X2E UPoB User manual

UPoB
Universal Power Bridge
User Manual
Version: 1.6 / April 2019

© 2019 X2E GmbH
This user manual is protected by copyright; all usual rights reserved. Reproduction of this user manual, even in
part, is only permitted with the approval of X2E GmbH. Any infringement will result in liability for damages and
may result in criminal prosecution.
All product names and brands used in this user manual are the property of their respective owners.

User Manual UPoB
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Table of contents
Introduction.............................................................................................4
Intended use............................................................................................4
Delivery contents .....................................................................................4
General safety instructions......................................................................5
Product overview.....................................................................................6
Identification.............................................................................................6
Block diagram..........................................................................................7
Connections and controls ........................................................................8
Installation.............................................................................................15
Mounting................................................................................................15
Connecting.............................................................................................15
Firmware update...................................................................................17
Cleaning................................................................................................18
Repair...................................................................................................18
Disposal................................................................................................18
Appendix...............................................................................................19
Technical specifications.........................................................................19
COM breakout cable..............................................................................20
Discharge times.....................................................................................21
Thresholds.............................................................................................22
Status messages ...................................................................................24

User Manual UPoB
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Introduction
Intended use
The UPoB is an automotive universal power bridge that protects the connected system, such
as a XORAYA data logger, against voltage fluctuations and power failures. The device is able
to override the fluctuations for their duration of time. In case of a complete power failure, a
minimal voltage level is maintained until the connected system is shut down safely.
The UPoB is designed for industrial areas and must not be used in residential areas.
You may only operate the UPoB within the scope of the technical specifications provided in
this user manual. Additionally, the use in hazardous areas is not allowed.
Delivery contents
UPoB (Universal Power Bridge)
power cable
COM breakout cable
user manual
USB driver
Check to ensure that the delivery is complete and all hardware components are in sound
condition. If the delivery is incomplete or supplied components are damaged, contact X2E
immediately. Do not use damaged components.

User Manual UPoB
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General safety instructions
The UPoB is only intended for use by qualified personnel. Read the user manual and espe-
cially this chapter thoroughly before operating.
CAUTION
Electric shock due to damaged components
Damages to the UPoB or the power cable can result in electric shock.
Check all components regularly for damages.
Only connect the UPoB if all components are undamaged.
CAUTION
Device damage due to vibrations, dirt or liquids
Excessive vibrations, dirt or liquids may result in malfunction or destruction
of the UPoB.
Avoid exposing the UPoB to excessive vibrations, dirt or liquids.
Keep the UPoB clean, especially plugs and sockets to ensure a reli-
able contact.
Never open the UPoB.
CAUTION
Device damage due to electrostatic discharge
Electronic components can be destroyed by electrostatic discharge.
Avoid touching connectors and connector pins.
Ground yourself before carrying the UPoB in your hands.
Operate the UPoB in an ESD-compliant environment.

User Manual UPoB
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Product overview
Identification
The identification plate and the buffer capacity label are located on the bottom side of the
UPoB.
The identification plate contains information about:
device type
serial number
configuration
date of manufacture / last modification
Configuration consists of three blocks:
product ID
product variant
hardware revision
This user manual applies to the Universal Power Bridge in hardware version 0302 and firm-
ware version 000307.
This label indicates the total capacitance of the integrated capacitors.

User Manual UPoB
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Block diagram
Capacitors
Charge
current Config
Micro-
controller
Trigger
level
Service
Monitor
4321
Normal
mode Bridge mode COM
Acoustic signals on mode change
The UPoB indicates changes between normal mode and bridge mode by
acoustic signals.

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Connections and controls
Front view
Back view

User Manual UPoB
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Vin (A)
Pin Function
A1 KL31
A2 KL30
Switching on/off threshold
Vin ≥10.9 V: UPoB switches on
Vin ≤10.0 V: UPoB switches off (if capacitors com-
pletely discharged)
Charging threshold
Vin ≥11.3 V: capacitors charging
Vin ≤11.0 V: capacitors stop charging
The capacitors get their maximum charging voltage
of 10.0 V if the input voltage is 12.0 V or higher.
Mode-changing thresholds
Vin ≤10.0 V: UPoB switches into bridge mode
Vin ≥10.3 V: UPoB switches back into normal mode
(All values stated here apply to 0 A output load current. Please
refer to the appendix for thresholds of further currents.)
Capacitors
Vin ≥ 10.3 VVin ≤ 10.0 V
Normal
mode Bridge mode

