Compact Module User Manual - E-T-A Elektrotechnische Apparate
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1. ETA ENGINEERING TECHNOLOGY Powerrlex Compact Module User Manual Instructions for Mounting and Installation s y gt 4 Zan N 79m T a CEUEWN EVAN us k Er 2 SS R User Manual PowerPlex Initial Release P PLEX COM24 E Index Helease Date 02 2015 Reference Document Publisher E T A Elektrotechnische Apparate GmbH Industriestra e 2 8 D 90518 Altdorf Tel 49 0 91 87 10 0 Fax 49 0 91 87 10 397 E Mail info e t a de Web www e t a de Copyright 2015 E T A GmbH The content of this document is the sole property of E T A GmbH No part of this publication may be reproduced or distributed in any form or by any means without the prior written permission of E T A GmbH Any person who does any unauthorized act in relation to this publication may be liable to criminal prosecution and civil claims for damages Limitation of Liabilities While every precaution has been taken in the preparation of these specifications the publisher assumes no responsibility for errors or omissions or for damages resulting from the use of the information contained herein Subject to change without notice Trademarks Trademarks or patents generally protect all references to software or hardware used in this document E T A GmbH 2015 Alle Rechte vorbehalten User Manual About this Manual The manual for the PowerPlex Compact Module is intended for the professional vehi2. For the PowerPlex modules however the installation is recommended close to the connected loads in order to reduce the amount of wiring CAUTION e Leave enough space for heat dissipation e Be sure to install the PowerPlex modules indoors e Pay attention to the built in version in order to achieve the required safety class The installation of the touch panel required at least the following tools drill jig saw screwdriver if necessary a rasp HMI Human Machine Interface in this case it means PowerPlex Touch Panels Touch PC etc PowerPlex Compact Module 9 Mounting User Manual GENERAL REQUIREMENTS FOR THE LOCATION When choosing the location you have to consider several factors which can affect the performance of the devices Table 8 shows the most important factors VENTILATION Make sure that the modules has enough space for proper ventilation on all sides Leave sufficient distance between modules MOUNTING AREA Ensure a secure attachment of the modules on the mounting surface Note the vehicle specific properties and attach no components at locations which affect the safety features of the vehicle In addition make sure that the mounting surface is flat and the terminals are directed downward to ensure the required level of protection CABLE ENTRY Ensure the mounting of the modules on a location where the cables can be decent routed and connected WATER INLET The device is designed to be mounted
3. elements for switching and protecting electrical loads The DC modules are free of any mechanical components and are thus hardwearing as well as shock and vibration proof E T A offers four PowerPlex modules for DC 12 V and DC 24 V systems Every module is different Table 4 shows exemplify the difference of two modules ore J Yo U 0 0 m POWER MODULE DC MODULES Total voltage DC 12V DC24V DC 12V DC24V Total current max 60 A per module 102 A per module digital 10 8 analog 4 4 10 max 10 A two are 4 max 1 A Outputs configurable as H bridge 6 max 8 A FLPC 2 max 25 A FLPC Protection Class IP20 IP22 Inputs Order number PP C COM24 00E 0 Z 00 PP M DC024 000 0 0 00 Table 4 Different PowerPlex modules 3 2 PowerPlex CAN Bus One PowerPlex control network may comprise up to 30 PowerPlex modules of any type The smallest PowerPlex network would be made up of two such modules interconnected by a CAN bus cable shown in Figure 3 The loads controlled by the module outputs here a lamp and a bilge pump will typically be installed somewhere in the vehicle not necessarily close to the input signal The distributed control architecture of PowerPlex therefore allows you to monitor and switch appliances anywhere on the vehicle from any point you wish A level sensor monitors the bilge area and feeds this analog information to Module 1 From there the information is t
4. Alam Collector L Adr 3 Man Deck Panel Module Enoe del s t No change Low Alam Buzzer L Adr 4 Man Deck Panel Module navigi dam colector 2 L Ad 9 Pot Engine Room Panel Module Doo Alam collector L Adr 44 Man Deck Power Module B ge Alam Colector L Adr 47 Man Deck Power Module Es BA cuf ut 18 8 Adr 18 SA Main Deck Panel Module Ade 3 PP M PM024 Post Engine Room Panel Module Adr 4 PP M PM024 Port Engine Room AC Module Adr 5 PP M AC230 Stbd Engine Room Panel Module Adr 6 PP M PM024 Stbd Engine Room AC Module Adr 7 PP M AC230 Main Deck Power Module Adi 8 PP M DC024 Helm Touch PC Adr 20 XPP TPCSW Helm Touch PC li Ade 21 XPP TPCSW Helm Touch PC Ill Ade 22 XPP TPCSW Helm Touch PC IV Ade 23 XPP TPCSW Helm Touch PC V Ade 24 XPP TPCSW Qe x Info window Collecting the Low Alaems where the buzzer veli stop when the PopUp s closed Scenario editor Data Status modbed not saved Status bar Figure 10 PowerPlex amp user interface The opening window WINDOWS SECTION DESCRIPTION Title bar Displays program name and version number Menu bar Offers interactive PowerPlex menus for creating modifying and testing PowerPlex configurations Toolbar Offers interactive icons for quick access to program functions such as Create Save Edit Delete Browser Displays the components of the PowerPlex c
5. MemorFlag 48 5 amp dr 48 Mg Analog MemorFlag 49 5 amp dr 43 xi PowerPlex Compact Module Anwenderhandbuch User Manual PowerPlex Ausgabe Release P PLEX COM24 E Index Ausgabedatum Release Date 02 2015 Alle Rechte vorbehalten All rights reserved ETTA ENGINEERING TECHNOLOGY E T A Elektrotechnische Apparate GmbH Industriestra e 2 8 90518 ALTDORF GERMANY Tel 09187 10 0 Fax 09187 10 397 E Mail info e t a de www e t a de
6. below deck Therefore the installation is recommended in a protected location ELECTRICAL INTERFERENCE PULSES The location should be selected at a sufficient distance to devices that can send out interference pulses Table 8 Requirements for the installation location 5 3 Precautions on Wiring For a reliable power distribution control and monitoring via a PowerPlex system is the choice of the correct cable types and lengths extremely important To avoid voltage drops it should be ensured that the cable quality is good and the cable cross section is correct Please read chapter 7 regarding the integration of the unit into the CAN bus network Wiring should be done carefully to achieve the maximum performance of the PowerPlex installation Table 9 lists the general notices which should be considered for the wiring of a PowerPlex system ITEM NOTE Cables should not be excessively bent Provide a enough diameter of the curve Cables must be protected from damage and heat Avoid the near to moving or hot parts and to machines Cables should be secured by clamps Excess cable lengths should be handled professionally Waterproof cable bushings are meaningful depending on the location Ensure a suitable strain relief by using the cover from the PowerPlex Compact Module Checking the cables for damage to the isolation especially after laying the cables Table 9 Precautions on wiring If during i
