Vector BRICK UPS 200 User Manual

BRICK UPS 200

Manual

Version: 2.1

Imprint

Vector Informatik GmbH
Ingersheimer Straße 24
D-70499 Stuttgart

The information and data given in this user manual can be changed without prior notice. No part of this
manual may be reproduced in any form or by any means without the written permission of the
publisher, regardless of which method or which instruments, electronic or mechanical, are used. All
technical information, drafts, etc. are liable to law of copyright protection.

© Copyright 2019, Vector Informatik GmbH. All rights reserved.

Contents

1 General Information .......................................................................................................................... 6

Important instructions .............................................................................................................. 6

Warranty and liability ............................................................................................................... 6

Trademarks .............................................................................................................................. 7

Used symbols and their meanings .......................................................................................... 7

2 Safety ............................................................................................................................................... 8

Proper Use and Intended Purpose .......................................................................................... 8

Hazards ................................................................................................................................... 8

Battery notice ........................................................................................................................... 8

Electrostatically Sensitive Components (ESD) ........................................................................ 9

Grounding practices............................................................................................................. 9

Warning of hot surface ............................................................................................................ 9

Disclaimer ................................................................................................................................ 9

3 System Configuration ..................................................................................................................... 10

BRICK UPS Configuration ..................................................................................................... 10

4 Accessories .................................................................................................................................... 11

Power Supply and Cable ....................................................................................................... 11

5 Product Identification ...................................................................................................................... 11

Scope of delivery ................................................................................................................... 11

Type plate .............................................................................................................................. 12

6 Functional description .................................................................................................................... 13

Overview ................................................................................................................................ 13

Signal description .................................................................................................................. 13

7 Technical Specification ................................................................................................................... 14

Base specification .................................................................................................................. 14

Electrical characteristics ........................................................................................................ 16

Mechanical details ................................................................................................................. 17

8 Product Description ........................................................................................................................ 18

BRICK UPS front view ........................................................................................................... 18

BRICK UPS rear view ............................................................................................................ 18

9 Interfaces, Control Elements and Indicators .................................................................................. 19

100 MbE MGMT .................................................................................................................... 19

HMI Battery status ................................................................................................................. 19

HMI System status................................................................................................................. 20

Power Switch ......................................................................................................................... 20

CARCTRL .............................................................................................................................. 21

CTRL Switch .......................................................................................................................... 21

SYSCTRL .............................................................................................................................. 22

GPIO ...................................................................................................................................... 22

HMI POWER OUT ................................................................................................................. 23

HMI POWER IN ..................................................................................................................... 23

10 Functional Description ............................................................................................................... 24

Failure Analysis ..................................................................................................................... 25

Battery Operation Behavior ................................................................................................... 25

11 Configuration options ................................................................................................................. 27

Ignition Mode ......................................................................................................................... 27

Master/Slave Operation ......................................................................................................... 28

12 BRICK UPS Status Management .............................................................................................. 29

Web Interface Overview ........................................................................................................ 29

Web Interface description ...................................................................................................... 31

13 Commissioning and Maintenance ............................................................................................. 34

Initial Commissioning Insert Battery Pack ............................................................................. 35

14 Installation .................................................................................................................................. 37

Typical Application ................................................................................................................. 37

Example Setup with a BRICK CORE COM ........................................................................... 38

Handling of internal components ........................................................................................... 39

15 Valid for: ..................................................................................................................................... 40

List of Figures

Figure 1: BRICK UPS Type plate (example) ......................................................................................... 12

Figure 2: BRICK UPS Mechanical Dimensions ..................................................................................... 17

Figure 3: BRICK UPS front view............................................................................................................ 18

Figure 4: BRICK UPS rear view ............................................................................................................ 18

Figure 5: Pin assignment 100 MbE MGMT connector .......................................................................... 19

Figure 6: HMI Battery status .................................................................................................................. 19

Figure 7: HMI System status ................................................................................................................. 20

Figure 8: Power Switch .......................................................................................................................... 20

Figure 9: Pin assignment CAR CTRL connector ................................................................................... 21

Figure 10: Control Dip-Switch ................................................................................................................ 21

Figure 11: Pin assignment SYS CTRL connector ................................................................................. 22

Figure 12: Pin assignment GPIO connector .......................................................................................... 22

Figure 13: Pin assignment HMI POWER OUT connector ..................................................................... 23

Figure 14: Pin assignment HMI POWER IN connector ......................................................................... 23

Figure 15: One BRICK UPS stand alone .............................................................................................. 28

