Orangewire System OW-503-4 User manual
Operating Instructions
OW-503-4
4 Channel Power Switch
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Overview
The OW-503-4 is a 4 channel intelligent power switch that controls four channels of power
in-to or out-of the SLSC Chassis. The board is used to provide programmatically switched
power to SLSC based Hardware in the Loop (HIL) systems and Devices Under Test (DUT).
Fully isolated high side hall-eect current sensors provide accurate real-time current data
(up to 55A) with four selectable filters while the DUT is operating. When the DUT is put
into sleep
mode (I < 100mA), a high accuracy shunt provides microamp current sense data to measure battery drawdown.
The OW-503-4 is designed for the National Instruments (NI) Switch Load Signal Conditioning (SLSC) system, to be used in
Hardware-In-the-Loop (HIL) simulators. This card is used to test prototype or production Electronic Control Units (ECUs or
generically Devices Under Test or DUTs) for the purposes of developing, verifying, and validating ECU soware and hardware.
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Absolute Maximum Ratings
Operating Current Measurement Range
±55A
Power-down Maximum Current
100mA
Operating Maximum Continuous Current
40A (fused)
Input Signal Voltage
200V
Reference Output
20A/Rail
Operating Specifications
General
Number of Channels
4
Reference Power Connectivity
12 position, 41A, 7.62mm Phoenix
Operating Current Sense Technology
Hall-Eect, LEM LAH 25-NP sensor
Operating Current Sense Accuracy
± 0.3% (Sensor accuracy)
Power-down Current Sense Technology
10Ω 0.1% resistor
Current Sense Outputs
Sensed Current Voltage Output
-10 to +10 V
Output Filter Cuto Frequencies
1kHz, 20kHz, 80kHz, 200kHz
Mechanical Installation/Removal
Insertion
Unlatch the insertion/extraction lever. Insert the card into any of the 12 SLSC chassis slots. It should fully engage with the rear
connectors and latch so the panel is flush with the other chassis panels. The insertion/extraction lever can be used to help latch
the card into place.
Extraction
Unlatch the insertion/extraction lever and pull it down to pry the card loose from the rear connectors. Once free, it can be fully
extracted by pulling on the faceplate panel.
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Front Panel Connections
Pinout
Connect to front panel with 2 position Phoenix Contact 1777723, available from OrangeWire Systems.
Wire size 24-12AWG with Ferrule, up to 10 AWG without ferrule. Recommended Wire: 12Awg PPE
65/30. Use Crimp tool HSC8 6-4.
Signal Description
OW-503-4 has four relays on it. All four relay common terminals are connected to the “IN” pins. All “IN” pins are connected to each
other. Relay normally open pins are connected to the ”OUT” pins. “COM” pins are connected to each other, and are not switched.
When a channel is switched “ON”, the OUT pin for that channel connects to the “IN” pins. Each pin can conduct up to 40A.
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Rear Panel Connections
Signal Description
Sleep Mode Current
OW-503-4 has 4 channels, each with a soware enabled 10Ω shunt for detecting current when the DUT is in power-down or “sleep”
mode. Each shunt has a positive and negative end, and both ends are available on the rear panel and can be connected to a fully
isolated Voltmeter. The signal is dierential: ±channel pairs carry the analog voltage from the shunt. Positive current will be
measured on the + and - pin when current flows from IN to channel OUT. Both channel pins will be common mode at the channel
output voltage, ie 12V relative to front panel COM.
Because this board passes power out the back, any adc or volt-meter used to sense the shunt voltage must be galvanically
isolated. Using non-isolated modules could result in damage to the module or the SLSC chassis.
Operating Mode Current
All 4 channels convert operating currents into -10 to +10V voltages at the rear panel, referenced to a common laboratory ground
(G). These voltages can be sensed by a real time National Instruments analog to digital module. Each channel has a 55A current
sense range, where the full scale ±10V signal corresponds to 55A. Positive outputs at the rear panel correspond to current flowing
from IN to channel OUT on the front panel.