7. by switching the associated control device such as switching ON a pump if the potable water tank level is too low e PROTECT APPLIANCES AND EQUIPMENT against dangerous overloads and short circuits by isolating the faulty load from the system and indicating its failure e PROVIDE BACKUP PROTECTION AND SWITCHING in the unlikely event of PowerPlex system or component failure i Distributing AC 230 V supply is with PowerPlex amp AC modules possible PowerPlex Compact Module 1 System Components Overview User Manual 2 System Components Overview With PowerPlex E T A offers a comprehensive on board system which combines safety comfort and reliability PowerPlex allows individual and flexible concepts for switching the illumination sirens special signals and much more It can automatically switch loads and will immediately inform the driver about undesirable behavior of the devices or the electrical installation This will ensure that everything works as it is designed to reassuring when loads are not always visible E T A PowerPlex is a decentralized power distribution system with electronic protection fully geared to the future Figure 1 shows a typical PowerPlex arrangement comprising a number of distributed PowerPlex components modules and user interfaces installed in different locations of a vehicle PowerPlex communication is based on the CAN bus principle using nodes that talk to each other over 2 wi
8. designed for stationary installation Normally you choose this PowerPlex module for your application if you have to switch loads up to 8 A 10 A We recommend installing of the modules in the vicinity of the loads to be controlled 5 1 Mounting Checklist The mounting includes the following installation steps STEP ACTION Application specific system planning Determining an installation location and preparation of all necessary equipment and tools Note of the serial number Cable laying Preparing of the required cutouts for cable and devices in the mounting plate Connection of the module for commissioning Mounting and system connection of all remaining PowerPlex components if not previously done System start by switching on Verification of system behavior through complete system test oO ON DM Oo BR oO MY Table 7 Mounting checklist The maximum number of system components is limited This must be considered during the planning and installation process of the complete PowerPlex system Our recommendation is approximately 30 PowerPlex modules per system The maximum number varies with the scope of the configuration so that also more modules are possible 5 2 Recommended Installation Location Generally is the installation location of all components PowerPlex completely flexible The PowerPlex HMI devices should be installed at the location that provides the maximum benefit for the user
9. function is individually configurable to fit the requirements of the different loads Based on CAN network communication the PowerPlex system makes individual wiring between loads and switching equipment to a thing of the past As the transmission of switching commands and status information is based on peer to peer CAN bus communication there is no need to have direct cabling between the operating element say a light switch and the load to be switched say a lamp The obvious advantage to the OEM lies in the reduced cabling and build costs and in the convenient system setup using Windows based configuration software As the system s control functions are freely configurable with respect to complexity and system size modification and expansion at a later stage is extremely easy PowerPlex FUNCTIONAL RANGE PowerPlex takes charge of the following tasks e DISTRIBUTE THE DC 12 V OR DC 24 V SUPPLY to all points of the boat where loads are installed such as lighting and heater control bilge pumps water pumps windscreen wiper motors etc e COLLECT STATUS INFORMATION from all sensors and operating elements around the vehicle such as temperature and tank level measurement points ON OFF status signals of actuators e SWITCH APPLIANCES AND EQUIPMENT ON AND OFF according to selectable predefined scenarios at the touch of a button e MONITOR APPLIANCES AND EQUIPMENT for out of range conditions indicate such faults and respond to them
10. of the module us2222000020200eennnnnnennnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnennnnnnnnnnnnneenn 12 Table 11 Cable cross sections for different current ratings cccccecccccseececceeeeeceeeeeceeeeeeceeseuceeseueeesseaeeeesenes 13 Table 12 Main features of the used CAN bus cable 22000220200nnsnnnennnnnnnennnnnnennnnnnennnnnnnnnnnnnnn nennen 14 Table 13 Computer requirements for the PowerPlex Configuration SOf WaAr EEE 15 Table 14 Computer Check llssesessssssesssssesssseseeeennnnnnnn nhan KK AKA KK KK KAKA isses ss KK A KAKA KA KK KK A KK KK sisse aa sss KK A KA 15 Table 15 Installing the PowerPlex Configuration Software cccccccccseeccccesscceceeeeceeeeeeeceeseeeeeesseeeesseeeeeseees 16 Table 16 Contents of the PowerPlex opening window lli kk k K KK nennen 17 Table 17 Coniguraton Men EC m 18 Table 18 Options Ment RT E 18 Table 19 Important information us22220000220000ennnnnnennnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnneenn 20 Appendix Appendix 1 Function of the analog inputs of a PowerPlex Compact Module eeeeeeeeeeeeeeeeene xi vi PowerPlex Compact Module User Manual About this Manual C
11. switch is OFF WARNING IGNITION HAZARD The operation of the module is NOT recommended in inflammatory environments WARNING HIGH VOLTAGE The housing of the module should NEVER be opened Also access to the internal components is not allowed unless it is pointed out in this manual CAUTION GROUNDING The unit must be grounded before switching on CAUTION WATER INGRESS Disclaimer Water Entry The water resistance of this module depends of the correct mounting E T A makes no warranty for damages caused by water ingress Table 19 Important information EMC INSTALLATION GUIDELINES The PowerPlex hardware and accessories conform to EMC Directives As a result electromagnetic interference between devices can be avoided which would otherwise degrade system performance A professional installation is therefore imperative To ensure the best EMC conditions the maximum distance between the various electrical devices should always be respected TECHNICAL ACCURACY All technical data in this manual was correct at the time of going to press to the best of knowledge and belief For any unintentional error E T A cannot be held liable Due to continuous product improvements by E T A may temporarily occur differences between the product and handbook Changes to the product or in the technical specifications shall be made without prior notice On our website E T A www e t a de you can ensure that they have the latest v
