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Transcript
Research Pi Sigma Sebring System HARDWARE REFERENCE Pi Sigma Sebring System Hardware Reference Research Part Number: 29M-071306-3E April 2001 Pi and the Pi logo are trademarks of Pi Group Limited © Pi Research, 2001, and Pi Research Inc. 2001 1 Disclaimer Pi Research makes no representation or warranties of any kind whatsoever with respect to the contents hereof and specifically disclaims any implied warranties of merchantability or fitness for any particular purpose. Pi Research Limited shall not be liable for any errors contained herein or for incidental or consequential damages in connection with the furnishing, performance or use of the software, associated hardware, or this written material. Pi Research reserves the right to revise this publication from time to time, and to make changes in the content hereof without obligation to notify any person of such revision or changes. A copy of the Pi Research Terms and Conditions of Sale is available on request, and includes a declaration of the warranty and limitation of liability which apply to all Pi Research products and services. Health and Safety information Under the terms of European and UK Health and Safety Legislation, Pi Research is required to classify any hazardous materials in the products it supplies and to provide relevant safety information to users. Any hazardous materials in Pi products are clearly marked with appropriate symbols. Product Safety Data Sheets relating to these materials are available on request. 2 Pi Sigma Sebring System Hardware Reference General connector information ............................................................ 15 Deutsch Autosport connectors ..................................................... 15 Deutsch Autosport part numbering .............................................. 17 Deutsch Autosport Micro HE connectors ..................................... 19 Deutsch Autosport Micro HE part numbering .............................. 20 Lemo connectors .......................................................................... 21 Lemo parts numbering .................................................................. 22 Connecting the MCU3 ............................................................................ 26 MCU3 power requirements .......................................................... 27 Star points ..................................................................................... 27 Connecting systems ..................................................................... 28 Connecting the MCU3 and SCU3 to a vehicle battery ................ 29 Fitting a backup battery ................................................................ 32 ECU systems ................................................................................ 33 Installation information ......................................................................... 36 General points on fitting looms ..................................................... 36 General points on fitting the MCU3 and SCU3 ............................ 39 Installing the MCU3 ...................................................................... 40 MCU3 dimensions ........................................................................ 42 SCU3 dimensions ......................................................................... 43 Octal passive junction box dimensions ........................................ 44 3 Installation notes The MCU3 The SCU3 Specifications ......................................................................................... 13 MCU3 Specifications .................................................................... 13 SCU3 Specifications ..................................................................... 13 Part numbers ................................................................................ 14 I/O cards Installation notes System expansion Introduction .............................................................................................. 7 Pi Sigma Sebring System specification ......................................... 7 Typical system ................................................................................ 9 Index Contents The MCU3 MCU3 internal analog debug channels ............................................... 47 MCU3 internal analog debug channels ........................................ 47 MCU3 connectors .................................................................................. 48 MCU3 connector details ............................................................... 48 MCU3 lefthand 66-way connector ................................................ 49 MCU3 righthand 66-way connector .............................................. 50 MCU3 system connector .............................................................. 51 MCU3 Digital channels .......................................................................... 52 MCU3 Digital Group 1 .................................................................. 52 MCU3 Digital Group 2 .................................................................. 53 Details of Digital Groups 1 and 2 inputs ....................................... 53 MCU3 Digital Group 3 .................................................................. 56 MCU3 Digital Group 4 .................................................................. 56 MCU3 miscellaneous connections ...................................................... 57 Battery outputs ............................................................................. 57 Battery inputs ................................................................................ 57 Buffered outputs ........................................................................... 58 MCU3 communications links ................................................................ 59 Serial communication ports .......................................................... 59 Serial port 1 – Pit communications ............................................... 60 Serial port 2A – ECU input ........................................................... 61 Serial port 2B – Telemetry ............................................................ 61 Serial port 3 – ADR ....................................................................... 62 Serial port 4A – CAN switches to MCU3 ...................................... 62 Serial port 4B – MCU3 to Dash .................................................... 63 Serial port 5 – TMS receive and ELB transmit ............................. 63 System communications ...................................................................... 64 Debug port .................................................................................... 64 PiNet ............................................................................................. 65 4 Pi Sigma Sebring System Hardware Reference SCU3 internal analog debug channels ................................................ 75 SCU3 connectors ................................................................................... 76 SCU3 connector details ................................................................ 76 SCU3 Lefthand 55-way connector ............................................... 77 SCU3 Righthand 55-way connector ............................................. 78 SCU3 connections ................................................................................. 79 SCU3 Digital Group 1 ................................................................... 79 SCU3 Digital Group 2 ................................................................... 80 SCU3 system connections ........................................................... 80 Installation notes The MCU3 The SCU3 The SCU3 Communication connectors ................................................................. 66 Download connector ..................................................................... 66 Download lead .............................................................................. 68 Download path connections ......................................................... 69 PC Network ................................................................................... 70 5 System expansion I/O card connections ............................................................................. 87 Introduction ................................................................................... 87 Signal naming conventions .......................................................... 88 I/O card external connection details ............................................. 90 MCU3 Selectronic card connections ............................................ 91 MCU3 LVDT card connections ..................................................... 92 MCU3 Moog/LVDT card connections ........................................... 93 MCU3 Pressure scanner card connections ................................. 94 MCU3 CAN card connections ...................................................... 95 SCU3 Selectronic card connections ............................................. 96 SCU3 LVDT card connections ..................................................... 97 SCU3 Moog/LVDT card connections ........................................... 98 Index Input/Output (I/O) cards ........................................................................ 83 Selectronic I/O card ...................................................................... 84 The LVDT I/O card ....................................................................... 84 Moog/LVDT I/O card ..................................................................... 85 Pressure scanner I/O card ........................................................... 85 CAN I/O card ................................................................................ 86 I/O cards I/O cards SCU3 Pressure scanner card connections .................................. 99 SCU3 CAN card connections ..................................................... 100 System expansion Connecting sensors ............................................................................ 103 Connecting sensors to a Selectronics I/O card .......................... 105 Sensor wiring information .................................................................. 109 Connecting a single ended sensor to a single ended input ............................................................... 109 Connecting a single ended sensor to a differential ended input ........................................................ 110 Connecting a strain gauge to a differential input ....................... 111 Connecting an RTD .................................................................... 112 Connecting a current output sensor ........................................... 113 Connecting a voltage output sensor to a single ended input ............................................................... 114 Connecting a voltage output sensor to a differential ended input ........................................................ 115 Miscellaneous connectors .................................................................. 116 Octal passive junction box .......................................................... 116 Tire Monitoring System (TMS) connections ............................... 120 Telemetry connections ............................................................... 121 Dash connectors .................................................................................. 122 Compact dash connections ........................................................ 122 Steering wheel dash connections .............................................. 125 Index Index ...................................................................................................... 129 Contact information ............................................................................. 132 6 Pi Sigma Sebring System Hardware Reference Introduction The Pi Sigma Sebring System is built around modular components which have common mechanical and electrical connections. Pi Sigma Sebring units connect and communicate using a dual-redundant on-car network. Pi Sigma Sebring System sensors use a standard 5-pin connection for analog sensors. Pi Sigma Sebring System specification The standard specification for a Pi Sigma Sebring System is: ■ ■ ■ ■ ■ ■ ■ ■ Main Control Unit (MCU3) Looms: System loom, front system loom, front sensor loom and rear sensor loom Steering wheel dash or Compact dash and satellite modules 32-channel beacon system Two wheelspeed sensors 24 analog input channels 8 digital channels Laptop Ethernet PCMCIA network card Cost options ■ Slave Control Unit (SCU3) 7 MCU3 specification The MCU3 has the following specification: ■ ■ ■ ■ ■ ■ ■ ■ ■ 8MB fast SRAM PCMCIA logging memory Three Selectronic Input/Output (I/O) cards, giving 24 analog input channels Eight digital channels Dual redundant PiNet network ports to connect to other units in the System 10MB 10baseT ethernet download port Serial ports (RS422 and RS232) Switches to CAN port Dual redundant battery supply Three accelerometers (longitudinal, vertical and lateral). SCU3 specification The SCU3, which is a cost option, has the following specification: ■ ■ ■ ■ ■ 8 Three Selectronic I/O cards, giving 24 analog channels Four digital channels Serial port RS422 bidirectional (at the same baud rate for input and output) Dual redundant PiNet network ports to connect to other units in the System Dual redundant battery supply. Pi Sigma Sebring System Hardware Reference Typical system The standard Pi Sigma Sebring System can be expanded to include additional cost option systems such as the Pi Laser Ride Height System, the Pi Telemetry System and the Pi Tire Monitoring System. Additional Octal passive junction boxes can also be added. A typical Pi SIgma Sebring system schematic with some cost options is shown in the next figure. 9 8 extra analog inputs (cost option) SCU3 (cost option) Octal junction box (cost option) Octal expansion (cost option) Front System loom (cost option) Front sensor loom (8 analog inputs) Wheelspeed Wheelspeed Beacon Debug MCU3 to ECU Compact dash and Satellite modules Tire Monitoring System (cost option) Download OR Laser Ride Height System (cost option) Steering wheel dash (cost option) System loom Octal junction box Pi telemetry (cost option) Wheelspeed (cost option) Wheelspeed (cost option) Rear sensor loom (8 analog inputs) A typical Pi SIgma Sebring system showing some cost options 10 Pi Sigma Sebring System Hardware Reference Installation notes Installation notes Installation notes Specifications MCU3 Specifications Description Value Input Voltage Range Supply current Operating Temperature Range Storage Temperature Range Environmental Weight +9.0V to +18V 1.2A at 13.8V 0°C to +60°C –40°C to +120°C IP65 2.7 lbs (1220 grams) with 3 Selectronics I/O cards fitted SCU3 Specifications Description Value Input Voltage Range Supply current Operating Temperature Range Storage Temperature Range Environmental Weight +9.0V to +18V 0.6A at 13.8V 0°C to +60°C –40°C to +120°C IP65 1.0 lb (452 grams) with 3 Selectronic I/O cards fitted Installation notes 13 Part numbers Item Part Number Pi Sigma MCU3 Pi Sigma SCU3 Pi Sigma ACU4 Pi Sigma Long download lead Pi Sigma Short download lead Pi Sigma LVDT I/O card Pi Sigma Selectronic I/O card Pi Sigma MOOG/LVDT I/O card Pi Sigma Pressure scanner I/O card Pi Sigma Application Card Pi Sigma Octal Passive Junction box Steering wheel dash Pi Sigma Compact dash PCMCIA ethernet card Switches to CAN interface box 01M-601101* 01M-601003* 01M-600517* 04C-00263 04C-00264 25M-600384 25M-600080 25M-600072 25M-600272 25M-600128 01M-601061 01M-032290-B 01M-032247 31A-0055 01M-032245 * These Part Numbers identify a component without I/O cards fitted. You must then specifiy the I/O cards required for your configuration. 