output 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
5.3 Event Handling ................................................................................................................................. 13
5.3.1 Event Type .................................................................................................................................. 13
5.3.1.1 Input follow ......................................................................................................................... 13
5.3.1.2 Input toggle ........................................................................................................................ 14
5.3.1.3 AND gate ............................................................................................................................ 14
5.3.1.4 OR gate .............................................................................................................................. 14
5.3.1.5 NOR gate ........................................................................................................................... 14
5.3.1.6 XOR gate ........................................................................................................................... 14
5.3.1.7 NOT gate ............................................................................................................................ 15
5.3.1.8 Flash .................................................................................................................................. 15
5.3.1.9 Delay input ON ................................................................................................................... 15
5.3.1.10 Delay input OFF ............................................................................................................ 15
5.3.1.11 Counter Increment ........................................................................................................ 15
5.3.1.12 Counter Decrement....................................................................................................... 15
5.3.1.13 Reset ............................................................................................................................. 15
5.3.1.14 Clock ............................................................................................................................. 16
5.3.1.15 Always ON .................................................................................................................... 16
5.3.1.16 Tri-state output .............................................................................................................. 16
5.3.1.17 Wiper output .................................................................................................................. 16
5.3.1.18 Event Flash ................................................................................................................... 16
5.3.1.19 Event Delay On ............................................................................................................. 16
5.3.1.20 Event Delay Off ............................................................................................................. 16
5.3.1.21 Event Wiper .................................................................................................................. 17
5.3.2 Event Name................................................................................................................................. 17
5.3.3 Source Input ................................................................................................................................ 17
5.3.3.1 Fault Status ........................................................................................................................ 17
5.3.4 Turn ON / Turn OFF .................................................................................................................... 17
5.3.5 Event 1 / 2 / 3 / 4 / 5 .................................................................................................................... 17
5.3.6 Time (ms) .................................................................................................................................... 18

Control Systems OBR Control Systems Inc
OBR Control Systems Inc Telephone : [phone] [e-mail]
32233 West 8 Mile Road www.obrcontrolsystems.com
Livonia, Michigan 48152
USA 3 / 92
5.3.7 CAN Inputs – Lost CAN Action ................................................................................................... 18
5.3.8 CAN Lost Timer ........................................................................................................................... 18
5.3.9 Start State ................................................................................................................................... 18
5.3.10 Output .................................................................................................................................... 18
5.3.11 Multiplier ................................................................................................................................. 18
5.3.12 Counter .................................................................................................................................. 18
5.3.13 Clock ...................................................................................................................................... 18
5.4 Miscellaneous ................................................................................................................................... 19
5.5 Special Functions ............................................................................................................................. 19
5.5.1 Special function ON .................................................................................................................... 19
5.5.2 Special function OFF ................................................................................................................... 19
5.6 Counters ........................................................................................................................................... 20
5.6.1 Increment Action ......................................................................................................................... 20
5.6.2 Decrement Action ........................................................................................................................ 21
5.7 Status ............................................................................................................................................... 21
5.7.1 Warning Light Status ................................................................................................................... 21
5.8 Events Monitor ................................................................................................................................. 22
5.9 Output Diagnostic ............................................................................................................................. 22
6 Compare two Calibration Files ................................................................................................................. 24
7 User Access Rights .................................................................................................................................. 25
7.1.1 Change User ............................................................................................................................... 25
7.1.1.1 Default Passwords ............................................................................................................. 25
7.1.2 Show User Params ..................................................................................................................... 25
7.1.2.1 Import and Export of User Access Rights .......................................................................... 26
8 Inputs ........................................................................................................................................................ 27
8.1 Digital Inputs ..................................................................................................................................... 27
8.1.1 Pin Configuration 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 Configuration for CAN Ports ................................................................................................. 34
9 Outputs ..................................................................................................................................................... 35
9.1 Tri-State ............................................................................................................................................ 35
9.1.1 Pin Configuration Tri-State Outputs ............................................................................................ 35
9.2 Low Power Outputs .......................................................................................................................... 36
9.2.1 Parallel Coupling ......................................................................................................................... 37
9.2.2 Pin Configuration Low Power Outputs ........................................................................................ 38
9.3 Low Power PWM Outputs ................................................................................................................ 39
9.3.1 Half Bridge – Full Bridge ............................................................................................................. 39
9.3.2 Current Draws ............................................................................................................................. 39
9.3.3 Pin Configuration Low Power PWM Outputs .............................................................................. 42
9.4 High Power Outputs ......................................................................................................................... 43
9.4.1 Pin Configuration High Power Outputs ....................................................................................... 44
9.5 High Power PWM Outputs ............................................................................................................... 45
9.5.1 Half Bridge – Full Bridge ............................................................................................................. 45
9.5.2 Current Draws ............................................................................................................................. 45
9.5.3 Pin Configuration High Power PWM Outputs ............................................................................. 48
9.6 Very High Power .............................................................................................................................. 49
9.6.1 Pin Configuration Very High Power Outputs ............................................................................... 50
9.7 Wiper Outputs .................................................................................................................................. 51
9.7.1 Pin Configuration Wiper Outputs................................................................................................. 52
9.8 Sensor Supplies ............................................................................................................................... 53
9.8.1 Pin Configuration 5 Volt VREF Outputs ...................................................................................... 53
9.9 Warning Light ................................................................................................................................... 53
9.10 Fault Reset ....................................................................................................................................... 53
9.10.1 Pin Configuration Warning Light Output ................................................................................ 53
10 Visualisation ..................................................................................................................................... 54