12. that during the entire work on the system the power supply has been disconnected and secured against unintentional restart Avoid large differences between the lengths of the and cables CONNECTION OF THE MODULE The connection of the PowerPlex Compact module to the power supply DC 12 V DC 24 V occurs by means of hexagon sockets M5x10 at the positive and negative terminals of the module Table 5 and Figure 7 CAUTION The module must be connected to a suitable overcurrent protector directly to the power supply To ensure the faultless commissioning of the entire system it should not be networked via another PowerPlex component in the system CABLE CROSS SECTIONS Suitable elements for overcurrent protection should be used to protect the PowerPlex components Therefore the amperage of the circuit breaker should have the maximum of the expected total current from all outputs of the used PowerPlex component The required cable cross section of the voltage supply line depends on the maximum rated current that will be transmitted in the PowerPlex system MAX TOTAL CURRENT e 1 18 E09 e ie Jes e Table 11 Cable cross sections for different current ratings PowerPlex Compact Module 13 Integration des Ger tes in das CAN Bus Netzwerk User Manual 7 Integration des Ger tes in das CAN Bus Netzwerk To build up the CAN bus network all PowerPlex components needs t
13. the 7 digit serial number for each PowerPlex component These are needed for the subsequent system configuration with the PowerPlex Configurations Software Later on when you are going to configure and define the modules role in the CAN network you will have to make the association between serial number CAN bus address and mounting position on the boat We recommend using the CAN bus address labels 1 to 30 provided and fix them to the upper right corner of the module covers to keep track of module identification For details on the recommended circuit and address labels please consult the module data sheets 3 4 The Module CAN Bus Address Every PowerPlex module connected to the CAN bus must have its own unique CAN bus address in the range from 1 to 30 for unambiguous identification within the network You assign the address when you set up your PowerPlex system using the PowerPlex Configuration software see PowerPlex Manual Volume 3 System Setup and Configuration We recommend to mark the modules in your PowerPlex system with their corresponding module addresses This allows you to keep track of module identification 6 PowerPlex Compact Module User Manual General Information PowerPlex amp Compact Module 4 General Information PowerPlex Compact Module Today field buses in particular CAN are indispensable Primarily due to increased demands for safety and comfort more and more electrical equipment is being i
14. AN USB Converter and Driver Software To upload a completed or modified PowerPlex Configuration into a PowerPlex Compact Module and other PowerPlex hardware you will have to connect your configuration PC to the CAN bus network of the PowerPlex system To do so you need the e CAN USB converter cable connecting the USB port of your computer to the 9 pin D SUB socket of the hardware The following adapters are supported by the PowerPlex Software CAN USB light adapter supplied by Sontheim PEAK USB PEAK PC e associated CAN USB driver software installed on your computer Figure 13 CAN USB converter cable example Peak NOTE The driver software of the selected CAN USB converter must be installed on the configuration computer PowerPlex Compact Module 19 Important Safety Information User Manual 10 Important Safety Information In the table below you find several information and safety information for the commissioning and use of the PowerPlex Compact Module WARNING INSTALLATION AND USE OF THE MODULE This equipment must be installed and operated in accordance with the instructions provided Disregard may result in personal injury damage to the boat or vehicle and reduced product performance WARNING SWITCHING OFF THE MAIN SWITCH Before starting the installation the main switch of the boat or vehicle may need to be turned off The cable connection should be established only when the main
15. RTIES Characteristic impedance 40 C 70 C 40 F 158 F 120 Q Conductor resistance 37 Q km max Insulation resistance 1 GO km Test voltage OTHER GENERAL PROPERTIES Resistance to ambient influences 1 5 kV UV weather oil coolant and microbe resistant Mechanical resistance Abrasion and notch resistant low adhesion Chemical resistance Acid and alkali resistant Thermal resistance Table 12 Main features of the used CAN bus cable Fa Helukabel CAN BUS 1X2X0 50 www helukabel de Caloric load 1 09 MJ m 14 PowerPlex Compact Module User Manual PowerPlex amp Configuration Software CAUTION Make sure that the beginning and end of the CAN bus network was completed with a 120 O resistor Both the first and the last PowerPlex component must have been equipped with a 120 O termination resistor This is for the proper and reliable operation of the installation PowerPlex crucial NOTE The terminating resistors are normally not included in delivery They can be ordered separately as an accessory 8 PowerPlex Configuration Software The PowerPlex Configuration Software is part of PowerPlex You will find it specified in the data sheets of the PowerPlex hardware modules under the heading Accessories When ordering your PowerPlex components please make sure to state explicitly whether or not you also need the PowerPlex Conf
16. SB Converter and Driver Software ssssssssssssssssesesseee nennen nennen nnne nnn nnn nnn KK KA KK A KK KA 19 TO Important 5afety MATOMMALON ks 5 3 4 3 y432 21351254254 net aU oium ea 20 MES c 21 leot TMT xi PowerPlex Compact Module V About this Manual User Manual List of Figures Figure 1 Exemplary PowerPlex system design in an ambulance vehicle i kn 2 Figure 2 Design your PowerPlex system PowerPlex amp components u022222000200000nnnnnnnennnnnne nennen 3 Figure 3 Minimum PowerPlex System design two PowerPlex modules connected via CAN bus cable 5 Figure 4 Several PowerPlex amp modules connected in a serial CAN bus topology E LE 5 Figure 5 PowerPlex amp Compact Module iu kk kk nenne KK KK K KAK KK nnns sss KAK KK KAK KK KK KK YA 7 Figure 6 PowerPlex Compact Module without snap on cover eneeeeesssssseennsnnnennennnennnnnnnnnnnnnnennnnnne nennen 8 Figure 7 Overview TOF INOUNUING kuin cun A ania SFR qua UNA DSRENOFD SV T 2UIJYUAS NOR vak UV DUE QUA URP Hot ed UMORE S OU kO und 11 Figure 8 Installation di AW INOS nennen d nekena A nana een d nipan an A Wana NARRAN RaR 12 Figure 9 PowerPlex amp components in a CAN bus system ssll kk nenne k kK nnn nnns 14 Figure 10 PowerPlex user inte