14 Pi Sigma Sebring System Hardware Reference The Pi Sigma Sebring System uses Deutsch Autosport and Deutsch Autosport Micro Harsh Environment connectors. Deutsch Autosport connectors Deutsch Autosport connectors are fitted to the Pi Sigma Sebring system components and looms. shell latch keyways Deutsch Autosport connector detail Deutsch Autosport connectors use a rotating sleeve to lock the two halves of the connector together. To connect Deutsch Autosport connectors: 1 2 3 4 Make sure that the two connectors are compatible by checking that the number of contacts and the position of the keyways is the same for both connectors. Align the keyways, and bring the two halves of the connector together. Apply light pressure to the connector as you slowly turn the knurled sleeve. When the latches connect with the sleeve, keep turning until you hear the sleeve click. Installation notes 15 Installation notes General connector information knurled sleeve latch Connecting a Deutsch Autosport connector Deutsch Autosport connector contacts The contacts of a Deutsch Autosport connector are labelled on the connector itself. The contact numbers are given on the outside and inside of the connector. 16 Pi Sigma Sebring System Hardware Reference The part number is made up using the AS range reference followed by the style, the shell size, the contact arrangement, the insert type and the shell keyway e.g. AS108-35PN. The modification code is only applicable if a special modification has been made to the connector. AS * ** – ** * * – *** Modification code Range reference Style: 0 = 2-hole flange receptacle (front fixing) 1 = Inline receptacle 2 = 2-hole box mount PCB receptacle 6 = Free plug 8 = Cap for plug 9 = Cap for receptacle Shell size Contact arrangement Insert type: P = pin, S = socket Shell keyways: N = Red (standard) A = Yellow (standard) D = Green (standard) B = Blue (alternative) C = Orange (alternative) U = Violet (Universal for test harnesses) Deutsch Autosport part numbering Installation notes 17 Installation notes Deutsch Autosport part numbering Autosport connector shell size and contact arrangements The shell size and contact arrangement are shown below. Three sizes of contact are available: size 22, size 20 and size 16. The table below shows which sizes can be fitted. 18 Shell size Contact arrangement Size 22 8 8 10 10 12 12 12 14 14 14 16 16 16 18 18 20 20 20 20 22 22 22 24 24 24 98 35 98 35 04 98 35 97 19 35 08 26 35 32 35 16 39 41 35 21 55 35 29 61 35 – 6 – 13 – – 22 – – 37 – – 55 – 66 – – – 79 – – 100 – – 128 Pi Sigma Sebring System Hardware Reference Number of contacts Size 20 Size 16 3 – 6 – – 10 – 8 19 – – 26 – 32 – – 37 41 – – 55 – – 61 – – – – 4 – – 4 – – 8 – – – – 16 2 – – 21 – – 29 – – Deutsch Autosport Micro Harsh Environment (HE) connectors are used on sensors, some components and sections of the System loom. Deutsch Autosport Micro HE connector shell styles The Deutsch Autosport Micro HE shell styles used in the Pi Sigma Sebring System loom and sensors are inline receptacles and free plugs. The inline receptacles are fitted with five socket contacts and the free plugs are fitted with five pin contacts. Inline receptacle - Shell style 1 Free plug - Shell style 6 heat shrink boot heat shrink boot colored ring (denotes keyway) latch locking mechanism colored ring (denotes keyway) Deutsch Autosport Micro HE connectors Deutsch Autosport Micro HE connector contacts The contact positions are counted from 1–5, with contact number 1 further identified with a white circle. Inline receptacle - type 1 1 Plug - type 6 1 outside view crimp view 1 1 crimp view outside view Counting Deutsch Autosport Micro HE contacts Installation notes 19 Installation notes Deutsch Autosport Micro HE connectors Deutsch Autosport Micro HE part numbering The part numbering system for the Deutsch Autosport Micro HE connectors is shown in the next figure. The part number is made up using the AS range reference followed by the style, the shell size, the contact arrangement, the insert type, the shell keyway and the letters HE e.g. AS606-05PN-HE. The modification code is only applicable if a special modification has been made to the connector. AS * 06 – 05 * * – HE – *** Range reference Modification code Harsh Environment Style: 0 = 2-hole flange receptacle 1 = Inline receptacle 2 = 2-hole flange receptacle withPCB contacts 6 = Free plug Shell size Contact arrangement Insert type: P = pin, S = socket Shell keyways: N = Red (standard) A = Yellow B = Blue C = Orange D = Green U = Violet (Universal for test harnesses) (Plug type 6 only) Deutsch Autosport Micro HE parts numbering Contact size Only one contact size (socket and pin) is available to fit the Deutsch Autosport Micro HE connectors. The contact crimp connection can accommodate cable gauges of 22, 24 and 26 AWG. 20 Pi Sigma Sebring System Hardware Reference Lemo connectors are used on some sensors. Use the following information to help you determine the type of Lemo you are working with. sleeve collet nut key position indicator outer release sleeve key Parts of a Lemo connector Counting Lemo pins Hold the Lemo with the pins facing you, and the key at the top. For all Lemo sockets, count pins anticlockwise. For all Lemo plugs, count pins clockwise. socket 1 outside view plug 1 1 solder or crimp view outside view 1 solder or crimp view Counting Lemo pins Installation notes 21 Installation notes Lemo connectors Lemo parts numbering The following diagram shows how the Lemo parts numbering system works. Plug FGC 0B 305 C N C D 42 Free socket PHC 0B 305 C N M D 42 Panel socket EGC 0B 305 C N L Shell configuration Third letter is key angle Collet size Example is Ø4.2mm Size and Series Pi use 0B, 1B and 2B Cable clamp collet Contact type A male solder C male crimp L female solder M female crimp Insert configuration Second and third figures are the number of contacts Shell material C chrome plated brass Insulator material Lemo parts numbering system Shell configuration Type Description FG FH EH EG PF PH PK 22 Straight plug with cable collet and strain relief 90° plug with cable collet and strain relief Fixed socket with nut fixing and visible shell Fixed socket with nut fixing, flush mounted Fixed panel socket with two fixing nuts, cable collet and strain relief Free socket with cable collet and strain relief Fixed panel socket with nut fixing and cable collet Pi Sigma Sebring System Hardware Reference The key on each Lemo ensures that the two connectors fit together correctly, guiding the latches into place, and reducing the mechanical stress on the pins. a Lemo key angle Key letter Connector size Key angle (a) G key A key B key B key C key C key 0B, 1B and 2B 0B, 1B and 2B 0B and 1B 2B 0B and 1B 2B 0° 30° 60° 45° 90° 60° Size and Series Pi Systems use three different size Lemos; 0B, 1B and 2B, with four different key angles. Insert configuration Size and Series Insert Possible number of contacts 0B 1B 2B 3 3 3 2, 3, 4, 5, 6 and 7 2, 3, 4, 5, 6, 7, 8 and 10 2, 3, 4, 5, 6, 7, 8, 10, 12, 14, 16, 18 and 19 Installation notes 23 Installation notes Lemo key angle Shell material Pi Systems use Lemo connectors with chrome plated brass shells. Insulator material The insulator material is chosen according to the operating voltage. Various insulation materials are available. Pi Systems use Lemo connectors with Polybutylenetesephtalate (PBTP) insulation material (code letter N). Contact type Pi Systems use Lemo connectors with crimp contacts (code letters C and M). Collet size Lemo connectors used for looms have a collet clamp to hold the cable securely in the connector. The collet clamp nut is designed to accept the coloured sleeves for strain relief and identification. The following table shows the minimum and maximum outside diameters of cable, that each collet will accept. Size and Series Collet min. Ømm max. Ømm 0B 1B 1B 2B 2B D M D M D 1.5 2.0 3.1 1.5 4.1 5.5 3.0 7.5 4.0 9.7 Connecting Lemos 1 Make sure that the two connectors are compatible. Forpositive identification, check that the number of pins and the position of the key are the same for both connectors. 2 Align the key position indicator (red dot) of both Lemos before pushing them together. 24 Pi Sigma Sebring System Hardware Reference Push the Lemo connectors together until they click. Gently pull on the loom to make sure that the connector has latched. Fit the rubber Lemo boots. Installation notes 3 4 5 Removing a Lemo To remove a Lemo connector: 1 2 Pull back the rubber boots. Grip the outer release sleeve and pull it back until the Lemo frees. CAUTION: Never force a Lemo together, and never try to unscrew a Lemo. Lemo boots Two Lemo boots are used for inline connectors. A single boot is used when connecting to a chassis Lemo, for example, a junction box connector. To fit Lemo boots properly: ■ ■ If you are working with an inline connector, push the two boots together evenly. The boots are designed so that the join does not align with the join between the two connectors. If you are working with a panel mounted Lemo, push the boot up as close to the panel as is possible. Lemo connectors with boots in place If you have fitted the Lemo boots correctly, you should not be able to see any metallic part of the connector. Gently pull on the loom to confirm that the Lemo has latched. Installation notes 25 Connecting the MCU3 Most cars have the negative terminal of the battery connected to the chassis, making a ‘negative earth’. Battery connections are often made through a Master Switch, which may be fitted in either the negative or positive, or both, supply leads from the battery. The Master Switch disconnects all electrical power in an emergency, and is required by the regulations governing most motor sports. When connecting an MCU3 you should make sure that: ■ ■ ■ the MCU3 remains powered when the engine is turned off; the MCU3 does not drain the car battery too much; the supply voltage to the MCU3 remains high enough for operation. When connecting an MCU3 to the battery: ■ ■ ■ ■ make all connections to, or as near as possible to, the battery terminals; use a ‘star point’ for connections to the battery; keep the wire between the battery terminal and the star point as short as is possible. Use heavy gauge wire, or braiding for this connection; use 20-gauge or 22-gauge wire for connections between an MCU3, and the star point. CAUTION: Before making any connections to the battery, make sure you are confident with any looms that you have made. Remove power from the MCU3 before making any alterations. 26 Pi Sigma Sebring System Hardware Reference The MCU3 needs a supply voltage between 9.0 volts and 18 volts to operate correctly. If the supply voltage is outside these limits, the MCU3 will switch off. Depending upon the loads that you have connected, the current consumption will be between 1 amp and 5 amps. The battery +ve and battery –ve supply lines are fitted with 5 amp fuses inside the MCU3. Star points All Pi Sigma Sebring battery connections must only be connected to the battery at one point. Multiple connections to a length of wire or the chassis, will introduce noise and upset the readings from sensors. Star points are single connection points for the positive and negative terminals of the battery. Connecting equipment at the star point reduces the variation in supply voltage as current returns to the battery from other electrical components. Installation notes 27 Installation notes MCU3 power requirements Connecting systems The most common form of electrical system for vehicles consists of a battery and an alternator, but no electrical starter motor. Power to the electrical components is made through the Master Switch, and a second three position ignition switch. If your vehicle has this type of electrical system, then connect your Pi System using the arrangement shown below. Use 20 or 22 gauge twisted wire to the Pi System. off to Pi System off power ignition star point to Pi System battery chassis Connecting a System to the battery 28 Pi Sigma Sebring System Hardware Reference Installation notes Connecting the MCU3 and SCU3 to a vehicle battery The MCU3 and SCU3 have dual redundant battery connections. WARNING: You must fit a backup battery if you are using safety critical or control applications. For details refer to the section Fitting a backup battery. Connecting the MCU3 Four pins connect the MCU3 to your vehicle’s battery star points. Two pins are on the lefthand 66–way and two pins are on the righthand 66–way connector. These battery connections provide all of the power to the MCU3 and are listed in the next table. MCU3 battery connections Pin Connection Function L9 L24 R9 R24 Car battery positive star point Car battery negative star point Car battery positive star point Car battery negative star point Battery +ve Battery –ve Battery +ve Battery –ve Pins L9 and R9 are cross-coupled inside the MCU3, using diodes. Pins L24 and R24 are commoned inside the MCU3. These arrangements ensure that the MCU3 functions if one of the battery supply lines breaks. The input is protected against reversed battery connections and transients of ±40 volts. The internal connections are represented in the next figure. Installation notes 29 66-way connectors on MCU3 5 amps 5 amps 5 amps 5 amps L9 R9 L24 MCU5 circuits Supply for sensors 5 amps R24 Representation of internal MCU3 battery connections Connecting the SCU3 Four pins connect the SCU3 to your vehicle’s battery star points. Two pins are on the lefthand 55–way and two pins are on the righthand 55–way connector. These battery connections provide all of the power to the SCU3 and are listed in the table below. SCU3 battery connections Pin Connection Function L1 L9 R1 R9 Car battery positive star point Car battery negative star point Car battery positive star point Car battery negative star point Battery +ve Battery –ve Battery +ve Battery –ve Pins L1 and R1 are cross-coupled inside the SCU3, using diodes. Pins L9 and R9 are commoned inside the SCU3. These arrangements ensure that the SCU3 functions if one of the battery supply lines breaks. The input is protected against reversed battery connections, and transients of ±40 volts. The internal connections are represented in the next figure. 