Control Systems OBR Control Systems Inc
OBR Control Systems Inc Telephone : [phone] [e-mail]
32233 West 8 Mile Road www.obrcontrolsystems.com
Livonia, Michigan 48152
USA 4 / 92
10.1 Digital Inputs ..................................................................................................................................... 54
10.2 Analogue Inputs ............................................................................................................................... 54
10.3 CAN Inputs ....................................................................................................................................... 55
10.4 Events............................................................................................................................................... 55
10.5 Outputs ............................................................................................................................................. 55
11 CAN BUS.......................................................................................................................................... 56
11.1 Data Bus ........................................................................................................................................... 56
11.1.1 CAN Bus Name ...................................................................................................................... 56
11.1.2 CAN Bus Speed ..................................................................................................................... 56
11.1.3 CAN Maximum Identifiers ...................................................................................................... 56
11.1.4 Termination ............................................................................................................................ 57
11.1.4.1 Correctly Terminated CAN Bus .................................................................................... 57
11.1.4.2 Incorrectly Terminated CAN Bus .................................................................................. 58
11.1.5 Error Report ........................................................................................................................... 59
11.1.6 CAN Bus Identity .................................................................................................................... 59
11.2 CAN Monitor ..................................................................................................................................... 59
11.3 CAN Export ...................................................................................................................................... 60
11.3.1 Configuration of Export Channels .......................................................................................... 60
11.3.2 Definition of Export Bytes ....................................................................................................... 61
“CON” - Constant Value .................................................................................................................... 61
“DS” - Digital Input Status.................................................................................................................. 61
“AL” - Analogue Input LSB ................................................................................................................ 61
“AM” - Analogue Input MSB .............................................................................................................. 61
“OS” - Output 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 Status ........................................................................................................... 63
“OCH” - Output Current Top Byte ..................................................................................................... 63
“OCL2” - Output Current LSB Byte (mA/2) ........................................................................................ 63
“OCM2” - Output Current MSB byte (mA/2) ...................................................................................... 63
“OCL4” - Output Current LSB Byte (mA/4) ........................................................................................ 63
“OCM4” - Output Current MSB byte (mA/4) ...................................................................................... 63
“OCS” - Output Current Single byte (A) ............................................................................................ 63
“TP” - Temperature Degrees Celcius ................................................................................................ 63
“VC” - Vehicle Current (A) ................................................................................................................. 63
“PFL” - PWM Frequency LSB............................................................................................................ 63
“PFM” - PWM Frequency MSB ......................................................................................................... 64
“PDC” - PWM Duty Cycle .................................................................................................................. 64
“CIL” - CAN Input LSB ....................................................................................................................... 64
“CIM” - CAN Input MSB ..................................................................................................................... 64
11.3.3 CAN bus export with row count .............................................................................................. 65
12 LIN Bus – Wiper Motor Control ........................................................................................................ 66
13 Serial Link ......................................................................................................................................... 68
14 Membrane Switch Panel .................................................................................................................. 69
14.1 Software installation ......................................................................................................................... 69
14.2 Connection to system ....................................................................................................................... 69
14.3 Main Menu ........................................................................................................................................ 70
14.3.1 File.......................................................................................................................................... 70
14.3.2 Device .................................................................................................................................... 70
14.3.2.1 Firmware Update .......................................................................................................... 70
14.3.3 Interface ................................................................................................................................. 70
14.3.4 Help ........................................................................................................................................ 70
14.4 Switches ........................................................................................................................................... 71
14.4.1 Position and Numbering ......................................................................................................... 71
14.4.2 Switch name ........................................................................................................................... 71
14.4.3 Mode ...................................................................................................................................... 71
14.4.4 Initial ....................................................................................................................................... 71