User Manual UPoB
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Configuration (B)
Switch Function when On
Trigger (1) sends trigger signal if the capacitance drops below the config-
ured trigger level (D)
Sleep (2) UPoB switches into sleep mode, where it does not send via
CAN and RS232, if:
the output load current drops below approx. 70 mA
UPoB wakes up if:
(Mode is On)
the output load current rises above approx. 80 mA
(Mode is Off)
the input voltage rises above 10.9 V
Mode (3) mirrors the state of the input voltage at the output
deactivates the voltage output if:
the input voltage drops below 10.0 V
activates the voltage output if:
the input voltage rises above 10.9 V
Output (4) voltage output (F) activated
(All values stated here apply to 0 A output load current. Please refer to the appendix for thresh-
olds of further currents.)
Impact of the output switch on other modes
In order for the sleep and mode switches to work as described, the output
switch needs to be On. Otherwise, the UPoB cannot be woken up from
sleep mode if the mode switch is On, for example.

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Charge current (C)
The charge current is included in the maximum input current of the UPoB.
Position Charge current
left 0.5 A
up 1 A
right 1.5 A
down 2 A
Trigger level (D)
If the trigger switch (1) is On and the remaining capacitance drops below the configured
level, the UPoB sends a trigger signal.
A trigger signal consists of:
an RS232 command to shut down a connected XORAYA data logger safely;
the data logger cannot be woken up by bus activity anymore
an impulse on the 5 V digital output for 100 ms
closing the relay output for 100 ms
illuminating the Info-LED for 100 ms
an acoustic signal
Position Trigger level
left charge at 25 %
up charge at 50 %
right charge at 75 %
down charge at 100 %

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LEDs (E)
LED Colour Meaning
On
yellow input voltage invalid or no input voltage
green input voltage valid
(off) no input voltage and capacitors discharged
Info yellow (blinking) discharge button (H) pressed
green (1x blinking) trigger signal sent
Status
yellow capacitors discharging,
charge higher than trigger level
yellow (blinking) capacitors discharging,
charge lower than trigger level
green capacitors completely charged
green (blinking) capacitors not charging and not discharging,
charge higher than 5 % and lower than 98 %
blue capacitors charging,
charge higher than trigger level
blue (blinking) capacitors charging,
charge lower than trigger level
(off) capacitors not charging and not discharging,
charge lower than 5 %
(all) red overcurrent
Vout and GND (F)
Bridge mode:
Vout = 12 V
Normal mode:
Vout ≈Vin - Vdrop
Vdrop depends on the output load current (max. 500 mV at 5 A)
Overcurrent protection
The UPoB is equipped with overcurrent protection that reacts within 500 ms
if the output load current rises above 5 A.

User Manual UPoB
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Reset (G)
This button covers the following functions:
restart the UPoB
acknowledge overcurrent event and reactivate voltage output
if connected via service interface (I), switch the UPoB into bootloader mode to per-
form a firmware update (further information in the corresponding chapter)
CAUTION
Device damage due to sudden voltage drop
Pressing the reset button deactivates the voltage output for a short period of
time. The connected system can be damaged or destroyed due to the sud-
den voltage drop.
Shut the connected system down safely before pressing the reset
button.
Discharge (H)
This button discharges the capacitors. The Status-LED indicates the current status of the dis-
charging process.
Discharge restriction
The discharge button is deactivated in sleep mode and when input voltage
or output current is present. An already started discharge process stops
when input voltage or output current is registered.
CAUTION
Device damage due to overheating
Discharging at high ambient temperatures can destroy the UPoB.
Press the discharge button only at room temperature.

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Service (I)
Use the Micro USB interface to update the firmware. For further information, refer to the cor-
responding chapter of this user manual.
The pin assignments conform to the USB standard.
COM (J)
The COM interface consists of:
an RS232 interface to communicate with a XORAYA data logger
a CAN interface to send status messages
a5V digital output
a relay output with opener, closer and voltage input
Pin Function
2 COM_RS232_RXD
4 RELAIS_CLOSER
5 RELAIS_OPENER
6 STATUSCAN3_P
7 COM_RS232_TXD
9 5V_DIGITAL_IO
11 STATUSCAN3_N
13 RS232_GNDIN
15 RELAIS_VCCIN

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Installation
Mounting
CAUTION
Device damage due to overheating
Overheating may result in malfunction or destruction of the UPoB.
Do not operate the UPoB outside the specified temperature range.
Do not operate the UPoB in the vicinity of heat sources.
Ensure adequate air circulation.
Do not cover the UPoB with other objects.
Mount the UPoB in such a way that it does not pose a hazard at any time.
Connecting
DANGER
Electric shock due to improper connection
Introducing the 4-mm plugs of the supplied power cable into low-voltage
sockets can be fatal.
Never introduce the 4-mm plug into low-voltage sockets.
CAUTION
Device damage due to wrong power supply
A wrong power supply can result in damage or destruction of the UPoB.
Only connect the UPoB to power supplies that correspond to the
technical specifications.
Pay attention to the correct polarity when connecting.
Disconnect service interface during standard operating mode
Make sure that the service interface (I) is disconnected in standard operat-
ing mode. Pull the plug if necessary and connect it again before updating
the firmware.