30 Pi Sigma Sebring System Hardware Reference 5 amps 5 amps 5 amps 5 amps L1 R1 L9 Installation notes 55-way connectors on SCU3 SCU3 circuits Supply for sensors 5 amps R9 Representation of internal SCU3 battery connections When you install the units, use the figure below as a guide. If your vehicle has a master switch configuration, refer also to the figure in section Connecting systems. Heavy gauge wire or braid 22-gauge twisted together L9 (MCU3) and L1 (SCU3) L24 (MCU3) and R1 (SCU3) star point R9 (MCU3) and L9 (SCU3) R24 (MCU3) and R9 (SCU3) battery chassis Battery connections (showing pin numbers for the MCU3 and the SCU3) WARNING: You must fit a backup battery if you are using safety critical or control applications. For details refer to the section Fitting a backup battery. Installation notes 31 Fitting a backup battery Some vehicles are fitted with an electrical starter motor. Under starting conditions, the battery voltage may drop to as low as 7 volts. A Pi Sigma Sebring will turn off if the supply voltage drops below 9.0 volts. To prevent your system from turning off, you can fit a separate battery, to maintain sufficient voltage for the System to operate. WARNING: You must fit a backup battery if you are using safety critical or control applications. Pi Research can supply a suitable backup battery. Contact Pi for more details. A suitable backup battery connection arrangement is shown below. backup battery off to Pi Sigma System righthand connector to Pi Sigma System righthand connector off power to Pi Sigma System lefthand connector star point ignition to electrical systems to Pi Sigma System lefthand connector battery chassis Connecting a backup battery 32 Pi Sigma Sebring System Hardware Reference Ground loops Your car may be fitted with an Engine Control Unit (ECU). Pi Sigma Sebring Systems can be connected to ECUs, enabling them to share information. Most ECUs will have a ground connection which may be chassis ground rather than directly to negative terminal of the battery. MCU3 star point battery ground loop ECU chassis Ground loop Connecting the ground of a Pi Sigma Sebring System to the ground connection of an ECU may create a ‘ground loop’. Ground loops can cause noise and incorrect sensor readings. Ground loops can also occur if the shell of a connector touches the chassis. This is why it is important to fit any protective rubber boots supplied with connectors. Installation notes 33 Installation notes ECU systems loom screen MCU3 battery vehicle chassis ground loop chassis Connector shell touches the chassis Ground loop caused by connector touching the chassis Testing for ground loops Ground loops can be avoided by making careful connection to battery star points and fitting protective rubber boots to all Lemo connectors. Before using your System, or if you are having problems with noise appearing in data from sensors, you should test for ground loops. To test for a ground loop: 1 Disconnect the System from the car battery. This is easily done by disconnecting the ECU connector on the System loom. 2 Using a multimeter, measure the resistance between the MCU3 case (or SCU3 case) and the chassis. If the resistance reading is low, then there is an electrical path to the chassis. 3 4 5 34 Starting with the sensor, loom or junction box that is furthest away from the MCU3 (or SCU3), unplug ONE component at a time and measure the resistance between the MCU3 case (or SCU3 case) and the chassis. Repeat step 3 until the resistance reading is infinite. Carefully check the component that you last disconnected for signs of shorting. Pi Sigma Sebring System Hardware Reference Installation notes multimeter loom screen MCU3 battery vehicle chassis chassis Testing for a ground loop If the resistance reading is greater than 10k ohms, then your System is electrically isolated from the chassis. If you are still experiencing noise problems, then you should check that boots are fitted to all connectors, and that no connector is making contact with the chassis through vibration. Avoiding ground loops The most common source of a ground loop is a grounded sensor. Ensure that all sensors used are either isolated from the chassis (or engine), or if that is not possible then isolate the screen connection from that sensor. Installation notes 35 Installation information This section gives information on how to fit the Pi Sigma Sebring System and loom to your car. General points on fitting looms The looms supplied by Pi Research are made from ‘55 spec’ military airframe wire that can withstand temperatures up to 150°C. Looms are terminated with Deutsch Autosport and Deutsch Autosport Micro HE connectors. Most sensors are terminated with Deutsch Autosport Micro HE connectors, but some are terminated in Lemo connectors. All looms are screened and covered with heatshrink sleeve unless otherwise specified. If you are making your own looms, then ask Pi Research for help with selecting suitable wire and connectors. Using poor quality wire and connectors may affect the performance and reliability of your Pi Sigma Sebring System. Fitting looms When fitting looms to your car, consider the following points: ■ ■ ■ Care should be taken when routing looms near the engine. Make sure that your looms do not make contact with hot engine components such as exhaust pipes, manifolds, turbochargers or brake components. Excessive heat will burn the protective heatshrink layer, and expose the inner screen and wires. This may lead to intermittent electrical faults and noise. When you install your looms, make sure that their position will not be affected by localised heating when the car is stationary. Remember that brake components can get very hot, and it will only be apparent after you have been running your car. The easiest way to install looms is to make all connections to the MCU3 first, and work away, towards the SCU3, junction boxes and sensors. Generally looms become thinner 36 Pi Sigma Sebring System Hardware Reference In general, looms should not be routed next to sources of electrical interference i.e. ignition coils, plug leads, alternators, fuel pumps, telemetry equipment, especially antennas, and ECUs. If you have to route a loom near any of these, try to avoid parallel runs. Notes ■ Allow looms to follow their natural curvature. Do not force them around very tight radii. ■ Where a loom passes through a hole in the chassis or bulkhead, make sure that there is no risk of the loom being cut or abraded. Making your own looms When making your own looms, use a spare length of cable, and route it exactly as the finished loom. Use off-cuts of cable to create branches and carefully mark the main loom where the branches occur. By spending time adjusting your dummy loom, you can achieve the optimum installation for your vehicle. If you are supplying a loom specification for Pi Research, take measurements from the dummy loom to create an engineering drawing. Pi Research measure looms from the face of connectors, and to the centre of loom branches. Installation notes 37 Installation notes further away from the MCU3. If you find that you have too much loom, a thinner loom is easier to coil up. Fixing looms The most popular way to secure looms to the chassis is using tie-wraps. When using a tie-wrap to secure a loom, make sure that the tie-rap grips a strong piece of the loom or the body of an insulated connector. tank tape chassis tie-wraps Securing a loom Never leave a connector free to move, as its weight will fracture the loom. Use ‘tank tape’ at frequent intervals to support the rest of the loom. 38 Pi Sigma Sebring System Hardware Reference Installation notes General points on fitting the MCU3 and SCU3 When fitting the MCU3 and SCU3 you should consider the following points: ■ ■ ■ ■ The units are resistant to water, but after prolonged exposure, water, oil and fuel may eventually work their way inside the units. Select a position where the units will not be in constant contact with any fluid. The units must be protected from vibration. Use the antivibration mounts. Make sure that air can flow over the units to keep them below +60°C. Try not to place the units near sources of electrical interference e.g. ignition coils, plug leads, ECUs, alternators and telemetry antenna. Installation notes 39 Installing the MCU3 Orientation The MCU3 contains three identical accelerometers which are used to measure acceleration about three axes: longitudinal, vertical and lateral. The accelerometers have corresponding channels in the Pi Workshop PC Software. The channel names in the software are Long Acc 02.00.61, Vertical Acc 02.00.60 and Lateral Acc 02.00.59. The MCU3 standard orientation axes are shown in the following figure. In the figure connector L is the lefthand 66-way connector, R is the righthand 66-way connector, and S is the system connector. Vertical acceleration +ve Longitudinal acceleration —ve Lateral acceleration —ve Front of car L R Lateral acceleration +ve S Longitudinal acceleration +ve Vertical acceleration —ve MCU3 standard orientation axes 40 Pi Sigma Sebring System Hardware Reference You can mount the MCU3 in a different orientation to the standard. The three axes of acceleration (longitudinal, vertical and lateral) will still be measured, but by a different accelerometer to that used in the standard orientation. The channel names in Pi Workshop Software remain the same, although they will be measuring acceleration along a different axis. You must set up a math channel in Pi Workshop Software to make use of the information from each channel. Refer to the Pi Workshop User Guide for information on how to set up a math channel to make use of the acceleration information if you fit the MCU3 in a non standard orientation. Fitting an MCU3 or SCU3 1 Select a suitable location for the unit. Make sure that the location does not exceed 60°C. Hot weather and localised heating effects will add to the ambient air temperature. 2 Use the mounting lugs and AV mounts supplied to secure the MCU3 and SCU3. CAUTION: The MCU3 and SCU3 cases act as a heatsink for internal electronic components. It is important that air can flow around all sides of the MCU3 and the SCU3. 3 When you have fitted the unit, make sure that air can flow all around it. Installation notes 41 Installation notes Re-orientation MCU3 dimensions Use the following diagram to help you fit an MCU3. 6.72" (170.0) 5.93" (150.5) 7.26" (184.5) 1.61" (41.0) 2.00" (51.0) 1.25" (29.2) View of MCU3 looking into bottom of unit (dimensions in inches and millimetres) Pi Sigma Sebring System Hardware Reference 0.39" (10.0) 0.70" (18.0) 4.53" (115.0) 5.0" (127.0) 0.60" (15.0) M4.0 x 10mm 4 positions 42 5.70" (145.0) 1.65" (42.0) 5.69" (144.5) Installation notes SCU3 dimensions Use the following diagram to help you fit an SCU3. 3.78"(96.0) 3.00"(76.0) M4 x 10mm 4 positions 4.33" (110.0) 0.83" (21.0) 0.39" (10.0) 0.60" (15.0) 0.70" (18.0) 4.52"(115.0) 5.00"(127.0) 5.70"(145.0) 1.65"(42.0) 2.75"(70.0) 1.33" (34.0) SCU3 view looking into bottom of unit (dimensions in inches and millimetres) Installation notes 43 Octal passive junction box dimensions 1A 1B 0.17"(4.50) 0.94"(24.0) Use the following diagram to help you fit an Octal passive junction box. 2A 2B 3A 3B 4A 4B 1.06"(27.0) 6.63"(166.0) M4 x 6.0 4 positions 0.09"(2.40) Octal passive junction box dimensions (in inches and millimetres) 44 Pi Sigma Sebring System Hardware Reference 0.09"(2.40) 0.75" (19.2) 6.35"(161.2) The MCU3 The MCU3 The MCU3 has a set of internal analog debug channels which monitor the health of the units. To view the channels they must be included in the logging table of the unit. The maximum rate that they can be logged at is 100Hz, but to conserve logging memory they should be logged at 10Hz or below. The most important channels to log are the Box battery voltage and Box temperature. Include the other channels if you can. MCU3 internal analog debug channels The MCU3 internal analog debug channel names are given in the next table. MCU3 internal analog debug channel names Channel Pi PC software name MCU3 Reference voltage (2.5V) PSU temperature (calibrated at 10mV/°C) Battery backup voltage (3.0V – 3.6V) for logging RAM Longitudinal Accelerometer Vertical Accelerometer Lateral Accelerometer Box temperature on Nose card Power supply +5V Power Supply +12V Power supply –12V Box battery voltage (9V–18V) Box battery input current ADC Ref.02.00.56 PSU Temp.02.00.57 Backup BattV.02.00.58 Long Acc.02.00.61 Vertical Acc.02.00.60 Lateral Acc.02.00.59 Temp.02.00.03 +5 Volts.02.00.50 +12 Volts.02.00.51 –12 Volts.02.00.52 Voltage.02.00.02 Supply Current.02.00.54 The MCU3 47 The MCU3 MCU3 internal analog debug channels MCU3 connectors This section gives information on the connectors used on the MCU3 and the pin out details for each connector. The figure below shows the position of the connectors on the MCU3. Lefthand 66-way Righthand 66-way System MCU3 connector identification MCU3 connector details The MCU3 is fitted with Deutsch Autosport connectors which are listed in the next table. MCU3 Deutsch Autosport connectors Description MCU3 Connector Loom Mating connector Lefthand 66-way Righthand 66-way System connector AS218-35PA AS218-35PN AS214-35SN AS618-35SA AS618-35SN AS614-35PN In the following tables the pin number prefix in the Pin column has the following meaning: L R S means the MCU3 Lefthand 66-way connector means the MCU3 Righthand 66-way connector means the MCU3 System connector e.g. L13 means pin 13 on the lefthand 66-way connector. 