17. ble connections were properly identified and wiring is well planned STEP ACTION Mark the drillings at the chosen installation location according to the dimension drawing Drilling the mounting holes Make sure that the module fits into the prepared hole Depending on the accessibility of the cable connections we recommend that all cables power CAN etc be connected even before the mounting the unit Important The cable connection should only be made when the main switch is Orr Check the power cable for correctness of the poles chapter 4 3 Table 6 Ensure that in operation the max allowable voltage is not exceeded Think of the terminating resistors if the device is the first or last node on the CAN bus Attach the modules without front cover into the two holes provided with cylinder head screws M4 by tightening the screws Table 10 Mounting of the module NOTE Protection class IP22 requires that the Compact Module is mounted vertically and that the PCB is coated 12 PowerPlex Compact Module User Manual Connecting to the Power Suppl 6 Connecting to the Power Supply After you have linked all PowerPlex components of your system via a CAN bus cable with one another you have to provide the power supply of the installation PowerPlex is suitable for either DC 12 V or DC 24 V CAUTION e Ensure that all electrical installations are performed in accordance with EN ISO 10133 e Make sure
18. change their addresses UPDATE FIRMWARE Updates the firmware of the PowerPlex modules DELETE MODULE CONFIGURATION Deletes the current configuration from a specific module or from all modules of the PowerPlex system In a new dialog box you will be asked to enter the bus address of the module s concerned CHANGE PROJECT FILE Calls a new project file mdb file into which the configuration can be saved CREATE NEW PROJECT Creates a new project mdb file and asks you for confirmation whether this new project file shall be the container for the new configuration s you are going to program Table 18 Options menu This action requires a connection between the Configuration PC and the CAN bus interface of the PowerPlex hardware 18 CAN INTERFACE Selects the CAN interface driver used for the Configuration PC PowerPlex connection virtuell Sontheim CANusb light PEAK PCI PEAK USB HSP USBCAN PowerPlex Compact Module User Manual CAN USB Converter and Driver Software THE TOOLBAR PowerPlex Configuration Options Debug Test Help The most important commands offered by the Ji xke b t b EU menus in the menu bar can alternatively be activated by symbols displayed in the toolbar Thus the toolbar buttons act as shortcuts to the actions most frequently used Create new configuration Transmit configuration to PowerPlex system Figure 12 Toolbar 9 C
19. cle electrician who wants to install and configure the E T A PowerPlex Compact system for controlling the vehicle s electrical equipment The manual in hand describes the analysis and configuration software which is part of the PowerPlex control and multiplexing system The manual gives you step by step instructions on how to set up your PowerPlex Compact Module in a PowerPlex System once the hardware has been properly installed We take you through About this Manual the dialog boxes and menus of the software The following manuals provide additional information about E T A PowerPlex PowerPlex Manual Volume1 Volume 1 System Description PowerPlex Manual Volume2 Volume 2 Hardware Installation and Maintenance PowerPlex Manual Volume3 Volume 3 System Setup and Configuration All manuals contain important information for the connection and the safe use of PowerPlex devices Safety must be observed All users must be informed of all precautions The manuals must be accessible to the user Here you find a general system overview a description of the PowerPlex system architecture and a detailed explanation about the function of each PowerPlex system component The Appendix contains background information which you may be interested in in connection with the principles of the PowerPlex system It gives you a short introduction into CAN networking and provides the technical data sheets of the main components such as P
20. cuits in accordance with established safety practices and standards Safety Instructions Please follow the installation and adjustment instructions in this manual carefully A Nonobservance may result in serious damage to the product or your system E T A will not accept liability or warranty claims for issues caused by incorrect installation or handling by the customer or a third party iv PowerPlex Compact Module User Manual About this Manual Contents EAST OU FIU GS TTC uu mn vi Mme diio m O vi Toi n vi Conventions and SYMDOIS ccccccccssssecceccaesececcceeeeeeeeseaeeeeessaeeeeeessaeeeeessseaseeeeessaaeeeeeessaaeeeeessaaeeeeeessageeeess vii 1 IL OLE Oi ne E Dmm 1 2 System Components Overview cccccccccsssssecccceeccaesseeecceeeeeeseeeeeceeeeseseeeeeeeeeeeesseeeaeeeceeesesssaaeeeeeeeeeesaas 2 3 PowerPlex System General Characteristic ccccccccccccccccccccccceceeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeseee es 4 3 1 PowerPlex Modules isscce ech concectcevaccecdavaeiecielnceiadduenecacdeeeadevtelancactscaecectetaccesdetteder etacceadd aececeetaeceed eseceve 4 3 2 POWOEFPIeX CAIUS ee ee an dissi bM Med ae ee ee 4 3 3 Noting the Serial Numbers rne E ETE san nuni an nune ra dedeessessaeceescndseeeaseeetenedes 6 3 4 The Module CAN Bus AdOreSS cccccccceecssseecceeeeeceee
21. ected to the DC power supply and to the CAN bus CAN Bus Line CAN L Figure 4 Several PowerPlex modules connected in a serial CAN bus topology The first and the last module of the CAN bus topology have to have a 120 O terminating resistor connected between the CAN High and the CAN Low signals to prevent interferences on the bus NOTE The first and the last module of the CAN bus topology have to have a 120 O terminating resistor connected between the CAN High and the CAN Low signals to prevent interferences on the bus PowerPlex Compact Module 5 PowerPlex amp System General Characteristic User Manual 3 3 Noting the Serial Numbers Every PowerPlex component has a unique serial number Before you actually mount the PowerPlex modules we recommend you make a note of all serial numbers and keep a list of which module with which serial number you mount where You find the serial number label of the PowerPlex Compact Module on the housing underneath the cover To see this label remove the module s snap on cover by clicking the covers top handle towards you and then pulling the cover off The serial number comprises 7 letters and digits The serial number serves as an identifier for new unconfigured modules which initially have the CAN bus address 0 You will come across the module serial number when you set up your PowerPlex system and assign CAN bus addresses using the PowerPlex Configuration Software NOTE Note
