EH2244A. Datasheet. Copyright ECOTRONS LLC. Vehicle Control Unit for Electric & Hybrid Vehicles V2.2. Revision History. All Rights Reserved

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1 EH2244A Datasheet V2.1 EH2244A Vehicle Control Unit for Electric & Hybrid Vehicles Datasheet V2.2 Revision History Copyright ECOTRONS LLC All Rights Reserved

2 Date Revision Description Nov V 1.0 First release April V 2.0 May. 9 th, 2018 V2.1 Minor revision on Pin description and Function description. May. 25 th, 2018 V2.2 Revised Chapter 4 to adapt to upgraded hardware Contact US: Web: info@ecotrons.com Copyright ECOTRONS LLC Page 2

3 Table of Contents Chapter 1 General Information Introduction Features... 5 Chapter 2 Mechanical Installation Mechanical dimensions Connectors Housing parameters... 8 Chapter 3 Hardware Parameters Hardware features Specifications Test standards Environment test standards EMC test standards Electrical performance test standards Chapter 4 Connector Pinouts Connector view Pinout and functions Chapter 5 Function Description Power-down delay Digital inputs Analog inputs Frequency inputs Low-side switch High-side switch H-bridge driver FlexRay Copyright ECOTRONS LLC Page 3

4 5.9 Communication module Basic introduction CAN wakeup function Torque safety monitoring module Controller hardware diagnosis Chip-level diagnosis Low-side switch diagnosis High-side switch diagnosis H-bridge driver diagnosis Chapter 6 Software Compatibility Production code generation - EcoCoder Powerful calibration software EcoCAL Reprogramming tool EcoFlash Copyright ECOTRONS LLC Page 4

5 Chapter 1 General Information 1.1 Introduction Vehicle Control Unit, or VCU, or Hybrid Control Unit, or HCU, is the core controller for an electric or hybrid vehicle. HCU receives the driver input signals, like pedal inputs, vehicle speed signals, and other inputs, manages the system energy, commands the driver demanded torque, coordinates the motor, battery pack, as well as the conventional powertrain in case of hybrid vehicles, and determines the overall vehicle drivability. HCU is the master of the vehicle control network, or CAN bus based network. 1.2 Features HCU is designed with ISO26262 function safety in mind, and comes with a main chip and a monitor chip built-in, for safety monitoring. HCU comes with the basic software, or BSW, support all typical input / output drivers for vehicle controls. The BSW is encapsulated in the MATLAB/Simulink environment, and the user can develop the control system with 100% model-based-design methods. The HCU hardware is abstracted from the application software and relieves the controls engineer from the challenge of the microprocessor configuration and embedded real-time software. HCU comes with a CAN bus based reprogramming tool, supported by our boot loader which is pre-programmed into the microprocessor. With some software configuration, Ecotrons HCU can be compatible with INCA, CANape, or any CCP based calibration tool. Copyright ECOTRONS LLC Page 5

6 Chapter 2 Mechanical Installation 2.1 Mechanical dimensions The housing dimensions are 207 x 150 x 36 mm. The housing color is silver, made of die-cast aluminum. Copyright ECOTRONS LLC Page 6

7 Copyright ECOTRONS LLC Page 7

8 2.2 Connectors HCU uses the automotive industry rated, "Tyco" brand, connectors. The connector meets the auto safety requirements. The connector has 121 pins total. The following table lists the connector model numbers. No. Name Type Supplier 1 81P sheath TE 2 40P sheath TE 3 Terminal(big) TE 4 Terminal(small) TE 5 81P back TE 6 40P back TE 2.3 Housing parameters Housing size: mm Materials:Die - casting aluminum Waterproof 121-pin connector Good rigidity waterproof breathable vent, good heat dissipation Copyright ECOTRONS LLC Page 8