48 Pi Sigma Sebring System Hardware Reference MCU3 lefthand 66-way connector Mnemonic C3–1E C3–GNDA EXC1 C3–1A C3–1B C3–1D NETAL GND1 LBAT+ C2–1A C2–1E C2–1B C3–1C NETBL DEBTX DEMDE C2–2A C2–2E C2–2B C2–1D C2–1C SIG1A DEBRX LBAT– C2–GNDA C2–3B C2–3D C2–3C C2–2D C2–2C SIG1B C3–3B C3–3A Signal description Card3 group 1 signal E Card3 signal ground* Digital group 1 excitation Card3 group 1 signal A Card3 group 1 signal B Card3 group 1 signal D PiNET A left** Digital group 1 ground Battery power +ve Card2 group 1 signal A Card2 group 1 signal E Card2 group 1 signal B Card3 group 1 signal C PiNET B left** MCU3 to Debug Debug mode Card2 group 2 signal A Card2 group 2 signal E Card2 group 2 signal B Card2 group 1 signal D Card2 group 1 signal C Digital input 1A Debug to MCU3 Battery power –ve Card2 signal ground* Card2 group 3 signal B Card2 group 3 signal D Card2 group 3 signal C Card2 group 2 signal D Card2 group 2 signal C Digital input 1B Card3 group 3 signal B Card3 group 3 signal A * Connect high current sensors here Pin L34 L35 L36 L37 L38 L39 L40 L41 L42 L43 L44 L45 L46 L47 L48 L49 L50 L51 L52 L53 L54 L55 L56 L57 L58 L59 L60 L61 L62 L63 L64 L65 L66 Mnemonic C2–3A C2–3E C2–4D C2–4B C4–1B C4–1C C3–3D C3–3C C3–3E C2–GNDB C2–4C C4–4B C4–4C C4–2B C4–1D C4–1E C4–1A C2–4A C2–4E C4–4D C4–3B C4–2D C4–2C C4–2A C4–4A C4–4E C4–3D C4–3C C4–GNDB C4–2E C4–GNDA C4–3E C4–3A Signal description Card2 group 3 signal A Card2 group 3 signal E Card2 group 4 signal D Card2 group 4 signal B Card4 group 1 signal B Card4 group 1 signal C Card3 group 3 signal D Card3 group 3 signal C Card3 group 3 signal E Card2 signal ground* Card2 group 4 signal C Card4 group 4 signal B Card4 group 4 signal C Card4 group 2 signal B Card4 group 1 signal D Card4 group 1 signal E Card4 group 1 signal A Card2 group 4 signal A Card2 group 4 signal E Card4 group 4 signal D Card4 group 3 signal B Card4 group 2 signal D Card4 group 2 signal C Card4 group 2 signal A Card4 group 4 signal A Card4 group 4 signal E Card4 group 3 signal D Card4 group 3 signal C Card4 signal ground* Card4 group 2 signal E Card4 signal ground* Card4 group 3 signal E Card4 group 3 signal A The MCU3 Pin L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16 L17 L18 L19 L20 L21 L22 L23 L24 L25 L26 L27 L28 L29 L30 L31 L32 L33 ** Route in Lefthand loom The Signal function is determined by the type of I/O cards fitted in the MCU3. The MCU3 49 MCU3 righthand 66-way connector Pin R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 Mnemonic C3-2E C3-GNDB EXC2 C3-2A C3-2B C3-2D NETAR GND2 RBAT+ C1-1A C1-1E C1-1B C3-2C NETBR ADDR1 A-GND R17 R18 R19 R20 R21 R22 R23 R24 R25 R26 R27 R28 R29 R30 R31 R32 R33 C1-2A C1-2E C1-2B C1-1D C1-1C SIG2A ADDR0 RBAT– C1-GNDA C1-3B C1-3D C1-3C C1-2D C1-2C SIG2B C3-4B C3-4A Signal description Card3 group 2 signal E Card3 signal ground* Digital group 2 excitation Card3 group 2 signal A Card3 group 2 signal B Card3 group 2 signal D PiNET A right** Digital group 2 ground Battery power +ve Card1 group 1 signal A Card1 group 1 signal E Card1 group 1 signal B Card3 group 2 signal C PiNET B right** Junction box address 1 Junction box address Ground-pin Card1 group 2 signal A Card1 group 2 signal E Card1 group 2 signal B Card1 group 1 signal D Card1 group 1 signal C Digital input 2A Junction box address 0 Battery power –ve Card1 signal ground* Card1 group 3 signal B Card1 group 3 signal D Card1 group 3 signal C Card1 group 2 signal D Card1 group 2 signal C Digital input 2B Card3 group 4 signal B Card3 group 4 signal A * Connect high current sensors here Pin R34 R35 R36 R37 R38 R39 R40 R41 R42 R43 R44 R45 R46 R47 R48 R49 Mnemonic C1-3A C1-3E C1-4D C1-4B C5-1B C5-1C C3-4D C3-4C C3-4E C1-GNDB C1-4C C5-4B C5-4C C5-2B C5-1D C5-1E R50 R51 R52 R53 R54 R55 R56 R57 R58 R59 R60 R61 R62 R63 R64 R65 R66 ** Route C5-1A Card5 group 1 signal A C1-4A Card1 group 4 signal A C1-4E Card1 group 4 signal E C5-4D Card5 group 4 signal D C5-3B Card5 group 3 signal B C5-2D Card5 group 2 signal D C5-2C Card5 group 2 signal C C5-2A Card5 group 2 signal A C5-4A Card5 group 4 signal A C5-4E Card5 group 4 signal E C5-3D Card5 group 3 signal D C5-3C Card5 group 3 signal C C5-GNDB Card5 signal ground* C5-2E Card5 group 2 signal E C5-GNDA Card5 signal ground* C5-3E Card5 group 3 signal E C5-3A Card5 group 3 signal A in Righthand loom The Signal function is determined by the type of I/O cards fitted in the MCU3. 50 Pi Sigma Sebring System Hardware Reference Signal description Card1 group 3 signal A Card1 group 3 signal E Card1 group 4 signal D Card1 group 4 signal B Card5 group 1 signal B Card5 group 1 signal C Card3 group 4 signal D Card3 group 4 signal C Card3 group 4 signal E Card1 signal ground* Card1 group 4 signal C Card5 group 4 signal B Card5 group 4 signal C Card5 group 2 signal B Card5 group 1 signal D Card5 group 1 signal E MCU3 system connector Pin Mnemonic Signal description Pin Mnemonic Signal description S1 SIG2B-B Digital signal 2B buffered o/p S20 IO4A Digital I/O 4A S2 SIG2A-B Digital signal 2A buffered o/p S21 SIOB2 RS422 to MCU3 2B, serial port 2 SOB2/RX RS232 to MCU3, serial port 2 S22 SOA4/TX MCU3 to RS422 2A, or RS232 serial port 4 RX2A RS422A ECU to MCU3 S23 SIA4/CH RS422 to MCU3 A serial port 4 or CANH S5 RX2B RS422B ECU to MCU3 S24 SIB4/CL RS422 to MCU3 B serial port 4 or CANL S6 FBAT1+ 750mA fused battery output 1 +ve S25 RX5B RS422 to MCU5 B, serial port 5 S7 FBAT2+ 750mA fused battery output 2 +ve S26 RENETTX+ MCU3 to pit +ve, serial port 1 S8 FBAT1– Battery output 1 –ve S27 RENETTX– MCU3 to pit –ve, serial port 1 S9 FBAT2– Battery output 2 –ve S28 LED LED status driver/Pit detect S10 CASE MCU3 case connection S29 TX5 RS232 MCU3 to ELB S11 GND3A Digital group 3 ground S30 SIOA2 RS422 to MCU3 2A, serial port 2 S12 GND3B Digital group 3 ground S31 SOA2/TX MCU3 to RS232, serial port 2 S13 EXC3 Digital group 3 excitation S32 RX5A RS422 to MCU3 5A, serial port 5 The MCU3 S3 S4 S14 PITGND LED/Pit detect ground S33 SOB4/RX MCU3 to RS422 2B, or RS232 serial port 2 S15 GND4B Digital group 4 ground S34 RENETRX+ Pit to MCU3+, serial port 1 S16 RX3 RS232 Spare S35 RENETRX- Pit to MCU3–, serial port 1 S17 EXC4B Digital group 4 excitation S36 IO3A Digital I/O 3A S18 TX3 RS232 to ADR S37 IO3B Digital I/O 3B S19 IO4B Digital I/O 4B The Signal function is determined by the type of I/O cards fitted in the MCU3. The MCU3 51 MCU3 Digital channels The MCU3 has eight fixed digital channels that can be used for wheelspeed sensors, crank sensors and any sensor that provides a digital output signal. The channels are arranged into four Groups, with each group providing different signal conditioning and excitation voltages to match different digital sensors. MCU3 Digital Group 1 MCU3 Digital Group 1 channels (1A and 1B) are input only. MCU3 Digital Group 1 inputs have programmable threshold levels, programmable hysteresis, programmable pre-scalar, programmable 125kHz–1MHz clock, fixed 10k ohm pull-up, 0–5V or 0–15V input range and switchable 10kHz or 2kHz input filter. You use Pi Workshop PC software to configure the channels. The Pi Workshop PC Software includes a calculator which helps to ensure that the settings for these digital channels are optimized. 52 Pin Mnemonic Signal description Normally used for L3 L22 L31 L8 EXC1 SIG1A SIG1B LNGD1 Digital Group 1 excitation Digital input 1A Digital input 1B Digital Group 1 ground Programmable 2.5V to 12.5V Front right wheelspeed Rear right wheelspeed Ground for Digital Group 1 signals Pi Sigma Sebring System Hardware Reference MCU3 Digital Group 2 MCU3 Digital Group 2 inputs have programmable threshold levels, programmable hysteresis, programmable pre-scalar, programmable 125kHz–1MHz clock, fixed 10k ohm pull-up, 0–5V or 0–15V input range and switchable 10kHz or 2kHz input filter. You use Pi Workshop PC software to configure the channels. The Pi Workshop PC Software includes a calculator which helps to ensure that the settings for these digital channels are optimized. Pin Mnemonic Signal description Normally used for R3 R22 R31 R8 EXC2 SIG2A SIG2B GND2 Digital Group 2 excitation Digital input 2A Digital input 2B Digital Group 2 ground Programmable 2.5V to 12.5V Front left wheelspeed Rear left wheelspeed Ground for Digital Group 2 signals Details of Digital Groups 1 and 2 inputs Input voltage levels Input 0–5V 0–15V Programmable threshold and hysteresis Programmable pre-scalar value % Count 1–16 (in steps of 1) Programmable timer Count rate Representation of Digital Groups 1 and 2 inputs The MCU3 53 The MCU3 MCU3 Digital Group 2 channels (2A and 2B) are input only. Programmable hysteresis Digital inputs can suffer from noise from electrical interference. Programmable hysteresis reduces the effect of noise by setting thresholds above which input voltages must rise and fall to register a valid logic 1 and logic 0. Using the Pi Workshop PC software you select a value between 20% and 80% of a reference voltage of 4.1V as the threshold voltage. You then select a hysteresis value of between 4% and 40% of the selected threshold voltage. The software will prevent selection outside of these limits, and will not allow invalid combinations to be entered. Half the hysteresis value is then added to the threshold value, and half the value is subtracted from threshold value. The resultant two voltages are the values above and below which the input voltage must rise and fall to register as a logic 1 and a logic 0. An example is shown below. In the example, the threshold voltage is 61% of the 4.1V reference, which gives a value of 2.5V. The hysteresis value is set to 8% of the threshold value 2.5V, which is 200mV. 100mV is added to the threshold voltage to give an upper value of 2.6V, and 100mV is subtracted from the threshold value to give a lower hysteresis value of 2.4V. Input voltage 2.6V Threshold voltage 2.5V 2.4V Logic 1 Logic 0 Signal used by the MCU Logic 1 Logic 0 Logic 0 Example of programmable hysteresis A logic 0 input can only change state to a logic 1 input if the input voltage rises above 2.6V. It will remain a logic input 1 until the voltage drops to 2.4V. 54 Pi Sigma Sebring System Hardware Reference Programmable pre-scalar values and programmable clock The MCU3 The maximum input frequency that the signal processing section of the digital I/O card can accept is 1kHz. You use a pre-scalar value that will divide the frequency of the input signal down to less than 1kHz. You then set a programmable timer to a value that will count the time between pulses after the division has taken place. The MCU3 55 MCU3 Digital Group 3 MCU3 Digital Group 3 has two channels (3A and 3B) which be can software configured as input or output channels. Digital Group 3 inputs have fixed slice levels, fixed hysteresis, switchable 2mA or 10mA current limited output, switchable 10k ohm pull-up, fixed 2kHz input filter. You use Pi Workshop PC software to configure the channels. Pin Mnemonic Signal description Normally used for S13 S36 S37 S11 S12 EXC3 IO3A IO3B GND3A GND3B Digital Group 3 excitation Digital I/O 3A Digital I/O 3B Digital Group 3 ground Digital Group 3 ground Programmable 2.5V to 12.5V Split beacon input† Spare Ground for Digital Group 3 signals Ground for Digital Group 3 signals † The end of lap beacon signal generated by the 32-channel beacon receiver is connected directly to the ECU via the wiring loom. It is NOT connected to the MCU3. MCU3 Digital Group 4 MCU3 Digital Group 4 has two channels (4A and 4B) which be can software configured as input or output channels. They use the same excitation voltage. Digital Group 4 inputs have fixed slice levels, fixed hysteresis, switchable 2mA or 10mA current limited output, switchable 10k ohm pull-up, fixed 2kHz input filter. You use Pi Workshop PC software to configure the channels. 56 Pin Mnemonic Signal description Normally used for S17 S20 S19 S15 EXC4B IO4A IO4B GND4B Digital Group 4 excitation Digital I/O 4A Digital I/O 4B Digital Group 4 ground Programmable 2.5V to 12.5V Switch level input Switch level input Ground for Digital Group 4 signals Pi Sigma Sebring System Hardware Reference MCU3 miscellaneous connections In the following tables, the pin number prefix in the Pin column means: means the MCU3 Lefthand 66-way connector means the MCU3 Righthand 66-way connector means the MCU3 System connector The MCU3 L R S Battery outputs Pin Mnemonic Signal description Normally used for S6 S8 S7 S9 FBAT1+ FBAT1– FBAT2+ FBAT2– Fused battery power Fused battery power Fused battery power Fused battery power 750mA fused battery power for TMS –ve for fused battery power for TMS 750mA fused battery power –ve for fused battery power Pin Mnemonic Signal description Normally used for L9 L24 R9 R24 BAT+ BAT– RBAT+ RBAT– Battery power+ Battery power– Battery power+ Battery power– Lefthand battery input +ve Lefthand battery input –ve Righthand battery input +ve Righthand battery input –ve Battery inputs The MCU3 57 Buffered outputs 58 Pin Mnemonic Signal description Normally used for S1 S2 Front left wheelspeed o/p to ECU Rear left wheelspeed o/p to ECU SIG2B-B SIG2A-B Digital signal 2B buffered o/p Digital signal 2A buffered o/p Pi Sigma Sebring System Hardware Reference MCU3 communications links The MCU3 supports a number of serial communications ports. Each port has its own characteristics which are selected via a combination of hardware and Pi Workshop PC software to give a different physical layer. The serial communication ports are summarised in the table below. Port Normal function Mode 1 2A 2B 3 Pit communication ECU input Telemetry ADR Ethernet 10baseT at 10Mbps RS422 out, RS422 in RS232 out, RS232 in RS232 out 38,400 baud max RS232 in 38,400 baud max RS232, RS422 or TTL, CAN RS232 or RS422 RS232 out RS422 in RS422 in 4A 4B 5 CAN switches to MCU3 MCU3 to Dash Engine Log Book (ELB) Tire Monitoring System (TMS) or Octal serial junction box (OSJB) The MCU3 59 The MCU3 Serial communication ports Serial port 1 – Pit communications This is the car to pit communication port. It uses 10baseT Ethernet and a fixed baud rate of 10Mbps. A pit detect download status function is also provided on this port via one pin which provides feedback to the MCU3, confirming the download link has been connected. For the MCU3 to recognize that it is in the pits, a 22k ohms resistor is connected between pin S28 and battery +ve. The Fischer connector on the download lead has a 22k ohms resistor fitted inside the shell, which provides this connection when the download lead is plugged into the download connector on the car. 60 Pin Mnemonic Description Function S26 S27 S34 S35 S28 S14 RENETTX+ RENETTX– RENETRX+ RENETRX– LED PITGND MCU3 to pit+ MCU3 to pit– Pit to MCU3+ Pit to MCU3– Pit detect Pit detect gnd 10baseT Ethernet 10baseT Ethernet 10baseT Ethernet 10baseT Ethernet Pit detect Ground for Pit detect Pi Sigma Sebring System Hardware Reference Serial port 2A – ECU input This port can be used for fixed transmit and fixed receive operation at RS422 levels. The port has the following configuration: Capable of 1Mbps operation Fixed RS422 transmit and receive 120 Ohms termination on RS422 receive Pin Mnemonic Description Function S4 S5 S21 S30 RX2A RX2B TXA TXB ECU to MCU3 ECU to MCU3 MCU3 to ECU MCU3 to ECU RS422 receive A RS422 receive B RS422 transmit A RS422 transmit B The MCU3 ■ ■ ■ Serial port 2B – Telemetry The MCU3 provides an RS232 communications link to connect to a telemetry system. The port has the following configuration: ■ ■ ■ Adjustable baud rate up to 115200 baud Bi-directional Fixed RS232 layer Pin Mnemonic Description Function S3 S31 SOB2/RX SOA2/TX Radio to MCU3 MCU3 to Radio RS232 to the MCU3 RS232 MCU3 to the telemetry system The MCU3 61 Serial port 3 – ADR The port has the following configuration: ■ ■ ■ Baud rate limited to 38,400 baud Bi-directional Fixed RS232 layer Pin Mnemonic Description Function S18 S16 TX3 RX3 MCU3 to ADR ADR to MCU3 RS232 from MCU3 RS232 from ADR Serial port 4A – CAN switches to MCU3 The port has the following configuration: ■ ■ Fixed CAN layer Software configurable to run at up to 1Mbps. Configuration 62 Pin Mnemonic Description Function S23 S24 SIA4 SIB4 CAN switches CAN switches CAN_H CAN_L Pi Sigma Sebring System Hardware Reference Serial port 4B – MCU3 to Dash This port can be used for fixed transmit operation at RS422, or RS232 transmit and receive levels. Standard configuration is RS422 transmit. The port has the following configuration: Capable of 921600 baud operation Software configurable for RS422 transmit or RS232 transmit and receive 120 Ohms termination on RS422 The MCU3 ■ ■ ■ Configuration Pin Mnemonic Description Function