Figure 16: Two BRICK UPS parallel-connected.................................................................................... 28

Figure 17: Three BRICK UPS parallel-connected ................................................................................. 28

Figure 18: Integrated Web Interface ...................................................................................................... 29

Figure 19: Web interface configuration tab ........................................................................................... 30

Figure 20: Web interface acknowledge ................................................................................................. 30

Figure 21: BRICK UPS battery slots ..................................................................................................... 35

Figure 22: BRICK UPS Power In connector .......................................................................................... 36

Figure 23: BRICK UPS CARCTRL connector ....................................................................................... 36

Figure 24: BRICK UPS Power Out connector ....................................................................................... 36

Figure 25: BRICK UPS Power switch .................................................................................................... 36

Figure 26: BRICK UPS typical application ............................................................................................ 37

Figure 27: Example Setup with BRICK CORE COM ............................................................................ 38

1 General Information

1

Important instructions

Prior to use of the unit it is essential to comply with the following instructions. As stipulated by law, we
are providing important safety information and advice how you can avoid damage to the device and
other fittings.

▪ Connection to the power supply must be carried out with correct polarity. Polarity reversal could

cause irreparable damages.

▪ The correct supply voltage is 12V or 24V DC
▪ Operation of the device is allowed only in circuits with safety low voltage within the admissible limit

values (SELV standard EN60950). This applies to all connections to the unit.

▪ The use of a power supply outside the limits defined above could cause damage or even

destruction of the device.

▪ It is forbidden to directly connect the unit to the 230 V mains voltage!
▪ Please avoid mechanical stresses when the device is installed.
▪ The unit has undergone a comprehensive final check to guarantee that it has left the facility in a

perfect condition. Prior to initial operation, the unit has to be examined for damage caused by
transport or inappropriate storage. If there is any damage to the unit it must not be taken into
service.

▪ The unit must not be operated with defective safety equipment or with incorrectly mounted or

inoperable safety/protection devices.

▪ Prior to initial operation, please check the suitability of the unit for the specific application. Please

take special note of the admissible environmental and operating conditions specified in the data
sheet.

▪ Any removal of identification numbers, repair work by yourself or modification of the unit is

forbidden.

▪ Prior to initial operation carefully read this user manual containing notes and warnings in order to

ensure safe operation.

▪ Unless specified differently, all technical data apply to an environmental temperature of 25°C. The

specified values are subject to the usual fluctuations.

▪ Stresses due to extreme environmental conditions (e.g. heat or cold) over a longer period of time

may influence reliability. Even under normal conditions of use within the admissible limits service
life may be reduced by permanent operation at the limits. Tolerance of the extreme values is
subject to the usual fluctuations.

Warranty and liability

We reserve the right to change the contents of the documentation and the software without notice.
Vector Informatik GmbH assumes no liability for correct contents or damages which are resulted from

the usage of the documentation. We are grateful for references to mistakes or for suggestions for
improvement to be able to offer you even more efficient products in the future.

Trademarks

All trademarks mentioned in this documentation and if necessary third party registered are absolutely
subject to the conditions of each valid label right and the rights of particular registered proprietor. All
trademarks, trade names or company names are or can be trademarks or registered trademarks of their
particular pro- prietors. All rights which are not expressly allowed are reserved. If an explicit label of
trademarks, which are used in this documentation, fails, should not mean that a name is free of third party
rights.

Used symbols and their meanings

Symbol

Meaning

Warning of general hazard. The kind of hazard is specified by the text next to the
symbol.

Warning of hazardous electrical voltage and the effects thereof.

This symbol refers to a hot surface that should not be touched without appropriate
precautions. There is danger of burning!

Warning of damages by electrostatic discharge
ESD (Electrostatically Sensitive Device) warning symbol

This symbol refers to general information about device and user manual.

This symbol introduces diverse details as to product configurations.

This symbol indicates that, in the case of non-observance of the warning, the device
or parts thereof could be damaged.

This symbol refers to instructions and recommendations for the connection of
external peripherals and their wiring.

2 Safety

In order to avoid personal injuries and damage to property, you have to read and understand the
following safety instructions and hazard warnings prior to installation and use of this hardware. Keep
this documentation (manual) always near the hardware.

Please observe the notes in chapter 1 in addition to this chapter.

Proper Use and Intended Purpose

The hardware may only be operated (i) according to the instructions and descriptions of this manual;
(ii) with the electric power supply designed for the hardware, e.g. USB-powered power supply; and (iii)
with accessories manufactured or approved by Vector.