Control Systems OBR Control Systems Inc
OBR Control Systems Inc Telephone : [phone] [e-mail]
32233 West 8 Mile Road www.obrcontrolsystems.com
Livonia, Michigan 48152
USA 5 / 92
14.4.5 Max......................................................................................................................................... 71
14.4.6 New / Leg ............................................................................................................................... 71
14.4.7 Press / Release ...................................................................................................................... 71
14.4.8 Green LED’s ........................................................................................................................... 72
14.4.9 Red LED’s .............................................................................................................................. 72
14.4.10 Extra / Group .......................................................................................................................... 72
14.4.11 Status ..................................................................................................................................... 72
14.5 CAN Bus ........................................................................................................................................... 73
Standard CAN Protocol – Transmit from MSP ......................................................................................... 73
14.5.1 Standard CAN Protocol – Receive switch status from PCM2 ............................................... 75
14.5.2 Standard CAN Protocol – Receive fault status from PCM2 ................................................... 76
14.5.3 Speed / Termination / PCM Select ......................................................................................... 77
14.5.4 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 Connector 1 – Battery Power Supply ............................................................................................... 86
16.2 Connector 2 – High Power Outputs ................................................................................................. 86
16.3 Connector 3 – Low Power Outputs .................................................................................................. 87
16.4 Connector 4 – Signal and Inputs ...................................................................................................... 88
17 Specifications ................................................................................................................................... 90
17.1 Inputs ................................................................................................................................................ 90
17.2 Outputs ............................................................................................................................................. 90
17.2.1 Very high power channels ...................................................................................................... 90
17.2.2 High power channels.............................................................................................................. 90
17.2.3 High power PWM channels .................................................................................................... 90
17.2.4 Low power channels .............................................................................................................. 90
17.2.5 Low power PWM channels .................................................................................................... 90
17.2.6 Wiper channels ...................................................................................................................... 90
17.2.7 Sensor supplies & warning light ............................................................................................. 91
17.2.8 Tristate Supplies .................................................................................................................... 91
17.3 Maximum current rating .................................................................................................................... 91
17.4 Temperatures ................................................................................................................................... 91
17.5 Communication ................................................................................................................................ 91
17.6 Power Supply ................................................................................................................................... 91
17.7 Dimensions ....................................................................................................................................... 92

Control Systems OBR Control Systems Inc
OBR Control Systems Inc Telephone : [phone] [e-mail]
32233 West 8 Mile Road www.obrcontrolsystems.com
Livonia, Michigan 48152
USA 6 / 92
1 Introduction
The award winning PCM2 takes the whole Power Control Module concept much further than
conventional modules. Based on our experience and success of the first generation module, PCM2
is a very powerful, flexible and technically advanced module. PCM2 is a huge step ahead of the old
model, in technology, features and its very high current handling ability.
It provides an effective and inspired alternative to conventional relays, circuit breakers, fuses and
wires that can so often be a tangle of complexity and untidiness around a typical racing car’s power
junction box.
PCM2 is a compact and light weight module, measuring 191 x 176 x 36 mm (excluding the
Autosport connectors).
PCM2 has 48 power output channels, arranged as:
- 26 normal power channels, each max 8 A continuous power supply.
- 2 normal and wiper motor power channels, each max 8 A continuous power supply.
- 4 low power channels with PWM, each max 8 A continuous power supply.
- 14 high power channels, each max 20 A continuous power supply.
- 2 high power channels with PWM, each max 20 A continuous power supply.
- 2 very high power channels, each max 20 A continuous power supply, inrush current up to
200A.
All outputs are protected against reversed battery polarity.
Current draw can be measured on all 48 power channels:
- 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 digital inputs with automatic sensing of high, low and floating potential.
- 16 analogue 0..5 Volt sensor inputs with 16 bit resolution.
- 64 individually programmable CAN inputs, 11 or 29 bit identifiers, with bit operator.
- 4 individually programmable CAN ports.
PCM2 is also equipped with 4 tri-state outputs. A tri-state output is only for use as an ECU trigger
signal. Do not connect any of these four channels to any output load.
In addition to the 4 CAN ports, PCM2 is also equipped with a LIN bus. PCM2 can be configured as
either a LIN bus master or slave.
Use the LIN bus for example to control the alternator charge current or to control the wiper motor.
Not in current software release.
Instead of using a conventional control program, PCM2 benefits from a multitasking operating
system.
Furthermore, PCM2 is equipped with a real time clock and also has a built-in data recording facility
with a memory capacity of typically 2 Gb, depending on requested data card capacity.
Data is downloaded via the Ethernet connection (not in current software release).
Please note that the maximum recommended current draw per channel is limited by the
connector contacts - not by PCM2’s driver stages. We have rated the individual channel’s
current draw in relation to the connector manufacturer’s specifications.
PCM2 is programmed to shut overloaded channels down if the current draw and internal junction
temperatures exceed pre-set levels.
Board temperatures are monitored and can be exported via CAN.