S22 S33 SOA4/TX SOB4/RX MCU3 to Dash MCU3 to Dash RS422 A circuit RS422 B circuit Serial port 5 – TMS receive and ELB transmit The receive side of this port is used for Tire Monitoring System (TMS) RS422 input. The transmit side of this port is allocated as an RS232 output from the MCU3 to an Engine Log Book (ELB). Pin Mnemonic Description Function S32 S25 S29 RX5A RX5B TX5 TMS to MCU3 TMS to MCU3 ELB RS422 A TMS to MCU3 RS422 B TMS to MCU3 RS232 from MCU3 to ELB The MCU3 63 System communications In addition to the serial communications ports there are ports which are used for system communications. Debug port The debug port allows communication with the logger card, and the application card if fitted within the MCU3. PiNet PiNet is the network which is used to connect the MCU3 and other units of the Pi Sigma Sebring system. The MCU3 communicates with the other units via the PiNet port on the MCU3. Debug port This port has an RS232 serial interface which allows communications with the logger card and if fitted within the MCU3, depending upon the voltage on the mode pin. The voltage on the mode pin determines which debug mode is selected. Open circuit is the normal configuration and debug mode is not enabled. Connecting 0V to the DEMDE pin enables logger card debug mode. Connecting +12V to the DEMDE pin enables application card debug mode. The port is defined as: 64 Pin Mnemonic Description Function L16 L23 L15 L9 DEMDE DEBRX DEBTX LBAT+ Debug mode Debug to MCU3 MCU3 to debug Battery power L24 LBAT– Ground The voltage on this pin controls debug mode RS232 debug receive RS232 debug transmit +12V enables application card debug mode when applied to DEMDE Ground for debug mode Pi Sigma Sebring System Hardware Reference PiNet Pin Mnemonic Description Function L7 L14 R7 R14 NETAL NETBL NETAR NETBR PiNet A left PiNet B left PiNet A right PiNet B right PiNet A for lefthand loom PiNet B for lefthand loom PiNet A for righthand loom PiNet B for righthand loom The MCU3 The MCU3 communicates with other units in the Pi Sigma Sebring system using the PiNet network. In normal configuration the PiNet is terminated in the MCU3 with a 120 Ohms resistor. It is essential that if you are making your own loom that PiNet is carefully loomed on the car. The A and B wires for each leg must be twisted and screened, and all connections must be terminated correctly. You should not use spurs, but link between one unit and the next until you reach the final unit. Right way Wrong way NETAL NETBL NETAL NETBL Unit Unit Unit Unit Connecting units with PiNet The MCU3 65 Communication connectors Download connector The download connector provides all of the communication connections from the Pi Sigma Sebring System. download connector washer panel cutout body panel locknut from system loom Ø15.0mm Ø0.57" Each time the car returns to the pit or garage area, and you want to download data from the System, or upload a setup from your PC, you will need to use this connector. 14.5mm 0.57" minimum 80.0mm / 3.5" Fitting the download connector The download connector is usually fitted in the bodywork area, behind the driver, near the roll-hoop. Generally, you should not fit the download connector where it will be exposed to continuous water spray, dust or mud. You will need to allow at least an 80mm (3.5 inches) behind the body panel to accommodate the loom. 66 Pi Sigma Sebring System Hardware Reference Connector Download connector Mating connector Sleeve colour Fischer S 104 A092 Fischer DK 104 A092 green Pin Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Shell No connection No connection No connection Pit detect/LED* No connection No connection No connection No connection RENETTX– RENETTX+ RENETRX– RENETRX+ +12V* No connection No connection No connection No connection No connection No connection Screen The MCU3 Fischer download connector pin details MCU3 pin Function S28 LED status driver/pit detect S27 S26 S35 S34 MCU3 to PC 10baseT MCU3 to PC 10baseT PC to MCU3 10baseT PC to MCU3 10baseT 12V for pit detect * Pins 4 and 13 linked with 22k ohms resistor in the Pi Sigma Download lead. The MCU3 67 Download lead The download lead is used to connect the PC ethernet card to the download connector on the vehicle. Two versions of download lead are available. The standard download lead is 10 feet (3.0m) long and the optional long download lead is 30 feet (10.0m) long. The long lead will enable the PC to remain in the garage and still connect to the vehicle when it is parked outside. PC running Pi software Car download lead download connector PCMCIA card Connecting download lead 68 Pi Sigma Sebring System Hardware Reference to System loom Download path connections The following figure shows the download path connections from MCU3 on the car to the PC ethernet card connector. Download lead Fischer (or Autosport) MCU (RENETTX+) S26 (RENETTX–) S27 (RENETRX+) S34 Fischer (or Autosport) 10 10 RJ45 3 9 9 6 12 12 1 11 11 2 Screen (RENETRX–) S35 Shell The MCU3 Car 15 (LED/PIT DETECT) S28 4 4 13 13 22k ohms +12V Download path connections The MCU3 69 PC Network It is possible to download data from the car to a PC which is part of a network. A typical network is shown in the next figure. Network hub Telemetry client Car server Car Telemetry client Download lead MCU A typical network Note: If you have such a network, it is important that the PCMCIA ethernet card supplied by Pi as part of the Pi Sigma Sebring System is used in the Car server PC to connect to the car download lead and is not used to connect to the network hub. 70 Pi Sigma Sebring System Hardware Reference Cross over cable If you do not have a network, you can link two PCs which do not have internal networking cards by using a standard cross over cable. This allows one PC to be connected as the car server computer and the second linked PC can then use the downloaded data. The arrangement is shown in the next figure. Car MCU The MCU3 Download lead Patch cable (cross over) Two PCs linked using a cross over cable The MCU3 71 The SCU3 The SCU3 SCU3 internal analog debug channels The SCU3 is a cost option addition to the standard Pi Sigma Sebring System. The SCU3 has a set of internal analog debug channels which monitor the health of the unit. To view the channels they must be included in the logging table of the unit. The maximum rate that they can be logged at is 100Hz, but to conserve logging memory they should be logged at 10Hz or below. The SCU3 The most important channels to log are the Box battery voltage and Box temperature. Include the other channels if you can. The SCU3 internal analog debug channel names are given in the next table. SCU3 internal analog debug channel names Channel Pi software name SCU3 Reference voltage (2.5V) PSU temperature Battery backup voltage (3.0V – 3.6V) Box temperature on Nose card Left battery voltage Right battery voltage Power supply +5V Power Supply +12V Power supply –12V Box battery voltage (9V–18V) Box battery input current Programming Voltage ADC Ref.05.00.56 PSU Temp.05.00.57 Backup BattV.05.00.47 Temp.05.00.03 Batt Volt (Left).05.00.62 Batt Volt (Right).05.00. +5 Volts.05.00.50 +12 Volts.05.00.51 –12 Volts.05.00.52 Voltage.05.00.02 Supply Current.05.00.54 Vpp Feedback.05.00.46 The SCU3 75 SCU3 connectors This section gives information on the connectors used on the SCU3 and the pin out details for each connector. The figure below shows the position of the connectors on the SCU3. Lefthand 55-way (yellow ring) Righthand 55-way (red ring) SCU3 connectors SCU3 connector details The SCU3 is fitted with two 55-way Deutsch Autosport connectors. SCU3 Deutsch Autosport connectors 76 Description MCU Connector Loom Mating connector SCU3 Lefthand 55-way SCU3 Righthand 55-way AS216-35PA AS216-35PN AS616-35SA AS616-35SN Pi Sigma Sebring System Hardware Reference Pin L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16 L17 L18 L19 L20 L21 L22 L23 L24 L25 L26 L27 L28 Mnemonic BAT+ NETBL** SCN C2-GNDA* C2-GNDB* NETAL** NETBL** NETAL** BAT– C2-1A C2-1A C2-1B ADDR1 IO1A D-GNDA* D-GNDB* C2-1E C2-1E C2-1D C2-1C C2-3B IO1B EXC1 GND1 C2-3A C2-3C C2-3D C2-4B Signal description Battery power +ve PiNET B left Loom screen to case Card2 signal ground Card2 signal ground PiNET A left PiNET B left PiNET A left Battery power –ve Card2 group 1 signal A Card2 group 1 signal A Card2 group 1 signal B Junction box1 address Digital I/O 1A Digital signal ground Digital signal ground Card2 group 1 signal E Card2 group 1 signal E Card2 group 1 signal D Card2 group 1 signal C Card2 group 3 signal B Digital I/O 1B Digital group 1 excitation Digital group 1 GND Card2 group 3 signal A Card2 group 3 signal C Card2 group 3 signal D Card2 group 4 signal B * Connect high current sensors here Pin L29 L30 L31 L32 L33 L34 L35 L36 L37 L38 L39 L40 L41 L42 L43 L44 L45 L46 L47 L48 L49 L50 L51 L52 L53 L54 L55 Mnemonic C2-4C DEMDE N/C C2-3E C2-4A C2-4D C2-2C SOA4/TX SIB4/CL DEBTX EXC2 C2-4E C2-2B C2-2D ADDR0 SOB4/RX DEBRX SIA4/CH C2-2A C2-2A C2-2E IO2B IO2A A-GND C2-2E GND2 EXC2 Signal description Card2 group 4 signal C Debug mode No connection Card2 group 3 signal E Card2 group 4 signal A Card2 group 4 signal D Card2 group 2 signal C SCU to RS422A/RS232 CAN_L/RS422B to SCU SCU to Debug Digital group 2 excitation Card2 group 4 signal E Card2 group 2 signal B Card2 group 2 signal D Junction box address 0 SCU to RS422B/RS232 Debug to SCU CAN_H/RS422A Card2 group 2 signal A Card2 group 2 signal A Card2 group 2 signal E Digital I/O 2B Digital I/O 2A Junction box addr ground Card2 group 2 signal E Digital group 2 ground Digital group 2 excitation ** Route in Left hand loom The Signal function is determined by the type of I/O cards fitted in the SCU3. The SCU3 77 The SCU3 SCU3 Lefthand 55-way connector SCU3 Righthand 55-way connector Pin R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 R24 R25 R26 R27 R28 Mnemonic BAT+ NETBR SCN C1-GNDA C1-GNDB NETAR NETBR NETAR BATC1-1A C1-1A C1-1B C3-1C C3-1B C3-GNDA C3-GNDB C1-1E C1-1E C1-1D C1-1C C1-3B C3-1D C3-1A C3-1E C1-3A C1-3C C1-3D C1-4B Signal description Battery power +ve PiNET B right• • Connect loom to case Card 1 signal ground Card 1 signal ground PiNET A right• • PiNET B right• • PiNET A right• • Battery power –ve Card1 group 1 signal A Card1 group 1 signal A Card1 group 1 signal B Card3 group 1 signal C Card3 group 1 signal B Card3 signal ground* Card3 signal ground* Card1 group 1 signal E Card1 group 1 signal E Card1 group 1 signal D Card1 group 1 signal C Card1 group 3 signal B Card3 group 1 signal D Card3 group 1 signal A Card3 group 1 signal E Card1 group 3 signal B Card1 group 3 signal C Card1 group 3 signal D Card1 group 4 signal B * Connect high current sensors here Pin R29 R30 R31 R32 R33 R34 R35 R36 R37 R38 R39 R40 R41 R42 R43 R44 R45 R46 R47 R48 R49 R50 R51 R52 R53 R54 R55 Mnemonic C1-4C C3-3C C3-3A C1-3E C1-4A C1-4D C1-2C C3-4B C3-4C C3-3B C3-3E C1-4E C1-2B C1-2D C3-2C C3-4D C3-3D C3-4A C1-2A C1-2A C1-2E C3-2D C3-2B C3-4E C1-2E C3-2E C3-2A Signal description Card1 group 4 signal C Card3 group 3 signal C Card3 group 3 signal A Card1 group 3 signal E Card1 group 4 signal A Card1 group 4 signal D Card1 group 2 signal C Card3 group 4 signal B Card3 group 4 signal C Card3 group 3 signal B Card3 group 3 signal E Card1 group 4 signal E Card1 group 2 signal B Card1 group 2 signal D Card3 group 2 signal C Card3 group 4 signal D Card3 group 3 signal D Card3 group 4 signal A Card1 group 2 signal A Card1 group 2 signal A Card1 group 2 signal E Card3 group 2 signal D Card3 group 2 signal B Card3 group 4 signal E Card1 group 2 signal E Card3 group 2 signal E Card3 group 2 signal A ** Route in Right hand loom The Signal function is determined by the type of I/O cards fitted in the SCU3. 78 Pi Sigma Sebring System Hardware Reference SCU3 connections The SCU3 has a number of digital, system and serial port connections which are described in this section. SCU3 Digital Group 1 channels (1A and 1B) are input and output. SCU3 Group 1 digital inputs have programmable slice levels, programmable hysteresis, programmable prescalar, programmable 125kHz–1MHz clock, fixed 10kOhm pull-up, 0–5V or 0–15V input range, switchable 10kHz/2kHz input filter and programmable 2.5V–12.5V excitation voltage. The Pi Workshop PC Software includes a calculator which helps to ensure that the settings for these digital channels are optimized. Pin Mnemonic Signal description Normally used for L23 L14 L22 L24 Programmable 2.5V to 12.5V User defined User defined Ground for SCU3 Group 1 signals EXC1 IO1A IO1B GND1 SCU3 digital group 1 excitation SCU3 digital input 1A SCU3 digital input 1B SCU3 digital group 1 ground Pin number refers to the Lefthand 55-way connector on the SCU3. The SCU3 79 The SCU3 SCU3 Digital Group 1 SCU3 Digital Group 2 SCU3 Digital Group 2 channels (2A and 2B) are input and output. SCU3 Group 2 digital inputs have programmable slice levels, programmable hysteresis, programmable prescalar, programmable 125kHz–1MHz clock, fixed 10kOhm pull-up, 0–5V or 0–15V input range, switchable 10kHz/2kHz input filter and programmable 2.5V–12.5V excitation voltage. The Pi Workshop PC Software includes a calculator which helps to ensure that the settings for these digital channels are optimized. Pin Mnemonic Signal description Normally used for L39 L51 L50 L54 Programmable 2.5V to 12.5V User defined User defined Ground for SCU3 Group 2 signals EXC2 IO2A IO2B GND2 SCU3 digital group 2 excitation SCU3 digital input 2A SCU3 digital input 2B SCU3 digital group 2 ground Pin number refers to the Lefthand 55-way connector on the SCU3. SCU3 system connections The SCU3 has a number of System connections, which are listed in the next table. Pin Mnemonic Description Comment R9 R24 L9 L24 R7 R14 L7 L14 RBAT+ RBAT– LBAT+ LBAT– NETAR NETBR NETAL NETBL Battery +ve Battery –ve Battery +ve Battery –ve PiNet A right PiNet B right PiNet A left PiNet B left Right battery +ve Right battery –ve Left battery +ve Left battery –ve Route in righthand loom. Twist with PiNet B right Route in righthand loom. Twist with PiNet A right Route in lefthand loom. Twist with PiNet B left Route in lefthand loom. Twist with PiNet A left Pin numbers refer to the 55-way connectors on the SCU3. 