9 Chapter 3 Hardware Parameters 3.1 Hardware features Main microprocessor Freescale SPC56xx: 150MHz, Flash 4MB, SRAM 192K, float point capable; Monitor microprocessor Freescale S9S08: automotive rated 8-bit low-cost microprocessor; CAN bus: 3 channels; Support CANA wakeup; Sensor 5v supply: 3 channels, each channel supports load up to 100 ma; Analog inputs: 30 channels, 12-bit ADC, support 13 channels 0-5v inputs, 17 channels 0-36V inputs; Digital inputs: 7 channels, 5 channels of low effective, 2 channels of high effective; Frequency inputs: 5 channels; Low-side driver: 18 channels, with 16 channels maximum current equaled to 250mA, 2 channels maximum current equaled to 5A. 2 channels could be configured as PWM output; High-side driver: 8 channels with rated current at 1A and maximum 1.5A, 2 channels could be configured as PWM output; H-bridge driver: 2 H-bridges, single maximum current is 7A, with current limit capability; FlexRay: Public version has no Flexray, but it could be provided with customer order. Copyright ECOTRONS LLC Page 9

10 3.2 Specifications name Supply voltage parameters DC 12/24V(9~32V) Working temperature -40~85 Humidity 0~95%, no condensation Storage temperature -40~85 Protection Mechanical shock Expected life Electric performance EMC Dimensions Weight IP67 Peak value is 50g 10 years ISO16750, ISO7637 standards CISPR mm 600g 3.3 Test standards Environment test standards Test items High and low temperature test Temperature shock Charged temperature cycle Test standard ISO ISO ISO Specific indicators hour hour +125 ~ circulation + 20 C to -40 C to + 85 C, for a total of 30 cycles per 8 hours Splash test ISO After standing at 85 C for 1 hour, the mixture was Copyright ECOTRONS LLC Page 10

11 sprayed with water at 0 C to 4 C for 10 s, followed by 100 cycles Salt spray test ISO Salt solution concentration: 5%, spray sedimentation rate: 1 ~ 2ml / (80cm2 * h). The test was performed in 4 cycles, each lasting 7 days, for a total of 28 days. Dustproof and ISO m deep water, placed for 30 minutes, IP67. waterproof test Vibration test ISO The frequency of random vibration is 20 ~ 2000Hz, the root mean square value of the spectrum is 107.3m / s2, the vibration time of X, Y, Z is 8h. Mechanical shock ISO The peak value is 50g, the duration for three-axis six-way half-sine impact is 6ms, each 10 times. Constant temperature and ISO Temperature +40 Humidity 85% RH normal work for 21 days humidity Temperature and humidity cycle ISO Low temperature operation and temperature + 23 humidity 93% RH cycle, 24 hours per cycle, 10 cycles EMC test standards Test items Test standard Specific indicators Conducted interference from electronic IEC CISPR AV and PK meet the four requirements components Radiated interference from electronic components IEC CISPR AV and PK meet the four requirements Radiated immunity of GMW Frequency Range: Modulation Copyright ECOTRONS LLC Page 11

12 electronic components to magnetic fields Electronic components of the electromagnetic field immunity (BCI) CI power supply transient interference CI on the signal line transient interference Electrostatic discharge (non-live mode) Electrostatic discharge (remote charge mode) GMW ISO ISO GMW GMW EH2244A Datasheet V2.2 Mode; Intensity: LEVEL2, Function Level A. Frequency Range: Modulation Mode; Intensity: LEVEL2, Function Level A. Function level A / C Function level A Discharge network: C=150pF R=2kΩ Discharge network: C=330pF R=2kΩ Electrical performance test standards Test items Test specification Over - voltage test 36V for 60 minutes Reverse polarity protection -28 V for 60 ± 6 s test AC voltage superposition test Umax = 32V, Upp 4V for 5 cycles Supply voltage slow down test Umin = 18V linearly decreases to 0V at a rate of 1V ± 0.1 / min, and then changes from 0V to Umin = 18V Voltage transient drop test Umin = 18V, down to 9V, continued for 10ms and then rise. Rise, fall time does not exceed 10ms Reset performance test The supply voltage Umin = 18V reduced by 5% and maintained for 5s, and then restore the supply voltage to Umin = 18V for at least 10s; Repeat the above steps, Copyright ECOTRONS LLC Page 12