The hardware is exclusively designed for use by skilled personnel as its operation may result in
serious personal injuries and damage to property. Therefore, only those persons may operate the
hardware who (i) have understood the possible effects of the actions which may be caused by the
hardware; (ii) are specifically trained in the handling with the hardware, bus systems and the system
intended to be influenced; and (iii) have sufficient experience in using the hardware safely.

The knowledge necessary for the operation of the hardware can be acquired in workshops and
internal or external seminars offered by Vector. Additional and hardware specific information, such as

„Known Issues“, are available in the „Vector KnowledgeBase“ on Vector´s website at www.vector.com.
Please consult the „Vector KnowledgeBase“ for updated information prior to the operation of the

hardware.

Hazards

The hardware may control and/or otherwise influence the behavior of control systems and electronic
control units. Serious hazards for life, body and property may arise, in particular, without limitation, by
interventions in safety relevant systems (e.g. by deactivating or otherwise manipulating the engine
management, steering, airbag and/or braking system) and/or if the hardware is operated in public
areas (e.g. public traffic, airspace). Therefore, you must always ensure that the hardware is used in a
safe manner. This includes, inter alia, the ability to put the system in which the hardware is used into a
safe state at any time (e.g. by „emergency shutdown“), in particular, without limitation, in the event of
errors or hazards.

Comply with all safety standards and public regulations which are relevant for the operation of the
system. Before you operate the system in public areas, it should be tested on a site which is not
accessible to the public and specifically prepared for performing test drives in order to reduce hazards.

Battery notice

CAUTION!

There is a risk of explosion if the battery is replaced incorrectly. Replace only with
the same or equivalent type recommended by the manufacturer. Discard used

batteries according to the manufacturer’s instructions.

Please also see the battery supplementary sheet!
Valid only for devices containing a battery.

Electrostatically Sensitive Components (ESD)

A sudden electrostatic discharge could destroy sensitive components. Therefore, proper packaging
and grounding prescriptions must be observed. Please always observe the following safety advices.

1. Plug-in cards always have to be transported in electrostatically safe containers or bags.

2. Please leave electrostatically sensitive components in their containers until they have reached the

electrostatically safe assembly site.

3. Take care that you are correctly grounded if you touch electrostatically sensitive components.

4. Make sure that electrostatically sensitive components are stored in protective packages or on

antistatic mats.

Grounding practices

By observing the following measures, electrostatic damage to the device can be avoided.

1. Lay out antistatic mats at the work place. Wear a grounding strap which is connected to the work
place and the working tools.

2. Use antistatic foot mats, foot grounding equipment or air ionizers to provide additional safety.

3. Only touch sensitive components, plug-in cards and units on the housing or at the outer edges of

the plug-in cards.

4. Avoid contact with pins, wires and conductor tracks.

5. Make sure that all voltage and signal sources are switched off before establishing or

disconnecting electric connections or connecting testing devices.

6. Avoid non-conductive materials such as usual mounting accessories made of plastics or
polystyrene at the work place.

7. Use conductive tools (e.g. ESD screwdrivers) when working on electrostatically sensitive units
and components.

8. Always put plug-in cards and drives on the antistatic mat with the component side downwards.

Warning of hot surface

The BRICK UPS can become very hot during operation and should not be touched
without appropriate precautions. There is danger of burning!

Disclaimer

Claims based on defects and liability claims against Vector are excluded to the extent damages or
errors are caused by improper use of the hardware or use not according to its intended purpose. The
same applies to damages or errors arising from insufficient training or lack of experience of personnel
using the hardware.

3 System Configuration

BRICK UPS Configuration

For the BRICK UPS, the following HW equipment features are available for the respective device
configuration:

Supply

Voltage Temperature

Performance Smart Battery

100Mbe

MGMT

SYS CTRL CAR CTRL GPIO

12V DC / 24V DC -20 ~ 60

°C

-20 ~ 60°C (limited current <0°C) Capacity

[Wh] @ nominal voltage

Max Current

[A]

Max Current

[A] @ -20°C

Nominal voltage

[V]

RJ45 100Mbe Ethernet K15/Ignition Output BRICK System Com. Interface K15/Ignition Input CAR System Com. Interface 4xGPI