80 Pi Sigma Sebring System Hardware Reference I/O cards I/O cards Input/Output (I/O) cards A range of I/O cards are available to fit into the I/O card slots in the MCU3 and SCU3. The I/O cards provide excitation voltages and signal conditioning for sensors. The Pi SIgma Sebring MCU3 has five I/O slots available and the SCU3 has three I/O slots available. The standard configuration for the Pi Sigma Sebring System has three Selectronic cards in the MCU3 and three Selectronic cards in the SCU3. Different I/O cards can be specified at time of order. I/O Card Classification LVDT Moog Selectronic CAN Pressure scanner High power High power Low power Low power Low power I/O cards Each I/O card has a power consumption which is classed as either high power or low power. This relates to the power consumption of the card, not sensors connected to them. The power classification of I/O cards is listed in the next table. Changes to existing I/O cards fitted can only be made by Pi Research and require the return of the MCU5 to Pi Research. I/O cards 83 Selectronic I/O card This is the standard I/O card installed in the MCU3 and the SCU3. The Selectronic I/O card provides suitable signal conditioning and excitation for sensors that are used in measurement purposes. The Selectronic I/O card provides six differential and two single-ended 16-bit resolution analog input channels. Channels are configurable using Pi Workshop PC software for gain, offset, input range, and excitation magnitude, which means that you can connect many types of sensor to the Selectronic card e.g. linear and rotary potentiometers, temperature sensors, accelerometers, RTD sensors, thermocouples, strain gauges, and load cells. The LVDT I/O card This card is an option which can be installed at time of order or which can be installed in a System at a later date. Linear Variable Displacement Transformer (LVDT) sensors provide a non-contact position measurement. They can be used in hostile environments where linear potentiometers are unsuitable. The LVDT I/O card is designed for precision measurement using LVDT sensors. The LVDT I/O card supports a maximum of five 5-wire LVDT sensors or ten 0–5V sensors. Different hardware configurations give combinations of LVDT channels, high-side driver outputs, and DC voltage operation. 84 Pi Sigma Sebring System Hardware Reference Moog/LVDT I/O card This card is an option which can be installed at time of order or which can be installed in a System at a later date and is for use with active applications only. The Moog/LVDT I/O card provides signal conditioning for LVDT sensors, or linear potentiometers for precision position measurement of a control system. The Digital Signal Processing (DSP) circuitry implements a closed-loop control algorithm, and DACs provide output current for solenoid valves and hydraulic actuators. High-side driver channels provide control for inductive loads. Pressure scanner I/O card Remote ground sensing is used to improve the accuracy of the measurements. The maximum acquisition rate is 50Hz and all 64 channels can be sampled at this rate. Multiple cards can be fitted to the System (e.g. one for the front of the car and the other for the rear of the car). The pressure scanner card has been designed to work with the ESP-32 and ESP-64 pressure scanners manufactured by Pressure Systems Inc. Contact Pi Research for more information. I/O cards 85 I/O cards The Pressure scanner I/O card connects to a single pressure scanner unit, which can have up to 64 measurement ports. The pressure scanner I/O card provides the necessary multiplexer signals to select each of the 64 pressure measurement ports on the pressure scanner unit. CAN I/O card This card is an option which can be installed at time of order or which can be installed in a System at a later date. The CAN I/O card provides serial communications and additional digital I/O. Two serial ports which can be software configured are included. The two serial ports can be asynchronous or synchronous. They have software configurable physical layers (RS232, RS422 or RS485), with independent baud rate selection to 1Mbit/s. The CAN I/O card has two CAN 2.0B ports, with independent baud rate selection to 1Mbit, with 16 message buffers, and soft enabled 120 ohms bus termination. In synchronous mode, HDLC operation is supported with clock recovery to 1Mbit. In asynchronous operation, all common formats (including 9-bit address/data) are supported with split baud rate operation on both ports at baud rates based on a 1Mbit maximum rate or a 921kbit maximum rate. In addition to the serial ports and the CAN ports, the card has a number of digital I/O ports. The digital I/O ports are: two single ended Digital I/O channels with programmable sensor excitation, two differential Digital I/O channels with programmable sensor excitation and two 1Amp High side drivers. 86 Pi Sigma Sebring System Hardware Reference I/O card connections Introduction The MCU3 and SCU3 both have a number of ‘slots’ in which different types of I/O card can be fitted. The slots all have a common pin out configuration which allows any type of I/O card to be fitted into any I/O slot. I/O cards The modular nature of the Sebring System means that it is not sufficient to specify a signal name e.g. SIG2A+/R, you also need to specify the unit (MCU3 or SCU3), card slot in the unit and the external connector pin number to uniquely identify a signal connection. I/O cards 87 Signal naming conventions Many of the connector pins of the Pi Systems are designed to accept signals of different protocols. The signal name mnemonics used to describe these connector pins are made up of a number of characters, the meanings of which are listed below. Character Meaning A B ADDR BAT CASE CH CL DE EXC GND SIG IO NET O RX S TX 1-9 ‘A’ leg of an RS422 balanced pair (see RS422 circuit definition below) ‘B’ leg of an RS422 balanced pair (see RS422 circuit definition below) Junction box address Battery Unit case connection CAN high (CAN_H) CAN low (CAN_L) Debug Sensor excitation Ground Signal input Input/Output Network Output RS232 receive Serial RS232 transmit Port number For example, signal mnemonic SOB2/RX describes a multi functional pin that is software configurable to be either an RS422 output B leg, or an RS232 receive input. 88 Pi Sigma Sebring System Hardware Reference RS422 circuit definition The EIA RS422 specification definitions for the A circuit and the B circuit are: ■ ■ The A terminal of the generator shall be negative with respect to the B terminal for a binary 1 (Mark). The A terminal of the generator shall be positive with respect to the B terminal for a binary 0 (Space). I/O cards The RS422 specification is written in terms of A and B, not + and –, however it can be inferred, (but is not defined) that A is +ve circuit and B is –ve circuit. I/O cards 89 I/O card external connection details The following tables give the external connections to each card slot. The tables also give the Group number (as used in the Pi Workshop PC Software), the signal Mnemonic, the Signal description and the MCU3 or the SCU3 connector pin number. In addition to the above information, the MCU3 Selectronic card connections table also details the pin number for the Sigma Passive Octal Junction box connector which is fitted to a standard Sebring loom. In the connection tables, the pin number prefix in the Card columns have these meanings: L R S means the MCU3 Lefthand 66-way (or SCU3 Lefthand 55-way) connector means the MCU3 Righthand 66-way (or SCU3 Righthand 55-way) connector means the MCU3 System connector Example In the next table (MCU3 Selectronic card connections), the differential signal input+, (mnemonic SIG2A+/R) for Group 2B will be on pin 19 of the MCU3 righthand 66-way connector if the applicable Selectronic card is in the Card 1 position in the MCU3. If the Selectronic card is in the Card 3 position in the MCU3 then the signal (mnemonic SIG2A+/R) will be on pin 5 of the MCU3 righthand 66-way connector. 90 Pi Sigma Sebring System Hardware Reference MCU3 Selectronic card connections 1A EXC1 Signal description Output Prog. Excitation, regulated, minimum load 120R OR 0.5A high power unregulated Octal Card 1 Card 2 Card 3 connector R10 L10 L4 Pin 6 1B SIG1A+ Input Differential analog input+ R12 L12 L5 Pin 7 1C SIG1A– Input Differential analog input– R21 L21 L13 Pin 18 1D SIG1B+ Input Single ended analog input R20 L20 L6 Pin 8 Signal ground 1E GND1 – R11 L11 L1 Pin 9 2A EXC2 Output Prog. Excitation, regulated, minimum load 120R R17 L17 R4 Pin 13 2B SG2A+/R Input R19 L19 R5 Pin 14 Differential analog input+/RTD 2C SIG2A– Input Differential analog input– R30 L30 R13 Pin 22 2D SG2B+/R Input Single ended analog input+/RTD R29 L29 R6 Pin 1 2E GND2 – Signal ground R18 L18 R1 Pin 2 3A EXC3 Output Prog.Excitation, regulated, minimum load 120R R34 L34 L33 Pin 3 3B SIG3A+ Input Differential analog input+ R26 L26 L32 Pin 15 3C SIG3A– Input Differential analog input– R28 L28 L41 Pin 16 3D SIG3B+ Input Differential analog input+ R27 L27 L40 Pin 17 3E SG3B–/I Input Differential analog input– / Current input R35 L35 L42 Pin 5 4A EXC4 Output Prog. Excitation, regulated minimum load 120R R51 L51 R33 Pin 12 4B SIG4A+ Input Differential analog input+ R37 L37 R32 Pin 21 4C SIG4A– Input Differential analog input– R44 L44 R41 Pin 20 4D SIG4B+ Input Differential analog input+ R36 L36 R40 Pin 19 4E SG4B–/I Input Differential analog input– / Current input R52 L52 R42 Pin 10 GNDA Signal ground R25 L25 L2 Pin 11 GNDB Signal ground R43 L43 R2 Pin 4 I/O cards Group Mnemonic I/O I/O cards 91 MCU3 LVDT card connections Group Mnemonic I/O Signal description Octal Card 1 Card 2 Card 3 connector 1A EX1A+/5H Output LVDT 1A Prog. AC Excitation +/+5V/ HSD1 R10 L10 L4 Pin 6 1B SIG1A Input R12 L12 L5 Pin 7 1C EXC1A– Output LVDT 1A Prog. AC Excitation – R21 L21 L13 Pin 18 1D SIG1B Input R20 L20 L6 Pin 8 LVDT 1A Signal Input + / Input 1A LVDT 1A Signal Input – / Input 1B 1E EX5-/G Output LVDT 5A Prog. AC Excitation – / Gnd R11 L11 L1 Pin 9 2A EX2A+/5 Output LVDT 2A Prog. AC Excitation + / +5V R17 L17 R4 Pin 13 2B SIG2A Input R19 L19 R5 Pin 14 2C EXC2A– Output LVDT 2A Prog. AC Excitation – R30 L30 R13 Pin 22 LVDT 2A Signal Input + / Input 2A 2D SIG2B Input R29 L29 R6 Pin 1 2E EX5+/5G Output LVDT 5A Prog. AC Excitation +/+5V/ Gnd LVDT 2A Signal Input – / Input 2B R18 L18 R1 Pin 2 3A EX3A+/5 Output LVDT 3A Prog. AC Excitation + / +5V R34 L34 L33 Pin 3 3B SIG3A Input R26 L26 L32 Pin 15 3C EXC3A– Output LVDT 3A Prog. AC Excitation – LVDT 3A Signal Input + / Input 3A R28 L28 L41 Pin 16 3D SIG3B Input LVDT 3A Signal Input – / Input 3B R27 L27 L40 Pin 17 3E SG5+/HA Input LVDT 5A Signal Input + / HSD5A R35 L35 L42 Pin 5 4A EX4A+/5 Output LVDT 4A Prog. AC Excitation + / +5V R51 L51 R33 Pin 12 4B SIG4A Input R37 L37 R32 Pin 21 4C EXC4A– Output LVDT 4A Prog. AC Excitation – R44 L44 R41 Pin 20 4D SIG4B Input LVDT 4A Signal Input – / Input 4B R36 L36 R40 Pin 19 SG5–/HB Input 4E 92 LVDT 4A Signal Input + / Input 4A LVDT 5A Signal Input – / HSD5 R52 L52 R42 Pin 10 GNDA Signal ground R25 L25 L2 Pin 11 GNDB Signal ground R43 L43 R2 Pin 4 Pi Sigma Sebring System Hardware Reference MCU3 Moog/LVDT card connections Signal description 1A LVDT 1A Prog. AC Excitation + /+5V/ 0.3Amp HSD1 EX1A+/5H Output Octal Card 1 Card 2 Card 3 connector R10 L10 L4 Pin 6 1B SIG1A Input LVDT 1A Signal Input + / Input 1A R12 L12 L5 Pin 7 1C EXC1A– Output LVDT 1A Prog. AC Excitation – R21 L21 L13 Pin 18 1D SIG1B Input LVDT 1A Signal Input – / Input 1B R20 L20 L6 Pin 8 1E OUT5– Output Current / Voltage Output 5 – R11 L11 L1 Pin 9 2A EX2A+/5 Output LVDT 2A Prog. AC Excitation + / +5V R17 L17 R4 Pin 13 2B SIG2A Input LVDT 2A Signal Input + / Input 2A R19 L19 R5 Pin 14 2C EXC2A– Output LVDT 2A Prog. AC Excitation – R30 L30 R13 Pin 22 2D SIG2B Input LVDT 2A Signal Input – / Input 2B R29 L29 R6 Pin 1 2E HSD5 Output High Side 1Amp Unregulated R18 L18 R1 Pin 2 3A EX3A+/5 Output LVDT 3A Prog. AC Excitation + / +5V R34 L34 L33 Pin 3 3B SIG3A Input LVDT 3A Signal Input + / Input 3A R26 L26 L32 Pin 15 3C EXC3A- Output LVDT 3A Prog AC Excitation – R28 L28 L41 Pin 16 3D SIG3B Input LVDT 3A Signal Input – / Input 3B R27 L27 L40 Pin 17 3E IO5+ I/O Output 5 / Sense / Ground R35 L35 L42 Pin 5 4A HSD4 Output High Side 1Amp Unregulated R51 L51 R33 Pin 12 4B IO4A+/SG I/O Output 4A / Sense / Ground R37 L37 R32 Pin 21 4C OUT4A– Current / Voltage Output 4A – R44 L44 R41 Pin 20 4D IO4B+/SG I/O Output Output 4B / Sense / Ground R36 L36 R40 Pin 19 4E OUT4B- Current / Voltage Output 4B – R52 L52 R42 Pin 10 GNDA Signal ground R25 L25 L2 Pin 11 GNDB Signal ground R43 L43 R2 Pin 4 Output I/O cards Group Mnemonic I/O I/O cards 93 MCU3 Pressure scanner card connections Group Mnemonic I/O Signal description Card 1 Card 2 Card 3 Octal connector 1A AD0 Output Multiplex Select Address 0 R10 L10 L4 Pin 6 1B AD1 Output Multiplex Select Address 1 R12 L12 L5 Pin 7 1C 1AD2 Output Multiplex Select Address 2 R21 L21 L13 Pin 18 1D AD3 Output Multiplex Select Address 3 R20 L20 L6 Pin 8 1E AD4 Output Multiplex Select Address 4 R11 L11 L1 Pin 9 2A AD5/H3 Output Multiplex Select Address 5/ HSD 3 not supported R17 L17 R4 Pin 13 2B GSNSE3 Input Not supported R19 L19 R5 Pin 14 2C GSNSE2 Input Not supported R30 L30 R13 Pin 22 2D GSNSE1 Input Not supported R29 L29 R6 Pin 1 2E GSNSE0 Input Remote Ground Sense Pressure Scanner 0 R18 L18 R1 Pin 2 3A AD6/H2 Input No connection R34 L34 L33 Pin 3 3B SENS3 Input Not supported R2 6 L26 L32 Pin 15 3C SENS2 Input Not supported R28 L28 L41 Pin 16 3D SENS1 Input Not supported R2 7 L27 L40 Pin 17 3E SENS0 Input No connection R35 L35 L42 Pin 5 4A HSD1 Output HSD1 - Not supported R51 L51 R33 Pin 12 4B SIG3 Input Not supported R3 7 L37 R32 Pin 21 4C SIG2 Input Not supported R44 L44 R41 Pin 20 4D SIG1 Input Not supported R3 6 L36 R40 Pin 19 4E SIG0 Input Signal Input Pressure Scanner 0 R52 L52 R42 Pin 10 GNDA Signal ground R2 5 L25 L2 Pin 11 GNDB Signal ground R43 L43 R2 Pin 4 94 Pi Sigma Sebring System Hardware Reference MCU3 CAN card connections Signal description Card 1 Card 2 Card 3 Octal connector 1A EX1A+/5H Output LVDT 1A Prog. AC Excitation + / +5V / 0.3Amp HSD1 R10&R11 L11&L10 R23 Pin 6 1B SIG1A Input LVDT 1A Signal Input + / Input 1A R12 L12 R14 Pin 7 1C EXC1A– Output LVDT 1A Prog. AC Excitation – R20 L20 R13 Pin 18 Pin 8 1D SIG1B Input LVDT 1A Signal Input – / Input 1B R19 L19 R22 1E EX5–/G Output Current / Voltage Output 5 – R17&R18 L17&L18 R24 Pin 9 2A EX2A+/5 Output LVDT 2A Prog. AC Excitation + / +5V R47&R48 L48&L47 R55 Pin 13 2B SIG2A Input LVDT 2A Signal Input + / Input 2A R41 L41 R51 Pin 14 2C EXC2A– Output LVDT 2A Prog. AC Excitation – R35 L35 R43 Pin 22 Pin 1 2D SIG2B Input LVDT 2A Signal Input – / Input 2B R42 L42 R50 2E EX5+/5G Output High Side 1Amp Unregulated R49&R53 L49&L53 R54 Pin 2 3A EX3A+/5 Output LVDT 3A Prog. AC Excitation + / +5V R25 L25 R31 Pin 3 3B SIG3A Input LVDT 3A Signal Input + / Input 3A R21 L21 R38 Pin 15 Pin 16 3C EXC3A– Output LVDT 3A Prog. AC Excitation – R26 L26 R30 3D SIG3B Input LVDT 3A Signal Input – / Input 3B R27 L27 R45 Pin 17 3E SG5+/HA I/O Output 5 / Sense / Ground R32 L32 R39 Pin 5 4A EX4A+/5 Output High Side 1Amp Unregulated R33 L33 R46 Pin 12 Pin 21 4B SIG4A Input Output 4A / Sense / Ground R28 L28 R36 4C EXC4A– Output Current / Voltage Output 4A – R29 L29 R37 Pin 20 4D SIG4B Input Output 4B / Sense / Ground R34 L34 R44 Pin 19 4E SG5–/HB I/O Current / Voltage Output 4B – R40 L40 R52 Pin 10 GNDA Signal ground R4 L4 R15 Pin 11 GNDB Signal ground R5 L5 R16 Pin 4 I/O cards I/O cards Group Mnemonic I/O 95 SCU3 Selectronic card connections Group Mnemonic I/O Signal description Card 1 Card 2 Card 3 Octal connector 1A Prog. Excitation, regulated, minimum load 120R, OR 0.5A high power unregulated R10&R11 L11&L10 R23 Pin 6 EXC1 Output 1B SIG1A+ Input Differential analog input+ R12 L12 R14 Pin 7 1C SIG1A– Input Differential analog input– R20 L20 R13 Pin 18 Pin 8 1D SIG1B+ Input Single ended analog input R19 L19 R22 1E GND1 – Signal ground R17&R18 L17&L18 R24 Pin 9 2A EXC2 Output Prog. Excitation, regulated, minimum load 120R R47&R48 L48&L47 R55 Pin 13 2B SG2A+/R Input Differential analog input+ / RTD R41 L41 R51 Pin 14 2C SIG2A– Input Differential analog input– R35 L35 R43 Pin 22 Pin 1 2D SG2B+/R Input Single ended analog input+ / RTD R42 L42 R50 2E GND2 – Signal ground R49&R53 L49&L53 R54 Pin 2 3A EXC3 Output Prog. Excitation, regulated, minimum load 120R R25 L25 R31 Pin 3 3B SIG3A+ Input Differential analog input+ R21 L21 R38 Pin 15 3C SIG3A– Input Differential analog input– R26 L26 R30 Pin 16 3D SIG3B+ Input Differential analog input+ R27 L27 R45 Pin 17 3E SG3B–/I Input Differential analog input– / current input R32 L32 R39 Pin 5 4A EXC4 Output Prog. Excitation, regulated, minimum load 120R L33 R46 Pin 12 R33 4B SIG4A+ Input Differential analog input+ R28 L28 R36 Pin 21 4C SIG4A– Input Differential analog input– R29 L29 R37 Pin 20 4D SIG4B+ Input Differential analog input+ R34 L34 R44 Pin 19 4E SG4B–/I Input Differential analog input– / current input R40 L40 R52 Pin 10 96 GNDA Signal ground R4 L4 R15 Pin 11 GNDB Signal ground R5 L5 R16 Pin 4 Pi Sigma Sebring System Hardware Reference SCU3 LVDT card connections Signal description Card 1 Card 2 Card 3 Octal connector 1A EX1A+/5H Output LVDT 1A Prog. AC Excitation + / +5V / HSD1 R10&R11 L11&L10 R23 Pin 6 1B SIG1A Input LVDT 1A Signal Input + / Input 1A R12 L12 R14 Pin 7 1C EXC1A– Output LVDT 1A Prog. AC Excitation – R20 L20 R13 Pin 18 1D SIG1B Input LVDT 1A Signal Input – / Input 1B R19 L19 R22 Pin 8 1E EX5–/G Output LVDT 5A Prog. AC Excitation – / Ground R17&R18 L17&L18 R24 Pin 9 2A EX2A+/5 Output LVDT 2A Prog. AC Excitation + / +5V R47&R48 L48&L47 R55 Pin 13 2B SIG2A Input LVDT 2A Signal Input + / Input 2A R41 L41 R51 Pin 14 2C EXC2A– Output LVDT 2A Prog. AC Excitation – R35 L35 R43 Pin 22 2D SIG2B Input LVDT 2A Signal Input – / Input 2B R42 L42 R50 Pin 1 2E EX5+/5G Output LVDT 5A Prog. AC Excitation + / +5V / Ground R49&R53 L49&L53 R54 Pin 2 3A EX3A+/5 Output LVDT 3A Prog. AC Excitation + / +5V R25 L25 R31 Pin 3 3B SIG3A Input LVDT 3A Signal Input + / Input 3A R21 L21 R38 Pin 15 3C EXC3A– Output LVDT 3A Prog. AC Excitation – R26 L26 R30 Pin 16 3D SIG3B Input LVDT 3A Signal Input – / Input 3B R27 L27 R45 Pin 17 3E SG5+/HA Input LVDT 5A Signal Input + / HSD5A R32 L32 R39 Pin 5 4A EX4A+/5 Output LVDT 4A Prog. AC Excitation + / +5V R33 L33 R46 Pin 12 4B SIG4A Input LVDT 4A Signal Input + / Input 4A R28 L28 R36 Pin 21 4C EXC4A– Output LVDT 4A Prog. AC Excitation – R29 L29 R37 Pin 20 4D SIG4B Input LVDT 4A Signal Input – / Input 4B R34 L34 R44 Pin 19 4E SG5–/HB Input LVDT 5A Signal Input – / HSD5B R40 L40 R52 Pin 10 GNDA Signal ground R4 L4 R15 Pin 11 GNDB Signal ground R5 L5 R16 Pin 4 I/O cards I/O cards Group Mnemonic I/O 97 SCU3 Moog/LVDT card connections Group Mnemonic I/O Signal description Card 1 Card 2 Card 3 Octal connector 1A LVDT 1A Prog. AC Excitation + / +5V / 0.3Amp HSD1 R10&R11 L11&L10 R23 Pin 6 EX1A+/5H Output 1B SIG1A Input LVDT 1A Signal Input + / Input 1A R12 L12 R14 Pin 7 1C EXC1A– Output LVDT 1A Prog. AC Excitation – R20 L20 R13 Pin 18 1D SIG1B Input LVDT 1A Signal Input – / Input 1B R19 L19 R22 Pin 8 1E EX5–/G Output Current / Voltage Output 5 – R17&R18 L17&L18 R24 Pin 9 2A EX2A+/5 Output LVDT 2A Prog. AC Excitation + / +5V R47&R48 L48&L47 R55 Pin 13 2B SIG2A Input LVDT 2A Signal Input + / Input 2A R41 L41 R51 Pin 14 2C EXC2A– Output LVDT 2A Prog. AC Excitation – R35 L35 R43 Pin 22 2D SIG2B Input LVDT 2A Signal Input – / Input 2B R42 L42 R50 Pin 1 2E EX5+/5G Output High Side 1Amp Unregulated R49&R53 L49&L53 R54 Pin 2 3A EX3A+/5 Output LVDT 3A Prog. AC Excitation + / +5V R25 L25 R31 Pin 3 3B SIG3A Input LVDT 3A Signal Input + / Input 3A R21 L21 R38 Pin 15 3C EXC3A– Output LVDT 3A Prog AC Excitation – R26 L26 R30 Pin 16 3D SIG3B Input LVDT 3A Signal Input – / Input 3B R27 L27 R45 Pin 17 3E SG5+/HA I/O Output 5 / Sense / Ground R32 L32 R39 Pin 5 4A EX4A+/5 Output High Side 1Amp Unregulated R33 L33 R46 Pin 12 4B SIG4A Input Output 4A / Sense / Ground R28 L28 R36 Pin 21 4C EXC4A– Output Current / Voltage Output 4A – R29 L29 R37 Pin 20 4D SIG4B Input Output 4B / Sense / Ground R34 L34 R44 Pin 19 SG5–/HB I/O 4E 98 Current / Voltage Output 4B – R40 L40 R52 Pin 10 GNDA Signal ground R4 L4 R15 Pin 11 GNDB Signal ground R5 L5 R16 Pin 4 Pi Sigma Sebring System Hardware Reference SCU3 Pressure scanner card connections Signal description Card 1 Card 2 Card 3 Octal connector 1A AD0 Output Multiplex Select Address 0 R10&R11 L11&L10 R23 Pin 6 1B AD1 Output Multiplex Select Address 1 R12 L12 R14 Pin 7 1C AD2 Output Multiplex Select Address 2 R20 L20 R13 Pin 18 1D AD3 Output Multiplex Select Address 3 R19 L19 R22 Pin 8 1E AD4 Output Multiplex Select Address 4 R17&R18 L17&L18 R24 Pin 9 2A AD5/H3 Output Multiplex Select Address 5/ HSD 3 – not supported R47&R48 L48&L47 R55 Pin 13 2B GSNSE3 Input Not supported R41 L41 R51 Pin 14 Pin 22 2C GSNSE2 Input Not supported R35 L35 R43 2D GSNSE1 Input Not supported R42 L42 R50 Pin 1 2E GSNSE0 Input Remote Ground Sense Pressure Scanner 0 R49&R53 L49&L53 R54 Pin 2 3A AD6/H2 Input No connection R25 L25 R31 Pin 3 3B SENS3 Input Not supported R21 L21 R38 Pin 15 3C SENS2 Input Not supported R26 L26 R30 Pin 16 3D SENS1 Input Not supported R27 L27 R45 Pin 17 3E SENS0 Input No connection R32 L32 R39 Pin 5 4A HSD1 Output HSD1 – Not supported R33 L33 R46 Pin 12 4B SIG3 Input Not supported R28 L28 R36 Pin 21 4C SIG2 Input Not supported R29 L29 R37 Pin 20 4D SIG1 Input Not supported R34 L34 R44 Pin 19 4E SIG0 Input Signal Input Pressure Scanner 0 R40 L40 R52 Pin 10 GNDA Signal ground R4 L4 R15 Pin 11 GNDB Signal ground R5 L5 R16 Pin 4 I/O cards I/O cards Group Mnemonic I/O 99 SCU3 CAN card connections Group Mnemonic I/O Signal description Card 1 Card 2 Card 3 Octal connector 1A EX1A Output Prog. excitation 120 ohms maximum load R10&R11 L10&L11 R23 Pin 6 1B IO1A+ I/O R12 L12 R14 Pin 7 Differential digital input+/output 1C SIG1A– Input Differential digital input– R20 L20 R13 Pin 18 1D SIG1B+ I/O Single ended digital input+/output R19 L19 R22 Pin 8 1E GND1 2A EX2A Signal ground Output Prog. excitation 120 ohms maximum load R17&R18 L17&L18 R24 Pin 9 R47&R48 L47&L48 R55 Pin 13 2B IO2A+ I/O Differential digital input+/output R41 L41 R51 Pin 14 2C SIG2A– Input Differential digital input– R35 L35 R43 Pin 22 2D IO2B I/O Single ended digital input+/output R42 L42 R50 Pin 1 Signal ground R49&R53 L49&L53 R54 Pin 2 I/O RS422A to MCU or CAN_H input+/output R25 L25 R31 Pin 3 2E GND1 3A SIA3/CH 3B SOA3/TX Output MCU to RS422A or RS232 R21 L21 R38 Pin 15 3C SIB3/CL I/O RS422B to MCU or CAN_L input+/output R26 L26 R30 Pin 16 3D SOB3/RX I/O MCU to RS422B or RS232 to MCU input+/output R27 L27 R45 Pin 17 3E HSD5A Output High side driver, 1 amp max. R32 L32 R39 Pin 5 4A SIA4/CH I/O R33 L33 R46 Pin 12 RS422A to MCU or CAN_H input+/output 4B SOA4/TX Output MCU to RS422A or RS232 R28 L28 R36 Pin 21 4C SIB4/CL I/O RS422B to MCU or CAN_L input+/output R29 L29 R37 Pin 20 4D SOB4/RX I/O MCU to RS422B or RS232 to MCU input+/output R34 L34 R44 Pin 19 HSD5B Output High side driver, 1 amp max. 4E 100 R40 L40 R52 Pin 10 GNDA Signal ground R4 L4 R15 Pin 11 GNDB Signal ground R5 L5 R16 Pin 4 Pi Sigma Sebring System Hardware Reference System expansion System expansion Connecting sensors The Pi Sigma system sensor connections are based on a 5-pin connector standard. The standard pinouts for a number of types of sensor are given in the tables below. 5-pin sensor connections Dual digital (Active) EXC+ Pin Dual Diff Single RTD Current loop LVDT MOOG/ HSD 1 EXC+ EXC+ EXC+ N/C EXC+ ~EXC+ HSD+ 2 SIGA+ SIG+ SIG+ RTD+ SIGGND ~SIG+ MOOG+ SIGA+ 3 SIGB+ N/C N/C N/C N/C ~SIG– N/C SIGB+ 4 SIGA– SIG– SIGGND RTD– I– ~EXC– MOOG– N/C 5 EXC– EXC– EXC– RTD– EXC– SIGGND HSD– EXC– Pin Dual digital Active (Passive) digital Passive digital 1 SIG– SIG– EXC+ RS422 CAN + RS232 CAN + RS422 Out RS422 In + RS232 Debug SIA CANH CANH SIA +12V 2 SIGA+ SIG+ SIG+ SOA TXD SOA TXD TXD 3 SIGB+ N/C N/C SOB RXD SOB RXD RXD 4 N/C SIG– N/C SIB CANL CANL SIB MODE 5 N/C EXC– N/C GNDREF GNDREF GNDREF GNDREF GNDREF System expansion 103 System expansion 5-pin sensor connections (continued) Key to 5-pin sensor connections tables 104 Name Description Name Description CANH CANL EXC+ EXC– GNDREF HSD+ HSD– I– IN A IN B MODE MOOG+ MOOG– N/C OUTA OUTB CAN link High side CAN link Low side Positive supply voltage Negative supply voltage (0V) Comms ground reference High Side Driver positive High Side Driver negative (0V) Current sensor input (sink) RS422 A input RS422 B input Debug mode input Moog Drive positive Moog Drive negative No Connection RS422 A output RS422 B output RTD+ RTD– RXD SIG+ SIG– SIGGND SIGA+ SIGA– SIGB+ SIGB– TXD ~EXC+ ~EXC– ~SIG+ ~SIG– RTD sensor positive end RTD sensor negative end RS232 input Signal positive input Signal negative input Signal ground (0V) Signal A positive input Signal B negative input Signal B positive input Signal B negative input RS232 output AC excitation AC excitation AC Signal input AC Signal input Pi Sigma Sebring System Hardware Reference Connecting sensors to a Selectronics I/O card The Selectronics I/O card has eight input channels, arranged in four pairs or Groups. Each Group has one excitation voltage commoned to both channels. Two of the groups have grounds for high power use and the other two groups have grounds for low power use. The following tables summarise the input functions of each channel in the groups. Selectronic I/O card input functions Inputs 1A and 1B Input Excite Excite options Type Mode Gain ADC ref Special Bipolar or Unipolar 0–640 Bipolar 0–8 Unipolar Absolute None 1A EXC1 0.5A unregulated BATT Differential OR 5.0–10V regulated 1B EXC1 0.5A Unregulated BATT Single ended Unipolar OR 5.0–10V regulated 0–8 Unipolar None Input Excite Excite options Type Mode 2A EXC2 5.0–10V regulated Differential Bipolar or 0–640 Bipolar Absolute/ RTD Unipolar 0–8 Unipolar Ratiometric Gain ADC ref 2B EXC2 5.0–10V regulated Single ended Unipolar only 0–8 Unipolar Special RTD System expansion 105 System expansion Inputs 2A and 2B Inputs 3A and 3B Input Excite Excite options Type Mode 3A EXC3 5.0–10V regulated Differential Bipolar or 0–640 Bipolar Absolute/ None Unipolar 0–8 Unipolar Ratiometric Gain ADC ref Special 3B EXC3 5.0–10V regulated Differential Bipolar or 0–640 Bipolar Unipolar 0–8 Unipolar Current (0–20mA) Inputs 4A and 4B Input Excite Excite options Type Mode 4A EXC4 5.0–10V regulated Differential Bipolar or 0–640 Bipolar Absolute/ None Unipolar 0–8 Unipolar Ratiometric Gain ADC ref Special 4B EXC4 5.0–10V regulated Differential Bipolar or 0–640 Bipolar Unipolar 0–8 Unipolar Current (0–20mA) Explanation of the headings in the Selectronic I/O card input functions tables are given below. Input The name of the channel. In Pi Workshop PC Software it will appear in the following format: Input1A.02.03.16 where: ■ ■ ■ ■ 106 Input1A refers to the channel .02 refers to the Node (02 is the MCU3, 05 is the SCU3) .03 refers to the Card number (0-5 where 0 is always the digital I/O card) .16 is a unique number assigned by Pi Workshop PC Software Pi Sigma Sebring System Hardware Reference Excite The Excite output associated with that Group. This is loom dependant but normally EXC1 is for Group 1, EXC2 is for Group 2 and so on. The programmable voltages work from 5V to 10V. The EXC outputs are rated for a 120 ohms load. i.e. 100mA at 12V or 40mA at 5V. Note: EXC1 has a 500mA unregulated option. Type Differential means that there is a signal – ve and a signal +ve. Single ended means that the signal –ve is grounded on the card. Generally, only low current sensors should be used with single ended inputs. These types of input are suited to temperature or pressure sensor where absolute accuracy is not imperative. Mode Gain Unipolar channels can be programmed by the user to have a gain from 0 to 8. Bipolar channels can be programmed by the user to have a gain from 0 to 640. You can mix and match gains with two exceptions: ■ ■ If one of the channels in a Group has unity gain then the other channel in the group must also have unity gain For inputs 1A and 2A they must both be either unipolar or bipolar. Changing one automatically changes the other. System expansion 107 System expansion Unipolar means that the input can only measure positive signals. Bipolar means that the input can measure both positive and negative signals. ADC ref There are two types of sensor available, absolute and ratiometric. Absolute sensors are usually active sensors, such as accelerometers, which have an internal voltage reference or regulator and are unaffected by drift in the excitation voltage. Ratiometric sensors, such as potentiometers or strain gauges, are affected by the excitation voltage. If you double the excitation voltage, you double the signal voltage. In ratiometric mode the Selectronics I/O card monitors the excitation voltage and compensates for any drift. This is useful for strain gauges where the gains are high, and where the excitation voltage can be increased (e.g. from 5V to 7V) to give more output. In ratiometric mode the calibration is unchanged even when the excitation is increased. This means that you can decrease the gain and improve the signal to noise ratio. Special Some inputs can accommodate special sensors e.g. RTDs and Current output type of sensor. Selecting Current operation limits the possible configurations of a Group. If inputs 3B or 4B are set to current input, then inputs 3A or 4A must be bipolar. Ratiometric mode is not available. 108 Pi Sigma Sebring System Hardware Reference Sensor wiring information Wiring information for some types of sensors is given in the figures below. Connecting a single ended sensor to a single ended input Group 1 Input 1B and Group 2 Input 2B are single ended inputs. 5-pin connectors I/O card Sensor EXC + – 1 SIG+ 2 GND* 5 System expansion *GND connection can use low current (100mA) signal grounds GND1 or GND2 or high current (500mA) GNDA or GNDB as appropriate Connecting a potentiometer to a single ended input System expansion 109 Connecting a single ended sensor to a differential ended input Group 1 Input 1A, Group 2 Input 2A, Group 3 Input 3A and Input 3B, Group 4 Input 4A and Input 4B are differential inputs. 5-pin connectors I/O card Sensor + – EXC 1 SIG+ 2 SIG– 4 GND* 5 *GND connection can use low current (100mA) signal grounds GND1 or GND2 or high current (500mA) GNDA or GNDB as appropriate Connecting a single ended sensor to a single ended input 110 Pi Sigma Sebring System Hardware Reference Connecting a strain gauge to a differential input Strain gauges can only be connected to differential inputs (Group 1 Input 1A, Group 2 Input 2A, Group 3 Input 3A and Input 3B, Group 4 Input 4A and Input 4B). 5-pin connectors I/O card EXC + – 1 SIG+ 2 SIG– 4 GND* 5 Sensor *GND connection can use low current (100mA) signal grounds GND1 or GND2 or high current (500mA) GNDA or GNDB as appropriate System expansion Connecting a strain gauge to a differential input System expansion 111 Connecting an RTD RTD sensors can only be connected to Group 2 Input 2A and Input 2B. The pull-up resistor (value 5k1 ohms) is enbled when RTD is selected as an input type in Pi Workshop. 