13 each time, the voltage reduction increased by 5%, until down to 0%, and then restore power supply Umin = 18V. Starting voltage test Power drift test Ground drift test Quiescent current measurement test Single - wire open circuit test Multi - line open circuit test Simulation of vehicle startup, the voltage fluctuation of the state: the voltage dropped to 12V and continued for 15ms and then returned to normal Simulation of two or more groups of power supply, there are different power supply on the product Simulation of two or more groups of power supply, there is a different impact on the product situation Average quiescent current 1mA Then disconnect the sample interface connection, each disconnect time to maintain 10 ± 1s, and then restore the connection of the line Disconnect the sample harness connector, disconnect the time to maintain 10 ± 1s, and then restore the connection of the line Copyright ECOTRONS LLC Page 13

14 Chapter 4 Connector Pinouts 4.1 Connector view The connector has a double row of total 121 pins. The pin numbers are arranged as below. 4.2 Pinout and functions ID Pin # Name Description Remarks 5V1 51 5V supply 1 5V Sensor supply 5V2 41 5V supply 2 5V Sensor supply 5V3 49 5V supply 3 5V Sensor supply Maximum current is 100mA Maximum current is 100mA Maximum current is 100mA A00 15 Analog input0 Pull up 10K Voltage Range: 0-5V A01 34 Analog input1 A02 16 Analog input2 Pull up 10K Voltage Range: 0-5V Voltage Range: 0-5V Copyright ECOTRONS LLC Page 14

15 Pull up 10K EH2244A Datasheet V2.2 A03 35 Analog input3 A04 17 Analog input4 A05 36 Analog input5 A06 18 Analog input6 A07 37 Analog input7 A08 31 Analog input8 A09 71 Analog input9 A11 32 Analog input11 A12 24 Analog input12 A13 43 Analog input13 Pull up 10K Pull up 10K Pull up 10K R_divider=100K R_pull_down=16K R_divider=100K R_pull_down=16K R_divider=100K R_pull_down=16K R_divider=100K R_pull_down=16K Pull up 1K R_divider=100K R_pull_down=16K Voltage Range: 0-5V Voltage Range: 0-5V Voltage Range: 0-5V Voltage Range: 0-5V Copyright ECOTRONS LLC Page 15

16 A16 13 Analog input16 A17 52 Analog input17 A18 33 Analog input18 A21 53 Analog input21 A22 10 Analog input22 A23 38 Analog input23 A24 20 Analog input24 A25 39 Analog input25 A30 22 Analog input30 R_divider=100K R_pull_down=16K Pull up 10K R_divider=100K R_pull_down=16K R_divider=100K R_pull_down=16K R_divider=100K R_pull_down=16K R_divider=100K R_pull_down=16K R_divider=100K R_pull_down=16K Pull up 1K R_divider=100K R_pull_down=16K Voltage Range: 0-5V Voltage Range: 0-5V Voltage Range: 0-5V Copyright ECOTRONS LLC Page 16

17 A31 79 Analog input31 Pull up 10K AD R_divider=100K R_pull_down=16K Resolution=12 bit A32 42 Analog input32 A33 23 Analog input33 R_divider=100K R_pull_down=16K Pull up 10K Voltage Range: 0-5V A34 61 Analog input34 R_divider=100K R_pull_down=16K A35 80 Analog input35 R_divider=100K R_pull_down=16K A36 72 Analog input36 A37 14 Analog input37 R_divider=100K R_pull_down=16K Pull up 10 Voltage Range: 0-5V A39 12 Analog input39 Pull up 10K Voltage Range: 0-5V KEYON 59 KEYON High Effective Analog input type, 10V Copyright ECOTRONS LLC Page 17