4xGPO

BRICK UPS 200

✓

✓

-

2x77

2x9

2x9

10,8

✓ ✓ ✓ ✓ ✓ ✓ ✓

- = not available

✓ = available

4 Accessories

Power Supply and Cable

Designation

Description

BRICK PowerCable

BRICK PWR Cable, red-black, pigtail, 4qmm, 1,5m

BRICK GPIO Cable

BRICK GPIO Cable, pigtail, 8x weiß FLRY 0,75 qmm, 1,5m

BRICK UPS CARCTRL Cable

BRICK UPS CARCTRL Cable IGN, LOAD, 0,75 qmm, 1,5m

BRICK UPS B2B POWER Cable

Cable Bridge to connect Power from UPS to BRICK, 4qmm, 35cm

BRICK UPS B2B CTRL Cable

Cable Bridge to connect CTRL from UPS to BRICK, 3pol to 4pol, 0,75 qmm, 35cm

5 Product Identification

Scope of delivery

The scope of delivery depends on the ordered system or set configuration. Please check the scope of
delivery according to the survey printed below.

BRICK UPS SB200NI2

BRICK UPS device

BRICK UPS 200

✓

Battery pack

2x NI3020HD

✓

Accessories

BRICK Power Cable

✓

BRICK GPIO Cable

✓

BRICK UPS CARCTRL Cable

✓

BRICK UPS B2B POWER Cable

✓

BRICK UPS B2B CTRL Cable

✓

Documentation
Manual BRICK UPS

online

Safety supplement

✓

- = not available

✓ = available

Type plate

Figure 1: BRICK UPS Type plate (example)

A type plate like this is located on the bottom of the
device. The example data used here refer to the
BRICK UPS 200.

Symbol

Meaning

Legal notice regarding the disposal of used appliances (WEEE)
CE label

6 Functional description

Overview

The BRICK UPS is designed to bridge gaps in any kind of automotive supply systems. It uses two Li­Ion smart batteries to provide the needed energy during voltage drops or even breakouts on board
supply. There is the opportunity to control the switching between operation from the board net and the

batteries with an additional signal called “LOAD”. This feature can be used to reduce the board nets

load. Furthermore, the BRICK UPS provides secondary functions like a management interface, two
CAN interfaces and several GPIOs.

Signal description

The BRICK UPS uses the following external Signals

Name

I/O

Description

VIN+

I

Positive potential of the supply voltage

VIN- I Negative potential of the supply voltage

VOUT+

O

Positive potential of the output voltage

VOUT-

O

Negative potential of the output voltage

IGN_IN

I

Ignition input, this signal is logically connected to IGN_OUT

IGN_OUT

O

Ignition output, this signal is logically connected to IGN_IN

LOAD

I

LOAD high allows the BRICK UPS to supply the load from the input voltage.
LOAD low forces to supply from the batteries

CAR_CAN

I/O

CAN interface with general purpose

SYS_CAN

I/O

CAN interface for in-system communication

Digital Input 1-4

I

General purpose inputs

Digital Output 1-4

O

General purpose outputs

7 Technical Specification

Base specification

Features

Details

Supply voltage

Typ. 12V DC / 24 DC, wide range 10V to 32V

Maximum Power Consumption

250W including battery charge current

Switch to USV mode

Vin < 10V

Energy Storage

2x Li-Ion Smart Batteries

Output Voltage
Ext. supply mode

14.8V ±5%

UPS mode

depending on used battery packs, see table UPS Configuration

Delivery Power

200W max

Network interfaces

1x 100Mbe (Management Interface)

Default network configuration

IP address

3

Subnet mask

0

Gateway

0

DHCP

off

GPIO

4xGPI
4xGPO, highside switching

On/Off control

Power Switch, please note,

CAR system control interface

1x CAN, termination resistor switchable, 1x Digital Input

BRICK system control interface

1x CAN, termination resistor switchable, 1x Digital Output

Housing dimensions

320 x 22 x 250 (B x H x T) mm

Cooling

Passive

Weight

approx. 3kg

Maximum Battery Charge Current

4A

Characteristics

Details

Operating temperature device

-25°C to +70°C

Storage temperature device

-40°C to +75°C

Storage temperature incl. battery

-20°C to 60°C, 80%RH

Operating temperature
battery discharge

SB200NI

0°C to +60°C (limited current <0°C)

SB200NI2

-20°C to +60°C

Operating temperature
battery charge,
controlled by battery

SB200NI

0°C to +50°C

SB200NI2

0°C to +50°C

Air humidity device

90% non-condensing

Vibration and shock

EN 60068-2-64:2008 (10-1000Hz – 33,8 m/s²)
EN 60068-2-27:2009 (half sine, 11ms, 500 m/s²)