5-pin connectors I/O card Sensor EXC 5k1 + – SIG+ 2 SIG– 4 GND* 5 *GND connection can use low current (100mA) signal grounds GND1 or GND2 or high current (500mA) GNDA or GNDB as appropriate Connecting an RTD 112 Pi Sigma Sebring System Hardware Reference Connecting a current output sensor Current output sensors can only be connected to Group 3 Input 3A and Input 3B, Group 4 Input 4A and Input 4B. 5-pin connectors I/O card + – EXC 1 SIG+ 2 SIG– 4 GND* 5 Sensor Current output sensor *GND connection can use low current (100mA) signal grounds GND1 or GND2 or high current (500mA) GNDA or GNDB as appropriate Connecting a current output sensor System expansion Note: You can connect a single ended sensor to Group 3 and Group 4 without an external ground strap if you turn on the current sense option in the Pi Workshop, which enables the sense resistor between SIG– and ground. System expansion 113 Connecting a voltage output sensor to a single ended input Connect 0–5V output sensors (e.g. pressure sensors) to Group 1 Input 1B and Group 2 Input 2B which are single ended inputs. 5-pin connectors I/O card Sensor EXC + – 1 SIG+ 2 GND* 5 Active sensor *GND connection can use low current (100mA) signal grounds GND1 or GND2 or high current (500mA) GNDA or GNDB as appropriate Connecting a 0–5V voltage output sensor to a single ended input 114 Pi Sigma Sebring System Hardware Reference Connecting a voltage output sensor to a differential ended input Group 1 Input 1A, Group 2 Input 2A, Group 3 Input 3A and Input 3B, Group 4 Input 4A and Input 4B are differential inputs. 5-pin connectors I/O card Sensor + – EXC 1 SIG+ 2 SIG– 4 GND* 5 Active sensor *GND connection can use low current (100mA) signal grounds GND1 or GND2 or high current (500mA) GNDA or GNDB as appropriate System expansion Connecting a 0–5V voltage output sensor to a differential ended input System expansion 115 Miscellaneous connectors Octal passive junction box The Octal passive junction box can be used to connect inputs from several sensors and is compatible with a range of I/O cards. The Octal passive junction box provides connection for 6 differential inputs and 2 single ended inputs making it compatible with a Selectronics I/O card. The Octal passive junction box can also be used with an LVDT I/O card. The Octal passive junction box can also be used with thermocouple sensors. Up to 7 thermocouple sensor inputs and a temperature reference can be connected to the junction box. 1A 1B 2A 2B 3A 3B 4A 4B Octal passive junction box (OPJB) - position of connectors 116 Pi Sigma Sebring System Hardware Reference Octal passive junction box connectors Description OPJB Connector Loom Mating connector Flying lead connector Connectors 1A to 4B AS612-35PN AS106-05SN-HE AS112-35SN AS606-05PN-HE Connection details The following tables detail the connections on OPJB. The tables are for a standard Pi Sigma Sebring configuration and assume that the connections are to a Selectronics I/O card. For connections to other I/O cards refer to the Octal connector column in the relevant table in the section I/O Cards. The Octal column in the following tables refers to the pin number on the flying lead 22-pin ‘Octal’ connectors on the System loom. Octal Input pin Group Mnemonic Signal description 6 7 8 18 4 1 2 3 4 5 EXC1 SIG1A+ SIG1B+ SIG1A– GNDB Programmable excitation Differential analog input + Single ended analog input Differential analog input – Signal ground 1A 1B 1D 1C GNDB System expansion Input connector 1A Input connector 1B Octal Input pin Group Mnemonic Signal description 6 8 – – 9 1 2 3 4 5 EXC1 SIG1B+ – – GND1 Programmable excitation Single ended analog input + No connection No connection Signal ground 1A 1D – – 1E System expansion 117 Input connector 2A Octal Input pin Group Mnemonic Signal description 13 14 1 22 11 EXC2 SIG2A+/R SIG2B+/R SIG2A GNDA Programmable excitation 100mA Differential analog input + or RTD input Single ended analog input + or RTD input Differential analog input – Signal ground Octal Input pin Group Mnemonic Signal description 13 1 N/C N/C 2 2A 2D EXC2 SIG2B+/R 2E GND2 Programmable excitation 100mA Single ended analog input No connection No connection Signal ground Octal Input pin Group Mnemonic Signal description 3 15 17 16 4 EXC3 SIG3A+ SIG3B+ SIG3A– GNDB Programmable excitation 100mA Differential analog input + Differential analog input + Differential analog input – Signal ground 1 2 3 4 5 2A 2B 2D 2C GNDA Input connector 2B 1 2 3 4 5 Input connector 3A 118 1 2 3 4 5 3A 3B 3D 3C GNDB Pi Sigma Sebring System Hardware Reference Input connector 3B Octal Input pin Group Mnemonic Signal description 3 17 N/C 5 9 EXC3 SIG3B+ TSIG SIG3B–/I GND1 1 2 3 4 5 3A 3D 3E 1E Programmable excitation Differential analog input + Temperature compensation signal Differential analog input – or current input Signal ground Input connector 4A Octal Input pin Group Mnemonic Signal description 12 21 19 20 11 EXC4 SIG4A+ SIG4B+ SIG4A– GNDA Programmable excitation 100mA Differential analog input + Differential analog input + Differential analog input – Signal ground Octal Input pin Group Mnemonic Signal description 12 19 N/C 10 2 4A 4D EXC4 SIG4B+ 4E 2E SIG4B–/I GND2 Programmable excitation 100mA Differential analog input + No connection Differential analog input – or current input Signal ground 1 2 3 4 5 4A 4B 4D 4C GNDA 1 2 3 4 5 System expansion System expansion Input connector 4B 119 Tire Monitoring System (TMS) connections The connection details below are for the Tire Monitoring System (TMS) which is a cost option to the standard Pi Sigma Sebring system. Connector details Loom connector TMS unit connector AS610-35-SN AS110-35-PN Connector pin information 120 MCU3 pin TMS pin Mnemonic Signal description S8 S6 S32 S25 FBAT1– FBAT1+ RX5A RX5B No connection – No connection – TMS power 0V TMS power + 9–18V (750mA) TMS to MCU3 data TMS to MCU3 ground 1 2 3 4 5 to 9 10 11, 12 13 Pi Sigma Sebring System Hardware Reference TICK BUS TICK OUT Telemetry connections The connection details below are for the Pi telemetry system, which is a cost option to the standard Pi Sigma Sebring system. Connector details Loom connector Radio connector Lemo FGC 1B 307 Blue sleeve Lemo EHG 1B 307 Connector pin information MCU3 pin Telemetry pin Mnemonic Signal description S31 S3 Battery –ve* Battery +ve* 1 2 3 4 5 6 7 Radio inhibit MCU3 data to telemetry radio Radio to MCU3 data Radio to MCU3 data Telemetry radio to MCU3 ground Telemetry power 0V Telemetry power 12V No connection SOA2/TX No connection No connection SOB2/RX - System expansion * Connect to battery NOT MCU3. System expansion 121 Dash connectors The Pi Sigma Sebring system can use a Pi Compact dash or a Pi Steering wheel dash to display information. The Compact dash can drive a number of satellite display modules. Dashes are connected to the MCU3 via the main loom and a number of smaller looms. Both types of dash require two remote switches (left and right) to control them. When used with the compact dash the remote switches require a Switches to CAN interface box. Compact dash connections The figure below shows the method of connecting a Compact dash and satellite modules to the System. Compact dash System loom – Dash and switches connector Satellite modules Dash and switches Y- loom Switches to CAN box Switch loom Left and right switches Connecting a Compact dash to the System Compact dash connector information 122 Description Loom connector Dash or box connector Compact dash Switches to CAN interface box Dash and switches y-loom AS606-05PN-HE AS606-05PN-HE AS606-05PB-HE AS106-05SN-HE AS206-05SN-HE AS206-05SB-HE Pi Sigma Sebring System Hardware Reference Dash and switches y-loom detail Compact dash connector Dash and switches Y- loom Loom CAN connector Left and right switches Switches to CAN box Switches connector Dash and switches y-loom Dash and switches y-loom dash connector MCU3 pin S22 S33 Dash Pin Mnemonic Signal description 1 2 3 4 5 SOA4/TX SOA4/RX BATT– BATT+ No connection MCU3 to dash RS422A data Dash to MCU3 RS422B data Battery – 12V battery + MCU3 pin Pin Mnemonic Function S23 1 2 3 4 5 SIA4/CH No connection BATT+ SIB4/CL BATT– Dash switch CAN High S24 System expansion Switches to CAN box - CAN connector 12V battery + Dash switch CAN Low Battery – System expansion 123 Switches to CAN box - switches connector 124 Pin Function 1 2 3 4 5 Left switch up Left switch down Right switch up Right switch down Ground Pi Sigma Sebring System Hardware Reference Steering wheel dash connections The steering wheel dash can be connected to the System as shown in the figure below. The left and right switches are wired onto the loom which is terminated with a 19-pin connector, which plugs into the rear of the Steering wheel dash. Steering wheel dash System loom – Dash and switches connector Left switch Steering column Right switch Connecting a Steering wheel dash via the steering column Description Loom connector Mating connector 19-pin connector Steering wheel dash AS connector AS608-35SN AS108-35PN System expansion Steering wheel dash connector information Steering wheel dash loom connector details AS608-35SN connector MCU3 pin Pin S23 S24 S22 S33 1 2 3 4 5 6 Shell Wire color Mnemonic Signal description Black Red Yellow Green Brown Orange Screen BATT– BATT+ SIA4/CH SIB4/CL SOA4/TX SOA4/RX Battery –ve Battery +ve Dash switch CAN High Dash switch CAN Low MCU3 to dash data Dash to MCU3 data System expansion 125 Steering wheel dash 19-pin connector details Pin Function Pin Function 1 2 3 4 5 6 7 8 9 10 Ground (black) RS422A (brown) Power (red) RS422B (orange) CAN_H (yellow) CAN_L (green) Right switch down (blue) Right switch up (violet) Left switch down (grey) Left switch up (white) 11 12 13 14 15 16 17 18 19 Switch ground (white/black) MRC ground (white/brown) MRC data (white/red) SW 1 down (white/orange) SW 1 up (white/yellow) SW 2 down (white/green) SW 2 up (white/blue) SW 3 down (white/violet) SW 3 up (white/grey) Pins 14 to 19 allow additional switches to be connected to the CAN interface which is contained within the steering wheel dash. Right switch connections Pin Function Wire color 1 2 3 Ground Switch up Switch down Black Violet Blue Left switch connections 126 Pin Function Wire color 1 2 3 Ground Switch up Switch down Black White Grey Pi Sigma Sebring System Hardware Reference Index Index C G Comms connectors 66 Download connector D Symbols 60 I/O cards CAN connections connector Analog debug channels 47 maximum logging rate 47, 75 122 MCU3 CAN card Box battery input current 125 MCU3 LVDT card 19-pin connector 126 MCU3 Moog/LVDT card Box battery voltage Dash connectors 47 Box temperature on Nose card Lateral Accelerometer Power Supply +12V Power supply +5V 47 Debug port Power supply -12V 122 Box battery input current Box battery voltage Box temperature 75 19 Power Supply +12V 75 Rear right wheelspeed Programming Voltage PSU temperature Reference voltage Download connector Download lead 75 Right battery voltage Backup battery 40 Lemo connectors 21 52 66 L boots 25 key angle 23 parts numbering system 22 69 MCU3 36 41 26 connecting the 26 MCU3 connectors 90 Lefthand 66-way 32 40 M Fitting an MCU3 fitting looms B 52 53 Download path connections F 75 Orientation 53 68 75 75 41 Installing the MCU3 Rear left wheelspeed 75 85 84 Fitting an MCU3 15 75 99 96 Installation 17 Front right wheelspeed 75 98 85 Selectronic 20 94 84 Pressure scanner Front left wheelspeed 75 Power supply -12V LVDT Digital inputs 75 97 Moog/LVDT Left battery voltage Power supply +5V 15 19 to connect 75 100 SCU3 LVDT card SCU3 Selectronic card part numbering Battery backup voltage SCU3 CAN card SCU3 Pressure scanner card part numbering 47 75 93 91 SCU3 Moog/LVDT card 16 contacts 47 126 64 Micro HE Vertical Accelerometer MCU3 Selectronic card 64 contacts 47 PSU temperature 125 Deutsch Autosport connectors 47 47 92 MCU3 Pressure scanner card 122 Compact dash 47 debug mode 47 Longitudinal Accelerometer 126 Right switch connections 47 95 Steering wheel dash loom connector 47, 52 83 86 connections 123 Left switch connections 47 Battery backup voltage SCU3 34 Compact dash A MCU3 33 Testing for I Dash connections 10baseT Ethernet Ground loops 66 Righthand 66-way System Index Index 90 90 90 Index 129 SCU3 connectors MCU3 Digital channels Digital Group 1 Digital Group 2 2A and 2B 3A and 3B 53 Lefthand 55-way 76 ECU input 77 Righthand 55-way ADC ref 56 CAN link 40 MCU3 power requirements Telemetry 104 connecting an RTD Octal passive junction box Connector details Debug mode input 117 connector 1A Excite 117 connector 1B 117 connector 2A 118 connector 2B Gain connector 3A 118 connector 3B 119 connector 4A 119 connector 4B 106 Mode 107 Bipolar PC Network 70 PiNet 71 reference voltage 54 54 Programmable pre-scalar values S 55 107 Moog Drive 104 Star points switches connector 104 Debug port PiNET Selectronics I/O card 105 Signal negative input 104 Special System 130 80 80 104 109, 110 108 107 Single ended 80 Pi Sigma Sebring System Hardware Reference 124 64 64 T Telemetry 121 connections 121 Tire Monitoring System connections Differential input 123, 124 123 System comms 88 104 79 2A and 2B CAN connector RTD sensor Digital Group 1 125 Switches to CAN box 104 104 single ended input 88 Steering wheel dash 104 104 79 Digital Group 2 63 27 RS422 input Type 60 90 Signal naming 107 Unipolar SCU3 connections 79 63 61 TMS receive 104 Signal positive input 1A and 1B Telemetry 104 connector RS232 output Programmable hysteresis 63 Sigma Passive Octal Junction box RS232 input 60 61 Pit communications 107 62 64 MCU3 to dash 107 Positive supply voltage 65 pit detect Debug port Negative supply voltage Cross over cable 62 CAN switches to MCU3 104 59 60, 61, 62, 63 ELB transmit High Side Driver Input 59 ECU input ground reference P ADR 104 107 Unipolar 119 Serial port 107 Bipolar 118 111 59 59 Tire Monitoring System 113 112 Current sensor input 116 59 Pit communication 108 connecting a strain gauge O 59 59 Octal serial junction box 108 connecting a current output sensor 27 59 MCU3 to dash ratiometric 56 MCU3 orientation MCU3 108 absolute sensors 59 59 Engine Log Book 78 Sensor connections 103 56 Digital Group 4 4A and 4B CAN switches details 52, 53 Digital Group 3 Serial comms ports 76 52 107 107 120 120 90 V Vehicle battery 29 connecting to 29, 30 W Wheelspeed buffered output Front right Rear left Rear right 58 53 52 53 52 Index Front left Index 131 Contact information For more information about Pi products and details of worldwide authorized agents, please contact: Pi Research Brookfield Motorsports Centre Twentypence Road Cottenham CAMBRIDGE UK Customer Support Tel +44 (0) 1954 253600 CB4 8PS Fax +44 (0) 1954 253601 Pi Research, Inc. 8250 Haverstick Suite #275 Indianapolis IN 46240 USA www.piresearch.com 132 Pi Sigma Sebring System Hardware Reference Tel Fax +1 (317) 259-8900 +1 (317) 259-0137