18 WAKE UP1 62 AC Wakeup signal, charger High Effective Analog input type, detector 10V WAKE UP2 81 DC Wakeup signal, charger High Effective Analog input type, detector 10V CANA SHILD 75 CANA Shielded cable CANAH 56 CANAH CANA signal CANAL 55 CANAL CANA signal CANB SHILD 77 CANB Shielded cable CANBH 57 CANBH CANB signal CANBL 76 CANBL CANB signal CANC SHILD 74 CANC Shielded cable CANCH 54 CANCH CANC signal CANCL 73 CANCL CANC signal LIN_BUS1 78 LIN Bus DI01 40 Digital input1 Low Effective, 1.5V Voltage Range: 0-5V DI02 6 Digital input2 Low Effective, 1.5V Voltage Range: 0-5V DI03 25 Digital input3 Low Effective, 1.5V Voltage Range: 0-5V DI04 7 Digital input4 Low Effective, 1.5V Voltage Range: 0-5V DI05 8 Digital input5 Low Effective, 1.5V Voltage Range: 0-5V DI06 65 Digital input6 High Effective, 9V Voltage Range: 0-24V DI07 46 Digital input7 High Effective, 9V Voltage Range: 0-24V GND 48 Signal ground Copyright ECOTRONS LLC Page 18

19 GND 2 Power ground EH2244A Datasheet V2.2 GND GND Power ground Power ground GND 4 Signal ground GND 5 Signal ground GND 58 Signal ground GND 60 Signal ground GND 70 Signal ground Hbridge1A 11 8 H-bridge 1A Peak current7a Hbridge1B 11 4 H-bridge 1B Peak current7a Hbridge2A 11 5 H-bridge 2A Peak current7a Hbridge2B 11 7 H-bridge 2B Peak current7a HSO High-side driver 5 1A, Peak current1.5a HSO High-side driver 6 1A, Peak current1.5a HSO High-side driver 7 1A, Peak current1.5a HSO08 99 High-side driver 8 1A, Peak current1.5a HSO High-side driver 9 1A, Peak current1.5a Copyright ECOTRONS LLC Page 19

20 HSO10 98 High-side driver 10 1A, Peak current1.5a HSO11 94 High-side driver 11 1A, Peak current1.5a Can be configured as PWM output HSO12 86 High-side driver 12 1A, Peak current1.5a Can be configured as PWM output DRVP DRVP DRVP power of H-bridge 9-32V DRVP power of H-bridge 9-32V LSO Low-side dirver1 250mA LSO Low-side dirver2 250mA LSO Low-side dirver3 250mA LSO Low-side dirver4 250mA LSO Low-side dirver5 250mA LSO Low-side dirver6 250mA LSO Low-side dirver7 250mA LSO Low-side dirver8 250mA LSO09 91 Low-side dirver9 250mA LSO10 89 Low-side 250mA Copyright ECOTRONS LLC Page 20

21 dirver10 EH2244A Datasheet V2.2 LSO11 92 LSO12 95 LSO13 97 LSO14 90 LSO15 96 LSO16 93 Low-side dirver11 Low-side dirver12 Low-side dirver13 Low-side dirver14 Low-side dirver15 Low-side dirver16 250mA 250mA 250mA 250mA 250mA 250mA LSO Low-side dirver17 5A Can be configured as PWM output LSO Low-side dirver18 5A Can be configured as PWM output SPEED1 64 SPEED2 47 SPEED3 66 SPEED4 11 SPEED5 30 Frequency input1 Frequency input2 Frequency input3 Frequency input4 Frequency input5 Maximum frequency 10KHz Maximum frequency 10KHz Maximum frequency 10KHz Maximum frequency 10KHz Maximum frequency 10KHz EXT_ERAY_ 9 FlexRay Copyright ECOTRONS LLC Page 21