IP protection class

IP20

Electromagnetic compatibility (EMC)

EMV Directive 2014/30/EU

Electrical safety

Low-voltage directive (LVD) 2014/35/EU

RoHS II directive

2011/65/EU

European Union

EN 55032 (Class B) and EN 55024
EN 62368-1 Safety

USA / FCC

Part 15 Subpart B

Electrical characteristics

Symbol

Description
Value

Unit
Min

Typ

Max

V

IN,MIN

Input voltage

10 - 32 V V

OUT,NET

Output voltage when supplied from board net

14,1

14,8

15,5

V

V

OUT,BATT

Output voltage when supplied from batteries

* * * V I

OUT,NET

Output current when supplied from board net

- - 15** A I

OUT,BATT

Output current when supplied from batteries

* * *

A

V

GPI,LOW

GPI Low voltage

4,2

4,3

4,4

V

V

GPI,HIGH

GPI High voltage

4,5

4,6

4,7 V V

GPI

GPI input voltage max

32

V

R

IN,GPI

GPI input resistance

12 kΩ

V

LOAD,LOW

LOAD Input Low voltage

4,2

4,3

4,4

V

V

LOAD,HIGH

LOAD Input High voltage

4,5

4,6

4,7 V V

LOAD

LOAD input voltage max

32

V

R

IN,LOAD

LOAD input resistance

12 kΩ

V

IGN_IN,LOW

IGN_IN Input Low voltage

4,2

4,3

4,4 V V

IGN_IN,HIGH

IGN_IN Input High voltage

4,5

4,6

4,7

V

V

IGN_IN

IGN_IN input voltage max

32

V

R

IN,IGN_IN

IGN_IN input resistance

12 kΩ

V

GPO,NET

GPO output voltage when supplied from board net

14,1

14,8

15,5 V V

GPO,BATT

GPO output voltage when supplied from batteries

* * *

V

I

GPO,NET

GPO output current when supplied from board net

- - 6** A I

GPO,BATT

GPO output current when supplied from batteries

- - 6

A

V

IGN_OUT,NET

IGN_OUT output voltage when supplied from board net

14,1

14,8

15,5 V V

IGN_OUT,BATT

IGN_OUT output voltage when supplied from batteries

* * * V I

IGN_OUT,NET

IGN_OUT output current when supplied from board net

- - 1** A I

IGN_OUT,BATT

IGN_OUT output current when supplied from batteries

- - 1

A

* Nominal voltage depending on used battery pack, see table in 3.1
** overall current is not allowed to exceed 15A (I

OUT+IGPO1+IGPO2+IGPO3+IGPO4+IIGN_OUT

≤ 15A)

Mechanical details

All dimensions are given in millimeters [mm].

Figure 2: BRICK UPS Mechanical Dimensions

8 Product Description

BRICK UPS front view

Figure 3: BRICK UPS front view

Pos.

Designation

Description

1 Battery slide-in cover

2

100 MbE MGMT

100Mb Ethernet Port for Management issues

3

HMI Battery status

User LEDs to indicate the battery status

4

HMI System status

User LEDs to indicate the system status

5

Power Switch

Turns the device on/off

6 Mounting holes with inner thread M4 (depth approx. 11.5mm)

BRICK UPS rear view

Figure 4: BRICK UPS rear view

Pos.

Designation

Description

1

CARCTRL

Car System control connector

2

CTRL SW

DIP-Switch for CAN termination for the SYSCTRL and CARCTRL connectors

3

SYSCTRL

BRICK System control connector

4

GPIO

4 GPI and 4 GPO

5

POWER IN

Power Input supply connector

6

POWER OUT

Power Output supply connector

7 Mounting holes with inner thread M4 (depth approx. 11.5mm)

❸

❹

❺

❻

❶

❷

❶

❷

❸

❹

❺

❻

❼

9 Interfaces, Control Elements and Indicators

100 MbE MGMT

This connector is designed as RJ45 sockets with integrated LEDs and corresponds to a 100BASE-T

Ethernet interface.