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COM interface
Connect the COM breakout cable to COM (J).
Connect the desired connectors of the COM breakout cable to the corresponding de-
vices.
Tighten all connector screws.
Voltage output
Connect Vout and GND (F) to the connected system, such as a XORAYA data logger.
Voltage input
Requirements for the DC power supply
A 12 V DC power supply must provide a current of 6 A.
This applies to a charge current of 0.5 A. For a higher charge current, a
more powerful power supply is required.
Connect the power cable to Vin (A).
Tighten the connector screws.
Connect the black connector of the power cable to 0 V or ground.
Connect the red connector of the power cable to a DC power supply in the specified
range.
Turn on the power supply.
The UPoB indicates its readiness by illuminating the On-LED.

User Manual UPoB
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Firmware update
Firmware updates provide bug fixes and new features for the UPoB. For this, you need a PC
which meets the following requirements.
Supported operating systems:
Microsoft® Windows® 7/8/10 (32 Bit or 64 Bit)
Hardware requirements:
Processor speed: at least 1 GHz
RAM: at least 1 GB
Execute the firmware update
Connect the UPoB to the power supply (see chapter Connecting).
Turn on the power supply.
Make sure the correct USB driver is installed.
Connect the UPoB via service interface (I) to your PC.
Press the reset button (G) on the UPoB.
Navigate to the folder where the firmware archive is located.
Unzip the archive.
Execute the file firmware_update_upob.bat.
Follow the instructions on the screen.

User Manual UPoB
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Cleaning
CAUTION
Device damage due to entering liquids
Entering liquids may result in malfunction or destruction of the UPoB.
Disconnect the UPoB from the power supply before cleaning.
Make sure that no liquids enter the UPoB.
Clean the UPoB with a damp, soft cloth as needed.
Repair
CAUTION
Device damage from opening the device
Unauthorised opening may result in malfunction or destruction of the UPoB.
Never open the UPoB.
Maintenance and repair must be carried out by X2E personnel only.
In case of malfunctions or damages, please contact X2E via e-mail to get information
about returning the UPoB: xoraya-ret[email protected]
Disposal
Within the European Union, the disposal of electrical devices is determined
by national rules that are based on the directive 2012/19/EU of the Euro-
pean Parliament and of the Council on waste electrical and electronic equip-
ment (WEEE). Accordingly, electrical and electronic equipment may not be
disposed of in household waste.
Outside the European Union, please contact your local authority so as to
comply with the correct method of disposal for electrical devices.

User Manual UPoB
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Appendix
Technical specifications
General
Dimensions (H x W x D) 64.4 mm x 105 mm x 164 mm
Input voltage
max. 28 V
bridge mode: max. 10.0 V
normal mode: min. 10.3 V
Output voltage bridge mode: max. 11.9 V
normal mode: max. Vin - 0.8 V
(at room temperature)
Output load current max. 4.8 A
Idle current max. 200 mA
Quiescent current max. 2 mA
DC voltage protection max. 40 V
Temperature range -40 °C to +85 °C
RS232
Baud rate 115,2 kbit/s
Data bits 8
Parity bit no
Stop bits 1
CAN
Baud rate 500 kbit/s
Termination 120 Ω
5 V digital output
Drive current max. 100 mA
Relay output
Voltage input 5 V to 48 V
Opener 5 V to 48 V, 100 mA
Closer 5 V to 48 V, 100 mA

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COM breakout cable
Pin Function
2 COM_RS232_RXD
4 RELAIS_CLOSER
5 RELAIS_OPENER
6 STATUS_CAN_ST_P
7 COM_RS232_TXD
9 5V_DIGITAL_IO
11 STATUS_CAN_ST_N
13 RS232_GNDIN
15 RELAIS_VCCIN
Pin Function
2 COM_RS232_RXD
3 COM_RS232_TXD
5 RS232_GNDIN
RS232
Pin Function
2 STATUS_CAN_ST_N
7 STATUS_CAN_ST_P
CAN
Pin Function
2 RS232_GNDIN
7 5V_DIGITAL_IO
5 V digital output (Digital_IO)
Colour Function
red RELAIS_VCCIN
yellow RELAIS_OPENER
green RELAIS_CLOSER
Relay output