Control Systems OBR Control Systems Inc
OBR Control Systems Inc Telephone : [phone] [e-mail]
32233 West 8 Mile Road www.obrcontrolsystems.com
Livonia, Michigan 48152
USA 7 / 92
For normal running conditions, the user can set limits for inrush current level and time, the fused
threshold for continuous current draw plus the number of retries and retry time intervals 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 offers CAN routing between ay of the 4 available CAN ports.
Please note that the PCM is not intended to be used to control safety-critical systems on a vehicle,
such as ABS braking, power steering, etc.
Ole Buhl Racing Ltd. shall not be responsible for any incidental or consequential damages or
injuries that may occur if the unit is used to control these, or similar, safety-critical systems.

Control Systems OBR Control Systems Inc
OBR Control Systems Inc Telephone : [phone] [e-mail]
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.

Control Systems OBR Control Systems Inc
OBR Control Systems Inc Telephone : [phone] [e-mail]
32233 West 8 Mile Road www.obrcontrolsystems.com
Livonia, Michigan 48152
USA 9 / 92
3 Software installation
The software does not need any installation, it can be run from a program folder which contains the
main initialisation file, the executable file and – if used – the device driver for the Peak System
PCAN interface.
The software can be down loaded from our web site – www.obr.uk.com.
3.1 Software installation from web-download
It is possible to download the PCM2 support tab from our web site. Go to www.obr.uk.com and
select the Support tab.
When you have downloaded the PCM2 software, open the folder where you saved the file and
double click on the installation file. This file is called SETUP PCM2 vX_YZ.EXE where X_YZ refers
to the software release version.
3.2 PC Software and Firmware Releases
Each new release of PCM2 firmware requires an updated, specific PC tool release.
Any new release of the PC tool is backwards compatible, meaning that it will support earlier PCM2
firmware releases.
Please note, that new 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
use tool and firmware having the same release version number.
3.3 Connection to system
Communication between the PC tool and a PCM2 is established via any of the available 4 CAN
ports, using a USB CAN interface. Connection is automatic; no user commands are required.
Support for three different versions of interfaces are provided with the system:
- Blue CANUSB interface from Lawicel.
- PCAN USB CAN interfaces from Peak Systems.
- EFI Technology USB-CAN interface (EFP02 or EFT20)
If you use the Peak System PCAN interface, it is essential that the file PCANBASIC.DLL is located
in the same PCM2 folder as the programme files.
Separate installation of interface drivers is required.
Access to the system may be limited due to the assigned user rights, please see section 4.5 and
section 7.
If you disconnect from the system, communication will be re-established when you plug the cable
in again.
3.4 Wiring Harness
OBR can supply complete, custom made wiring harnesses for bespoke installations.
Our harnesses are manufactured by specialists, using only the best suitable materials for use in
the harsh environment of a modern racing or rally car.

Control Systems OBR Control Systems Inc
OBR Control Systems Inc Telephone : [phone] [e-mail]
32233 West 8 Mile Road www.obrcontrolsystems.com
Livonia, Michigan 48152
USA 10 / 92
4 Main Menu
The PC tool has 6 main menu sections:
4.1 File
You can open an existing configuration file by clicking on FILE and then select OPEN.
Use F2 as a hot key to open a new configuration file.
Default file location is in this folder: c:\program files\obr control systems\powerbox
You can save a configuration file on your PC by clicking on
FILE, then SAVE. Now select the folder where you want to
save the file (by default c:\program files\obr control
systems\powerbox), type a file name and click OK. Use F3
as a hot key to save a configuration file.
Click on Save Hex to save a configuration file as a hex file.
Use F4 as a hot key for this function.
You can display differences between two configuration files 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 PCM2 product family:
- PCM2 is this 48-channel module.
- hPCM_AC is the 8-channel module, which has these main features:
o 8 high side outputs
o 2 CAN port with full routing option
o 8 analogue 0..5V sensor inputs
o 8 digital inputs
4.3 Device
4.3.1 Read
You can read the PCM2 configuration file by clicking on
READ in the menu DEVICE.
Use F8 as a hot key to read the configuration from PCM2.
4.3.2 Write
You can upload a new configuration from the PC tool to
PCM2 by clicking on WRITE.
Use F9 as a hot key to write a new configuration file to
PCM2. Once the new configuration file has been
transmitted to the PCM2, the module is re-booted
automatically.
An error message may pop up:
It is not possible to send a configuration file to PCM2 if more
than one event controls a single output.
Please see section 5.3.
Please note, that a configuration file can only be uploaded if the battery supply voltage is above 10
Volts.