22. eeeecceeeeeseeeeseeeeeeessaeeuseceeeesesseasseeeeeeeessaaaeeeeeees 6 4 General Information PowerPlex Compact Module ueeeeeeeeeseeeeeeeeeee nennen nnn nnns 7 4 1 TSCM GAL D ii EEA TT 7 4 2 CODE OLIVE a 8 4 3 Inputs Outputs and Inter C S i kk kk k k kk n nnns nna nnns naar KK KK KK KK KA 8 5 MOUTON NENNT mmm 9 5 1 MOUNINO GNECKIUSTE 9 5 2 Recommended Installation Location eeeseseessesssseeseeeeeeeene nennen KEK KK K k nnn nnn nnn 9 5 9 Precautions on NIIT m 10 5 5 hedl cd DI TTS S lO Seren ae een 11 5 6 Mounting of the Modulen een hen 12 6 Connecting to the Power Supply iu kk a kk K KAK KAK K k KK KK KA KK KAK KK KK KK KK KA 13 7 Integration des Ger tes in das CAN Bus Netzwerk E kk k k kK KK KAKA KAK KA 14 8 PowerPlex Configuration Software ssssssssse eee 15 8 1 Computer Regue CNl irarria kniei ea ee 15 8 2 Installing the Software lsssssesseisssssseeeeeeenenne nennen nenne a ka dal a kanan daka baka Wa nnns u d ka d l ad b hai d 16 8 3 Short todo First STEDS s xasiya ck n eut ee eka ney n K elatis te kla ne Zeiten 16 5 95 TNE Opening WANG OW E aa 16 oae TEM A sc ERE 17 9 CAN U
23. ersions of the manuals PowerPlex 20 PowerPlex Compact Module User Manual Notes 11 Notes PowerPlex Compact Module 21 Notes Notes User Manual 22 PowerPlex Compact Module User Manual Appendix Appendix Appendix 1 Function of the analog inputs of a PowerPlex Compact Module ele alee 1 Z A amp dr 3 PP C BCOT Inputs E Analog inputs e cap Level 4V 5 7 Adr 27 g digital Level 5 amp dr 28 coll Temperature 5 amp dr 29 e Charge Discharge 5 Adr 30 u y Discharging Current 5 7 Adr 31 e Mj Charging Current 5 amp dr 32 e m Current Power a i Aai eM um Een un ya hh 25 j que e eM M Curent Power output 84 36 5 Adr 36 e P Current Power output 84 3 5 Adr 37 e M Current Power output 84 38 5 Adr 38 M M Current Power output 8A 38 4 5 7 adr 39 M M Current Power output 84 40 75 Adr 40 eA M Current Power output 84 41 7 5 7 amp dr 41 M M Current Power output 84 42 75 amp dr 42 e M4 Supply voltage 43 5 dr 43 e M Analog MemorFlag 44 5 amp dr 44 e M Analog MemorFlag 45 5 7 fAdr 45 eM M Analog MemoryFlag 46 5 amp dr AB eM M Analog MemoreFlag 47 5 amp dr 4A7 eM Analog
24. following chapter explains the principal interactive elements of the PowerPlex analysis and configuration software NOTE Please see the Manual PowerPlex Manuel Volume3 System Setup and Configuration to get detailed information about How to configure a PowerPlex System 8 3 1 The Opening Window The opening windows opens immediately upon program start It offers all the functions that you need to configure a PowerPlex system These are amongst others e Insert define and modify PowerPlex modules e Specify and manage module inputs and outputs e Assign links between inputs and outputs e Print out system information Upload the configuration into the PowerPlex modules using the CAN bus interface 16 PowerPlex Compact Module User Manual PowerPlex amp Configuration Software Title bar Menu bar Tool bar E lo xJ BowerPlex Configuration Test te aeu j MIK e o 220 amp ETA PS 22 0ckhn i l Helm 1 Ade 1 IPP M DCO241 Project file PowedPex mdb Project file path XNPROJEKTE PowePtex PowerPlex browser rye TEH last Save date 0304 2012 101801 1A outputs oo APR NY Buzzer le nav 3 7 P m E towing nav ight 278 Adr 14 v edate 0 x 100 ms ara eter V top NUC nav koh 3 8 Adr 15 Oft deiy x 100 me Sy teaming koh 8 Adr 16 Actrve tme 0x 100 m z LB Rated cunert 4 gt rout leka to Tene 100 ms alarm mute timer L Ade 2 Hem 1 Startup dels On High
25. iguration Software You may already have the software from a previous PowerPlex project You also can download the Configuration Software from our E T A website NOTE The PowerPlex Configuration Software will not automatically delivered with the ordered PowerPlex components You may already have received this software with a previous order or you downloaded it from our E T A Website If you need the software please make sure to explicitly specify it on your order or download it from our Website 8 1 Computer Requirements The PowerPlex analysis and configuration software runs on any computer or laptop that uses the Windows operating system Please check your computer to make sure that it meets the following basic requirements TECHNICAL DATA Operating system Windows Windows XP Processor Pentium Ill or higher RAM Minimum 256 MBytes Recommended 512 MBytes Hard disk memory Minimum 500 MBytes Screen resolution Minimum 500 MBytes Input devices Mouse or other screen pointing device Interfaces USB 2 0 Table 13 Computer requirements for the PowerPlex Configuration Software Prior to installing the PowerPlex configuration software check your computer to ensure that it is prepared for the new software STEP ACTION Verify that the computer s hard disk has sufficient free memory space Uninstall a prior version before installing the new version of the PowerPlex Configuration Software
26. inuous current load output Power MOSFET high side switching max current rating 8 A 10 A adjustable from 1Ato8A 10Ain 1 A steps typical voltage drop Uon at rated current at 25 C 60 mV overload tripping range 1 01 1 30 x In Approvals Authority KBA Voltage ratings DC 12 24 V Ordering number PP C COM24 00E 0 Z 00 Table 5 Principal technical data For further information please see the relevant data sheet PowerPlex Compact Module 7 General Information PowerPlex Compact Module User Manual 4 2 Scope of Delivery By default contains the delivery of your PowerPlex Compact Module mounted e Housing of the module e Cover Additional you could order the following accessories e USB CAN converter e Stocko connector 2 3 4 5 pole e Different adapters GND e 120 Q terminating resistor 0102 O3 O4 O5 O6 O7 08 09 O10 O11 For further information please see the relevant data sheet or visit www e t a de 4 3 Inputs Outputs and Interfaces Figure 6 shows an overview about the connectors and interfaces from the PowerPlex Compact Module without snap on cover Figure 6 PowerPlex Compact Module without snap on cover INPUT WHAT TO TERMINALS CABLE PROTECTION amp STATUS OUTPUT CONNECT CONNECTION NDICATION COMMENTS INTERFACE COM1 CAN bus CAN bus cable come 4 pole stocko connector SAE J1939 protocol LIN bus LIN bus cable COM3 RS232 l1 16 2 pole stocko connec