22 B_P EXT_ERAY_ B_N 28 (Upgradable) FlexRay (Upgradable) EH2244A Datasheet V NC 68 NC 19 NC 21 NC 26 NC 27 NC 29 NC 44 NC 45 NC 50 NC 63 NC 69 NC 82 NC 83 NC 84 NC 85 NC 87 NC 88 NC Copyright ECOTRONS LLC Page 22

23 Chapter 5 Function Description 5.1 Power-down delay The power-down delay of HCU can be controlled by an internal circuit. The "power-down delay" or "after-run" function, is often needed for control application, where the system need to do some "housing keeping" jobs, after the user keys off the vehicle. For example, the controller will store the critical data into non-volatile memory, or NVM. It is controlled by the internal switch "Power Delay", when the level of CAN _INH, LIN Wake, KEYON, WAKE UP1, WAKE UP2 and the internal Power Delay has a high level, the switch SW1 is turned on. Specific implementation of software: If the external logic level is high, the level of Power Delay is controlled by the internal to high, while the external logic input is low, it will delay for a period of time to turn the level of Power Delay to low. BATT1 CAN_INH LIN Wake KEYON A14 A15 OR OR SW1 VPWR PowerDelay Copyright ECOTRONS LLC Page 23

24 5.2 Digital inputs The digital input module has 7 channels. DI1-DI5 is by default valid for low level input, and DI6-DI7 is by default valid for high level input. 5V R Filter GPIO Switching signal Low level input valid VPWR Switching signal Filter GPIO R High level input valid Copyright ECOTRONS LLC Page 24

25 5.3 Analog inputs The analog input module has 30 channels. It has 13 channels with 0-5V inputs and are built-in pull-up resistors, it has 17 channels with 0-36V inputs and are built-in pull-down resistors. All channels have 5V reference voltage which follows voltage of main chip. 5V R Filter AD Signal input Pull up Filter AD R Signal input Pull down Copyright ECOTRONS LLC Page 25

26 5.4 Frequency inputs The Frequency input module has 5 channels, and supports optional pull-up and pull-down resistor. The default configuration is pull-down resistor. The user doesn t need to add an external pull-up (down) resistor because the frequency input module has integrated pull-up (down) resistors. VPWR R Filter IPWM pull-up 过滤器 IPWM R pull-down 5.5 Low-side switch HCU provides 18 Low side switching channels with over-current protection, over-temperature protection and over-voltage protection. 16 channels have 250mA drive current capability, and they can detect the load open / short circuit and other Copyright ECOTRONS LLC Page 26

27 failures. 2 channels have 5A drive current capability, and they can t detect the load state. And LSO17, LSO18 support PWM output, and you can run pumps and so on. Please refer to the chapter for low-side switch diagnosis. 5.6 High-side switch High side switch module provides 8 high side switch channels with short circuit protection, over-temperature protection and over-voltage protection, the maximum current is 1.5A. HSO11, HSO12 can be configured to PWM control modes. Please refer to the chapter for high-side switch diagnosis. Copyright ECOTRONS LLC Page 27

28 5.7 H-bridge driver HCU has TWO built-in H-bridge. It has two outputs, and the maximum current support is 7A, with current limiting function. It can be configured to switch mode, or PWM mode. 5.8 FlexRay HCU provides an upgrade option, one channel FlexRay. It has faster data rates, more flexible data communications, more comprehensive topology selection and fault-tolerant computing. FlexRay also provides reliability features that many CAN networks do not have. In particular, the redundant communication capabilities of FlexRay enable complete replication of network configuration through hardware and progress monitoring. In addition, FlexRay can perform synchronous (real-time) and asynchronous data transmission to meet the needs of various systems in vehicle. Copyright ECOTRONS LLC Page 28