Pin

Signal

RJ45 Network socket

1

100MbE_TX+

Figure 5: Pin assignment 100 MbE MGMT connector

2

100MbE_TX-

3

100MbE_RX+

4

Connected to Pin 5, 75 Ω
termination

5

Connected to Pin 4, 75 Ω
termination

6

100MbE_RX-

7

Connected to Pin 8, 75 Ω
termination

8

Connected to Pin 7, 75 Ω
termination

Collision LED on the right (green)

State

Description

On

collision

Off

no collision

Link LED on the left (yellow)

State

Description

On

good link

Blink

activity

Off

no link

HMI Battery status

LED

Signal

LED array

1

Battery 1 charge status: ≥75%

Figure 6: HMI Battery status

2

Battery 1 charge status: ≥50%

3

Battery 1 charge status: ≥25%

4

Battery 1 charge status: <25%

5

Battery 2 charge status: ≥75%

6

Battery 2 charge status: ≥50%

7

Battery 2 charge status: ≥25%

8

Battery 2 charge status: <25%

Please note that blinking LEDs indicate the batteries are being charged.
Fast flashing LEDs No. 4 & 8 indicate very low charge status <9%.

Pin ❽

Pin ❶

❶

❷

❸

❹

❺

❻

❼

❽

HMI System status

LED

Signal

LED array

K15

IGN_IN on CARCTRL is high

Figure 7: HMI System status

IGN

IGN_OUT on SYSCTRL is on

LOAD

LOAD_IN on CARCTRL is high

OPT

reserved for internal use

VIN

Input voltage on POWER_IN is
present

DC

POWER_OUT is powered from
POWER_IN connector

BAT

POWER_OUT is powered by
Batteries

PWR

System is active

Power Switch

State

Signal

Switch

On

Device is turned on

Figure 8: Power Switch

Off

Device is turned off

CARCTRL

This connector is used for power control (see connection diagram chapter 14)

Pin

Signal

3,50mm Pitch connector

1

CAR_CAN_High (do not use)

Figure 9: Pin assignment CAR CTRL connector

2

IGN_IN

3

CAR_CAN_Low (do not use)

4

LOAD_IN

Signal description: If LOAD_IN is high, the UPS is allowed to power a connected sink from
the supply on the Power In connector, else it is powered from the batteries. The IGN_IN
state is mapped to the IGN_OUT Pin of the SYSCTRL connector. See more details in

chapter 10.

Matching counterpart:
Molex UltraFit Receptiple Housing Art.-Nr.: 172258-1004
Molex Female Crimp Terminal 22 & 20 AWG Art.-Nr.: 172253-3123

CTRL Switch

Sw

Signal

Dip Switch

1

CAN termination (120Ω) for CAN_CAR
on CARCTRL connector

Figure 10: Control Dip-Switch

2

„On“(on startup): The BRICK UPS

starts with the default network
configuration (see chapter base
specification).

„Off“(on startup): The BRICK UPS

starts with the last saved network
configuration

3

CAN termination (120Ω) for CAN_SYS
on SYSCTRL connector

SYSCTRL

This connector needs to be connected to BRICK CORE COM for System control (see connection
diagram chapter 14)

Pin

Signal

3,50mm Pitch connector

1

SYS_CAN_High

Figure 11: Pin assignment SYS CTRL connector

2

SYS_CAN_Low

3

IGN_OUT

Matching counterpart:
Molex UltraFit Receptiple Housing Art.-Nr.: 172256-1003
Molex Female Crimp Terminal 22 & 20 AWG Art.-Nr.: 172253-3123

GPIO

Pin

Signal

3,50mm Pitch connector

DO1

Digital Output 1

Figure 12: Pin assignment GPIO connector

DO2

Digital Output 2

DO3

Digital Output 3

DO4

Digital Output 4

DI1

Digital Input 1

DI2

Digital Input 2

DI3

Digital Input 3

DI4

Digital Input 4

Matching counterpart:
Molex UltraFit Receptiple Housing Art.-Nr.: 172258-1008
Molex Female Crimp Terminal 22 & 20 AWG Art.-Nr.: 172253-3123

HMI POWER OUT

This connector needs to be connected to BRICK CORE COM for power supply (see connection
diagram chapter 14)

Pin

Signal

1

VOUT-

Figure 13: Pin assignment HMI POWER OUT connector

2

VOUT+

Matching counterpart:
Molex MiniFit Sr. Receptiple Housing Art.-Nr.: 42816-0212
Molex Female Crimp Terminal 12, 10 & 8 AWG Art.-Nr.: 42815-0012

HMI POWER IN

This connector needs to be connected to Car power (see connection diagram chapter 14)

Pin

Signal

1

VIN-

Figure 14: Pin assignment HMI POWER IN connector

2

VIN+

Matching counterpart:
Molex MiniFit Sr. Receptiple Housing Art.-Nr.: 42816-0212
Molex Female Crimp Terminal 12, 10 & 8 AWG Art.-Nr.: 42815-0012

Pin ❶

Pin ❷

Pin ❶

Pin ❷

10 Functional Description

Basically, as soon as the UPS is switched on it will supply power on output, either from battery or by
the integrated DC/DC power supply. This diagram shows how the UPS operate in different situations.
Please note if switched on the UPS is always in active mode, so it will charge either the vehicle battery
or the integrated SMART Battery.