27. n the menu bar offers all the commands necessary to change system and program settings Options Test Help Display editor Default dtl Tell mu za 1 USO ay BOOT i NEW Creates a new PowerPlex configuration LOAD Loads an existing configuration for further modification IMPORT Imports a configuration previously exported and saved in mux file format SAVE Saves the edited configuration under the specified name Note that a newly created configuration can only be saved after its first module has been inserted SAVE AS Saves the edited configuration under a new name EXPORT Exports the configuration to a file in mux format TRANSMIT Transmits the edited configuration to the PowerPlex hardware modules PRINT Takes you to a selection dialog in which you select the documents you wish to print out EXIT LANGUAGE Closes the PowerPlex program after having reminded you to save your modifications Select the language of the Graphical User Interface GUI of the configuration software The language changes during online mode DISPLAY EDITOR Opens the Display editor which assists you in designing the texts and screens to be displayed on the connected touch screen Update firmware Delete module configuration Change project file Create new project CAN interface CHANGE MODULE ADDRESSES Gives you access to the hardware modules in order to
28. nstallation direct and alternating current DC AC used adequate isolation must be ensured 10 PowerPlex Compact Module User Manual Mountin 5 5 Required Dimensions PowerPlex modules are intended for wall mounting The PowerPlex Compact Module is mounted from the front onto the prepared mounting plate For mounting we recommend M4 cylinder head bolt The required dimensions are shown in Figure 7 2x M4 cylinder head bolt Plus terminal Minus terminal 7 hexagon socket MSx hexagon socket 10 in delivery included in delivery max tightening torque 2 2 Nm max tightening torque 2 2 Nm Figure 7 Overview for mounting The cables are connected from the side and or from below This should be considered during the planning and ensures easy installation without a possible bending of the cable According to the EMC conditions should always sufficient space between the various electrical devices The necessary space requirement of the PowerPlex Compact Module is shown in Figure 8 PowerPlex Compact Module 11 Mounting User Manual CLE ELLE EEE EELS EEE ala pia ee ee ee ee No 15 311 12 20 Figure 8 Installation drawings 5 6 Mounting of the Module The PowerPlex Compact Modules requires no separate cutout at the installation location Before you start the installation make sure that Thelocation was selected in consideration of product specific requirements e ca
29. nstalled in vehicles During the development of the PowerPlex Compact module was especially taken to ensure that it meets the specific requirements in special vehicles and watercraft and optimally complement the PowerPlex system Especially the PowerPlex Compact Module provides outputs for dimming of electrical loads are also available The PowerPlex Compact Module offers eight power outputs with up to 8 A or 10 A depending on the configuration You can connect switches push buttons lamps and other appliances to a PowerPlex Compact Module Figure 5 PowerPlex8 Compact Module 4 1 Technical Data The following table shows which principal features the PowerPlex Compact Module has TECHNICAL DATA Voltage rating DC 12 V DC 24V Operating voltage 9 33V DC Totoal current max 60 A per module Operating temperature range 30 50 C 4 122 F Storage temperature range 30 85 C 22 185 F Protection class IP20 coated PCB CAN according to SAE J1939 250 kBit s Mass Approx 380 g Inputs 10 digital inputs 0 50 O ON gt 100 kO OFF 4 analoge inputs 1 for capacitive level monitoring 0 4 V with external DC supply max 100 mA Rin 40 kO resolution 10 bit 1 for temperature monitoring for KTY13 6 1 for battery monitoring via external shunt resistor measuring range 60 mV 1 for four point level indication Outputs 10 outputs with 8 A 10 A max cont
30. o be connected to each other Figure 9Fehler Verweisquelle konnte nicht gefunden werden A CAN bus must be terminated with a 120 Q resistor at the beginning and at the end of the bus Terminating resistors are not included in a Compact Module If the module is operating as first or last node at 120 Q Abschlusswiderstand the CAN bus a 120 O terminating resistor GAN BG reowerrlex Touch Panel 7 0 120Q Abschlusswiderstand CAN Bus is to be considered chapter 9 CAN USB Converter and Driver Software Figure 9 PowerPlex components in a CAN bus system A typical CAN bus cable is a twisted pair cable comprising two wires CAN H and CAN L and the shield wire SHLD Table 12 lists the principal characteristics of the type of CAN bus cable to be used The following specifications are those of a typical CAN bus cable type CAN BUS 1X2X0 50 HOC as supplied by HELUKABEL www helukabel de MECHANICAL PROPERTIES Inner conductor diameter 0 97 mm Conductor nominal cross sectional area 0 5 mm Conductor material copper bare Conductor class Class 2 stranded Number of cores 2 Total shielding CU braid tinned Core colors CAN H White wh CAN L Brown bn Cable external diameter 7 0 mm Outer sheath color violet Mass 69 kg km Minimum bending radius laying 90 mm static 48 mm Operation temperature ELECTRICAL PROPE
31. on your windows based computer chapter 8 2 Installing the Software Table 14 Computer Check PowerPlex Compact Module 15 PowerPlex amp Configuration Software User Manual NOTE You have to have administrator access rights to be able to install the PowerPlex Configuration Software 8 2 Installing the Software The PowerPlex Configuration Software can be downloaded directly online via the E T A website For this purpose the username and password are required to be made on request Upon request we provide the configuration software also provides a USB stick The PowerPlex Configuration Software no longer requires you to run through an installation procedure The PowerPlex Configuration Software can also be started from a USB stick If an even earlier version of the PowerPlex Configuration Software is installed on your computer make sure to uninstall it before you use the newer version STEP Action Download the PowerPlex Configuration Software from the provided Internet address to a new folder on your computer s hard disk In the folder double click the software archive and extract all files to the same or a different folder Ms cse To start the PowerPlex Configuration Software look in the folder with the extracted program files and double click the POWERPLEX EXE PowerPlex Table 15 Installing the PowerPlex Configuration Software 8 3 Short Introduction First Steps The