Operating current out pins (I
O
and G) are galvanically isolated from all front panel pins. Rear panel signals share a common ground
(G). Pins G* on the signal midplane are normally not connected to anything, but can be ground if the PXI jumpers on the card are
connected. Jumper settings depend on the mapping of the cabling and adapter used to connect to the real time adc module.
Typically, jumpers should be connected in PXI applications, and disconnected in Compact-RIO applications.
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Pinouts
Signal Midplane Pinout for OW-503-4 (Identical for all 12 card positions)
*Lab Ground if PXI jumpers on OW-503-4 are connected.
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Reference Connections
OW-503-4 brings all 8 references from the OW-130 Signal Midplane. Jumper wires are used to make connections between the IN,
OUT, or COM signals and the Signal Midplane Reference Rails. To switch power to a Midplane Reference Rail, connect the output
terminal (example: red) to the rail that is to be switched. Power can also be sourced between the midplane rails and IN terminals
(yellow), or COM and rails (blue). The connection to the Signal Midplane rails is rated to 20A. The terminals are rated to 32A.
Connections can be doubled for additional carrying capacity. Zip-tie mounts are provided for cable management. The screw
terminals can connect 12awg wire with ferrule, and up to 10awg wire without ferrule. Recommended Wire: 12Awg PPE 65/30. Use
Crimp tool HSC8 6-4.
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Operation
Theory of Operation
OW-503-4 is designed to switch power to devices under test, or to the Signal Midplane power rails. Each channel has a 40A,
soware enabled relay. Relay common for all channels is connected to the IN net. Relay normally open is connected to the output
for each channel.
0-55A current sense circuit is based on LEM LAH-25-NP closed loop Hall Eect sensors. The when current flows through the sensor
primary winding, the hall sensors generate a proportional current in the secondary winding to cancel out the flux in the core. The
cancellation current needed is governed by the turns ratio of the primary (input) and secondary (output) windings, much like a
transformer. A resistor converts the output current to an output voltage, and a selectable set of parallel capacitors provide low
pass filtering of this signal.
Output Voltage is calculated by: , where = 182, = 1000.Vo=Ns
R I
o o RoNs
Caution: Sensor output voltage must stay in balance with the input current! . The board power supply is limited to182IV o= . o
±10V. If the output reaches 10V, the input current must not go any higher than 55A or the sensor cores may become permanently
magnetized and the sensors will need recalibration. Note that when the sensor is o, no secondary cancelling current will flow,
and the core will be magnetized by any input current. The switch protects the sensor when power is o.
Each channel has a 10Ω 0.1% soware selectable shunt to measure current when the DUT is in sleep or power-down mode. The
dierential signal from the shunt runs directly out the back of the chassis, where it can be sensed by a fully dierential ADC or
voltmeter. Because is is sensing power directly, the adc or voltmeter must be galvanically isolated. When not enabled, the shunt is
bypassed.
Configuration
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PXI Jumpers
The OW-503-4 can be used with multiple real time NI Analog to digital conversion modules and multi-meters. Because many of
these modules have dierent pinouts and grounding patterns, the OW-503-4 has jumpers B1-B3 to enable compatibility with all
types. Jumper settings depend on the mapping of the cabling and adapter used to connect to the real time adc module. Typically,
jumpers should be connected in PXI applications, and disconnected in Compact-RIO applications. To set the jumpers, swipe the
soldering iron slowly along the jumper pads. To unset it, swipe it quickly across the solder pads.
Output Filter (Manual Setting)
The output filter for each channel can be set manually, or with soware. To set manually, place the output filter jumper J6 in the
position which best matches the filter frequency needed: 1, 20, or 80 kHz. If the jumper is not placed in one of these positions, the
circuit will output frequency content up to 200 kHz.
Output Filter (Soware Setting)
Output filters can be controlled through soware via the SLSC interface. See the soware manual for instructions.
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