29 5.9 Communication module Basic introduction CAN communication module provides three CAN channels, CANA, CANB, CANC; and all of them are CAN2.0B high speed bus. CANA and CANC have a default terminal resistance, CANB does not. PC 120Ω CANCH CANCL Driver Driver Driver CAN Bus 120Ω CANAH CANAL CANBH CANBL CAN Bus CANH CANL CANH CANL CANH CANL CANH CANL 120Ω 120Ω 120Ω CAN Node CAN Node CAN Node CAN Node CAN wakeup function CANA support CAN wakeup function, VCU can be waked up by CANA. When KEYON signal is off, the VCU is power down. If other nodes send messages to CANA bus, the VCU will be waked up after receive messages, then VCU goes into working mode. CAN wakeup function can be used for VCU remote wakeup from other nodes, or from remote intelligent terminal. Copyright ECOTRONS LLC Page 29

30 5.10 Torque safety monitoring module The design of HCU is based on advanced safety monitoring concept. It uses master-slave chip architecture to assure the safety of the system, as shown in Figure, the master chip is a 32-bit microcontroller SPC56xx, the slave chip is an 8-bit S9S08 automotive chip. Three-level architecture Level 1:Vehicle control functions, including all vehicle control functions and fault diagnosis. Level 2:this is to monitor the Level 1 by a redundancy design, and it is independent to the Level 1. If there is discrepancy between Level 2 and the Level 1, Level 2 will make the torque command in the CAN bus message Neutral. Neutral means no hazard acceleration. Level 3:By adding a slave chip to monitor the master controller, the 2 chips cross check each other. If the handshake fails, it will neutralize the torque command, so it does not Copyright ECOTRONS LLC Page 30

31 create hazard situation Controller hardware diagnosis Chip-level diagnosis Support Flash and RAM diagnostics of the master chip. Support kernel self-test diagnostics of the master chip. Support diagnosis of the slave chip Low-side switch diagnosis LSO1-LSO16 are the output channels of an integrated chip-driven. These channels support the fault diagnosis function. The fault diagnosis is based on the integrated chip diagnosis. Low-side drive LSO17, LSO18 use a circuit driver, and don t support low side drive circuit fault diagnosis. Using the integrated chip with the diagnostic function, you can read the chip fault information through SPI communication High-side switch diagnosis The high side drive circuit output channel is HSO5-HSO12, and all channels don t support high side drive circuit fault diagnosis H-bridge driver diagnosis H-bridge circuit fault diagnosis uses the integrated chip with the diagnostic function, you can read the chip fault information through SPI communication. Copyright ECOTRONS LLC Page 31

32 Chapter 6 Software Compatibility MATLAB/Simulink based software development environment. Model based design. Enhanced Auto code generation EcoCoder. o Refer to " EcoCoder Manual". Hardware encapsulation and abstraction One click compile and make process. CCP/XCP protocols. Powerful calibration tool EcoCAL. o Refer to " EcoCAL manual for EV ". Commercial compiler Code Warrior. Compatibility with INCA, CANape calibration software. CAN bus based boot loader EcoFlash tool. o Refer to " EcoFlash Manual". Copyright ECOTRONS LLC Page 32

33 6.1 Production code generation - EcoCoder EcoCoder is an enhanced auto code generation library added on top of Simulink s generic Embedded Coder. It links the Simulink s models directly to the target, and it gives the user the capability to generate the production code by "ONE CLICK". Refer to "EcoCoder Manual" for details. Copyright ECOTRONS LLC Page 33

34 6.2 Powerful calibration software EcoCAL EcoCAL is a professional calibration tool, developed by Ecotrons. It is based on the CCP/XCP protocols, and uses the CAN bus for data communication. It parses the standard A2L files, and manages the calibration data in the format of S19 files, Mot file or CAL file. Refer to "EcoCAL manual for EV " for more details. Copyright ECOTRONS LLC Page 34

35 6.3 Reprogramming tool EcoFlash EcoFlash is a simple PC based GUI software tool to reprogram the controller, developed by Ecotrons, using CAN bus for reprogramming, with a typical boot loader pre-programmed in the microprocessor. Refer to "EcoFlash manual" for more details. Copyright ECOTRONS LLC Page 35