Vin

Load

IGNin

IGNout

Charge

Output

DC

Bat

UPS on UPS off

Pos.

Designation

Description

LED

HMI System

1

Vin

Supply Voltage from vehicle connected to POWER IN

VIN

2

Load

Pin 4 of CARCTRL connector, it indicates if it is allowed to
take power from vehicle. Typically connected to a

dedicated signal “engine run” if not available it is

recommended to connect to IGN

LOAD

3

IGNin

Pin 2 of CARCTRL connector, Ignition in (Terminal 15)
signal from Vehicle it will force to power on the BRICK
CORE COM by IGNout signal

K15

4

IGN out

IGNout out on SYSCRTL connector it is passed through
signal from IGNin

IGN

5

Charge

The battery will be charged

DC

6

Output

Output Voltage on POWER OUT connector, depending
on Vin and LOAD it will be either

14,8V DC from UPS

or SMART-Battery Voltage

DC

BAT

7

ON/OFF

UPS Switch ON / OFF

PWR

Failure Analysis

Status

Description

LED

State

HMI Indication

UPS System cannot be started

No SMART Battery in System

DC

OFF BAT

OFF

System goes down in STOP Mode
→no Output

SMART Battery Overcurrent,
with 1 Batterie >16A,
with 2 Batteries >20A

DC

OFF

BAT

OFF

Overcurrent Problem on Output

DC

Flash

SMART Battery will not be charged

Battery load state more than 80%
LOAD Signal not active
Output Power >150W

DC

OFF

Battery Operation Behavior

Description of the UPS during the discharge and charge cycle.

Status

Description

LED

State

HMI Indication

UPS in Battery Operation

Vin is < 10V

K15
IGN
LOAD
VIN
DC
BAT
PWR

ON
ON

-­OFF

OFF
ON

ON

(battery capacity between 50%-75%)

Capacity down at 15%

IGN signal Off and BIRCK shut
down, can be switched on again by
PWR button

K15

IGN

LOAD
VIN
DC
BAT
PWR

ON

OFF

-­OFF
OFF
ON
ON

Capacity down at 10%

BIRCK shut down, can be switched
on again by PWR button,

BRICK run until UPS is down to 0%

Battery LED 4 & 8 flashes

K15
IGN
LOAD
VIN
DC
BAT
PWR

ON
OFF

-­OFF
OFF
ON
ON

External Power switched
on

Vin > 10V

K15
IGN
LOAD
VIN

DC
BAT

PWR

ON
OFF

-­ON

ON
OFF

ON

Back in “normal” Mode

Battery State more than 20%

K15

IGN

LOAD
VIN
DC
BAT
PWR

ON

ON

ON
ON
ON
OFF
ON

LED off

LED on

LED flashing

❶

❷

❸

❹

❺

11 Configuration options

Ignition Mode

There are two different ways to control the „IGN_OUT“ signal on the „SYS_CTRL“ connector.

Name

Description

K15

“IGN_OUT” is turned on with a rising edge and turned off with a falling edge

on “IGN_IN”

K15_ON_SIODI_OFF

“IGN_OUT” is turned on with a rising edge on “IGN_IN” and turned off with
a power off request on the SYS_CAN interface. Please contact the support
for further information.

The common Ignition Mode is K15. K15_ON_SIODI_OFF is a special function, used to keep
the plugged devices alive after the supply already is powered down. An example application
could be a measurement system in a vehicle environment.

Master/Slave Operation

The BRICK UPS is able to be parallel-connected with up to two other BRICK UPS to improve the
maximum output power and the overall stored energy of the system. The Web Interface offers a
possibility to configure the chosen setup.

Please note, that the devices have to be interconnected correctly. It is recommended to use
the provided cables or contact the support for further options.

One BRICK UPS stand-alone:

Figure 15: One BRICK UPS stand alone

Two BRICK UPS parallel-connected:

Figure 16: Two BRICK UPS parallel-connected

Three BRICK UPS parallel-connected:

Figure 17: Three BRICK UPS parallel-connected

If there is a wrong configuration several calculations like e.g. the overall capacity of the batteries
cannot be done. An example setup with two BRICK UPS is shown in chapter „1.1 “.