32. onfiguration in tree form It navigates you through the configuration i e to modules inputs outputs input output assignments for editing Diagnostics window Displays diagnostics information during testing and debugging Parameters Displays important parameters of the selection Status bar Shows the status of the PowerPlex configuration e oaded or not loaded e X new but not yet saved e modified but not yet saved Scenario editor Assists you in the creation modification and deletion of switching scenarios Info window Displays information on program execution and the progress of data transmission It also informs about errors that may have occurred Table 16 Contents of the PowerPlex8 opening window 8 3 2 he Menu Bar The PowerPlex menu bar gives you access to all menus for editing configurations and setting program parameters in PowerPlex 4 1 1 PowerPlex Configuration Options Test Help ke s 5 b IP 59 L E Ly Figure 11 Menu bar PowerPlex Compact Module 17 PowerPlex amp Configuration Software THE PowerPlex CONFIGURATION MENU User Manual The PowerPlex Configuration menu provides you with all the commands you require to handle the configuration PowerPle Mew Load Import Save Save AS Export Transmit Opkions Umschalt Strg F3 Print Exit Sir Table 17 Configuration Menu THE OPTIONS MENU The Options menu i
33. onventions and Symbols The following conventions and symbols are used throughout this manual and are defined as follows Menu names and items text you must select in the PowerPlex Configuration Software such as menu items buttons and commands Words and characters you see on the screen when you are working with the PowerPlex ITALICS configuration software In some cases italics are used to emphasize a new term or an important fact NUMBERED indicate sequential steps for completing a procedure BOLD LISTS Information that is critical for successful application and understanding of the product is displayed on a light blue background indicates the progression of menu choices you should select in the graphical user interface GUI such as File Print IMPORTANT Table 1 Conventions used in this manual WARNING You are in a situation that could cause bodily injury Before you work on any equipment you must be aware of the hazards involved with electrical circuitry and be familiar with standard practices for preventing accidents CAUTION In this situation you might do something that could result in equipment damage or loss of data INFORMATION At this point you get an information which could be especially useful for the application Table 2 Symbols used in this manual PowerPlex Compact Module vii About this Manual User Manual viii PowerPlex Compact Module User Manual In
34. owerPlex modules and circuit breakers Volume 2 of the PowerPlex Manual Box gives you step by step instructions on how to install the system Here you find out where and how to mount the PowerPlex Power Modules and the PowerPlex Panel Modules how to wire them up and how to connect the appliances and equipment you wish to control The final chapter summarizes the installation instructions and provides you with a Quick Installation Guide Volume 3 describes the PowerPlex Configuration Software and gives you step by step instructions on how to set up your PowerPlex system once the hardware has been properly installed We take you through all the dialog boxes and menus of the software and create a configuration example This example configuration shall be loaded into the PowerPlex hardware and tested A separate chapter is dedicated to special PowerPlex functions that allow you to create a highly sophisticated CAN bus based control system for the boat s entire electrical equipment PowerPlex Compact Module About this Manual User Manual Qualified Personnel The PowerPlex Compact Module may only be installed connected and set up in conjunction with this documentation Commissioning and operation of a device system may only be performed by qualified personnel Within the context of the safety notes in this documentation qualified persons are defined as persons who are authorized to commission ground and label devices systems and cir
35. ransmitted to Module 2 over the CAN bus As soon as the measured bilge level i e the analog input value exceeds a predefined limit value Module 2 sends a switching command to the load i e the Bilge pump to switch on the pump and empty the bilge to an acceptable level Information on the bilge pump status can be sent back to Module 1 to light up the visual Bilge pump running indicator Module 2 monitors the position of a light switch ON or OFF at one of its digital inputs sends this switch signal to Module 1 which switches the light ON or OFF depending on the switch position 4 PowerPlex Compact Module User Manual PowerPlex amp System General Characteristic Bilge level sensor Light switch Inputs Module 2 Module 1 Bilge pump running Outputs Lamp Outputs Bilge pump CAN Bus Figure 3 Minimum PowerPlex System design two PowerPlex modules connected via CAN bus cable The example illustrates the principle of applying sensor and switch signal information to the module inputs and sending switching or indicating commands to the outputs of the same or another module A typical PowerPlex control system will of course interconnect a much larger number of modules and their inputs and outputs which are distributed over the entire vehicle Figure 5 illustrates the electrical connection of several PowerPlex modules in a serial CAN bus topology Each module must be conn
36. re serial connections Therefore the key components of the PowerPlex system are such nodes distributed over the Mm vehicle The PowerPlex term for these interconnected nodes is module Figure 1 Exemplary PowerPlex amp system design in an ambulance vehicle To install and setup a PowerPlex system are different hardware components necessary e One or more PowerPlex modules e g PowerPlex Power Module PowerPlex Compact Module in care and attention of the module specific requirements e USB CAN Converter cable and driver software for transferring the configuration gt more in chapter 9 e USB cable for the USB service interface for transferring application specific user interfaces to PowerPlex Touch Panels You also need CAN bus cables to connect the PowerPlex components to the CAN bus A number of manufacturers provide standard cables Further information about required cable properties in chapter 7 of the manual PowerPlex connects regulates controls and monitors a wide variety of loads switches and sensors over CAN precisely and securely It controls status functions operating modes and command executions Ideally matched software and hardware components provide a total solution with an enormous potential for individual customization Each PowerPlex module protect loads and harness against overcurrent In addition the modules are used to collect sensor data from level and temperature sensors as well as shunt re
37. rface The opening WINKOW ccccccsseeceeeeeeeeeeeeeaaeeeeeeeessaeeeceeessaaeeeeeessaaeeeess 17 Figure Wal MENU Dar MEER EE 17 FIGUR 122 TOO MD AN NR UE 19 Figure 13 CAN USB converter cable example Peak cccccscssccceceeeeseeeeeeeeeseeeeceeeeseeeeesaaeeeeeessaaeeeeeesaaaeeeess 19 List of Tables Table 1 Conventions used in this Tan sins i sea slan nan niv ind a bna wa ba rina k n saa n v nennen nnn bay nnns seas wa le na hen ka vii Table 2 Symbols used in this manual uus2202u0ssssnnnesnennnennnnnnennnnnnennennnnnnnnnnennnnnnnnnnnnnnnnnnnnnennnnnnne KA KK KK A KA vii Table 3 Accessories to complete the PowerPlex system ccccccccccceseeeeeceeeceeceesceeceeeeeeceeeceeseaseeessaeeeessaaeees 3 Table 4 Different PowerPlex modules 0022200002000000000nnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnne nennen KK KA anne sna inris 4 Table 5 Principal technical data 2u00220200esnennnennnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnennnnnnennenn 7 Table 6 Inputs outputs and interfaces of PowerPlex amp Compact Module E Eii EEE 8 Table 7 Mounting Checklisten Em T 9 Table 8 Requirements for the installation location seeeesseeeessseeessseeeee nennen KAK KK k 10 Table 9 Pr cautions On WIG TT c 10 Table 10 Mounting
38. sistors Your PowerPlex system will most probably comprise a certain number of each module type depending on the size of the electrical system you wish to monitor and control and on the current rating of the loads you wish to switch Use the PowerPlex Configuration Software to program different control configurations save them on the computer and load them into different PowerPlex control systems as required Once a PowerPlex configuration has been completed it is loaded into the PowerPlex modules also called nodes using a CAN bus interface It is also over this CAN bus interface that you connect the PowerPlex Software when you want to test analyses and debug the PowerPlex installation 2 PowerPlex Compact Module User Manual System Components Overview In Figure 2 you see our complete PowerPlex product range for designing your PowerPlex system solution DC 12 V124 V AC 122 VI2320 V E g g Power Fanel Compact Mini Power Modul Power Madul Modul Modul Modul Modul wall mouni fiush mount Firmware Configuration SW Bedienger te Power Key Pro Keypad Seren Touch Panel4 2 Touch Panel 7 0 Touch FC 12 Figure 2 Design your PowerPlex system PowerPlex components Other components which are necessary to get a functional system are in Table 3 specified ACCESSORIES DESCRIPTION POWERPLEX CONFIGURATION SOFTWARE Windows based configuration software for defining the addresses charac
39. teristics and functions of the PowerPlex modules assigning inputs and outputs to them and carrying out system tests and analysis CAN USB CONVERTER PLUS DRIVER SOFTWARE CAN USB adapter to connect the CAN bus hardware to the USB interface of the computer running the PowerPlex configuration software and or to the USB interface of a touch panel that might be connected to the system N G TERMINATING RESISTORS r Qu Two 120 resistors terminate the CAN bus network one at each end of the bus structure CAN BUS Kabel CAN BUS CABLE gt A standard twisted pair CAN bus cable comprising two wires CAN H and CAN L and the shield SHLD connects two PowerPlex modules to each other VOLTAGE SUPPLY 12 V DC or 24 V DC battery voltage supply LINE PROTECTION Protection of the L connection from the PowerPlex module to the battery or the bus Recommended E T A thermo magnetic circuit breaker type 8345 Table 3 Accessories to complete the PowerPlex amp system PowerPlex Compact Module PowerPlex amp System General Characteristic User Manual 3 PowerPlex System General Characteristic 3 1 PowerPlex Modules PowerPlex modules are the key components of the PowerPlex control network According to CAN bus terminology they are the nodes in the network and form the switching relaying and control points PowerPlex for DC systems incorporates high end power semiconductors with integrated protective
40. tor Control inputs switching to ground Switch pushbutton I9 amp 110 I7 amp l8 2 pole stocko connector Control inputs switching to ground or to positive configurable Level sensor S1 5 pole stocko connector Four point level indication Load control S2 4 pole stocko connector Battery monitor S3 3 pole stocko connector battery monitoring via external shunt resistor Temperature sensor S4 2 pole stocko connector temperature monitoring for KTY13 6 Level sensor Step less Input digital Input analog S5 5 pole stocko connector capacitive level monitoring Short circuit and overload proof Current limiting and electronic safety disconnection ensured by semiconductor blade terminals 6 3 mm components used in the modules female connectors not included in delivery Serrated lock washer and washer included in delivery Cable lug up to max 16 mm usable not included in delivery blade terminals 6 3 mm Output Power Loads 8A 10A 8A 10A max DC 12 V or DC 24V Min DC 9 V Max DC 32V terminal terminal Voltage hexagon socket M5x10 supply Table 6 Inputs outputs and interfaces of PowerPlex Compact Module CAUTION To avoid accidental short circuits make sure that the module is disconnected from the power supply before you make any connections 8 PowerPlex Compact Module User Manual Mounting o Mounting The PowerPlex Compact Module is
41. troduction 1 Introduction PowerPlex is a decentralized electrical power distribution system All PowerPlex Modules ensure alone or in combination with other PowerPlex components reliable control and monitoring of all installed electrical devices and functions They protect loads and harness against overcurrent In addition the modules are used to collect sensor data from level and temperature sensors as well as shunt resistors Outputs for dimming of electrical loads are also available Particularly in combination with a connected Touch PC or PowerPlex Touch Panel PowerPlex provides easy and fast access to alarm information and operation hours counts which facilitates service and maintenance jobs All modules of a PowerPlex system are communicating via CAN bus using a SAE J1939 based protocol PowerPlex can be configured directly by the vehicle manufacturer using the PowerPlex Configuration Software on a standard PC The configuration is transferred to the modules via the CAN bus using a USB CAN adapter Thanks to its system properties PowerPlex is the perfect solution for smart electrical systems in boats and vehicles Typical applications are e Buses special vehicles camper caravans etc e Watercraft e g recreational boats and workboats BENEFITS FOR THE OEM The E T A PowerPlex system provides switching and controlling timer functions real load status indication overcurrent protection and wire break detection Each
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