It is absolutely necessary to use batteries with a similar state of charge, when a system with
two or more BRICK UPS in parallel is used.

12 BRICK UPS Status Management

Web Interface Overview

The integrated Web Interface offers a suitable way to monitor the operating parameters of the BRICK
UPS. The standard IP address can be found in chapter 6, the technical specification.

❷

❸

❺

❹

Figure 18: Integrated Web Interface

❶

❻

The configuration tab offers some general opportunities to parameterize the BRICK UPS. The main
constituents are the network configuration and the general-purpose output configuration.

Figure 19: Web interface configuration tab

Every time the configuration has been changed by pressing the “save config” button, an

acknowledgement will appear. Figure 20: Web interface acknowledge shows an example output.

Figure 20: Web interface acknowledge

❾

❼

❽

❿

Web Interface description

Section ❶:
Tab Selection to switch between system monitoring and configuration interface.

Section ❷:
Contains system parameters

Name

Description

Prduct revision

Hardware revision

Firmware revision

Software revision

Serial number

Consecutively number

Status

Expresses Warnings and Errors

Temperature

Actual housing temperature

Powered by

Output is powered by Batteries or UPS supply voltage

IP address

IP address with subnet mask and default gateway

Section ❸:
Contains input parameters

Name

Description

UPS IN

Input voltage on with 0,1V resolution

K15

State of the IGN_IN signal on CARCTRL connector, “on” indicates logic high, “off” logic low

LOAD

State of the LOAD signal on CARCTRL connector, “on” indicates logic high, “off” logic low

DI1

State of the Digital Input 1 signal on GPIO connector, “on” indicates logic high, “off” logic low

DI2

State of the Digital Input 2 signal on GPIO connector, “on” indicates logic high, “off” logic low

DI3

State of the Digital Input 3 signal on GPIO connector, “on” indicates logic high, “off” logic low

DI4

State of the Digital Input 4 signal on GPIO connector, “on” indicates logic high, “off” logic low

Section ❹:
Contains output parameters

Name

Description

UPS OUT

Voltage, current and power on the HMI POWER OUT connector

IGN

State, current and power of the IGN_OUT signal on SYSCTRL connector

DO1

State, current and power of the Digital Output 1 signal on GPIO connector

DO2

State, current and power of the Digital Output 2 signal on GPIO connector

DO3

State, current and power of the Digital Output 3 signal on GPIO connector

DO4

State, current and power of the Digital Output 4 signal on GPIO connector

If there is an overcurrent on one of the outputs, a Warning in the Status Box in Section ❷
will occur for about 10 seconds. This status is reversible.

Section ❺:
Contains battery parameters

Name

Description

battery x

Charging level of the battery

manufacturer

Battery manufacturer

device name

Battery device name

cycle count

Number of load cycles, the battery ran through

capacity threshold

Charging difference of the batteries, percentage of the total charge

total

Average charge of both batteries

discharge balance

Unsymmetrical discharge, percentage of the total discharge

Section ❻:
Contains cumulated battery parameters for master/slave system

Name

Description

total capacity

Average capacity of all used batteries in the master and slave devices

output power

Total output power of all master and slave devices

Please note, that only the Master in a Master/Slave system is able to show the cumulated
battery parameters.

It is absolutely necessary to use batteries with a similar state of charge, when a system with
two or more BRICK UPS in parallel is used.

Section ❼:
Contains network configuration parameters

Name

Description

address

Current physical address, can be overwritten

subnet mask

Current subnet mask, can be overwritten

gateway

Current gateway, can be overwritten

DHCP

Checkbox activates/deactivates DHCP

Section ❽:
Contains GPO behavior parameters

Each GPO has got the following different configuration options:

Name

Description

ON

GPO is permanently on

OFF

GPO is permanently off

K15

GPO follows the signal „IGN_IN“, see chapter „Signal description“

S0

SIODI

GPO controlled by SIODI API

Section ❾:
Contains general configuration parameters

Name

Description

IGN

Configures the link between the signals “IGN_IN” and “IGN_OUT”. See chapter „11.1 Ignition
Mode“ for more information.

Master/Slave

Sets the configuration for the master/slave operation. See chapter „11.2 Master/Slave
Operation“ for more information.

LED Activity

Master/Slave mode is only necessary to be configured as long as there are two or more
BRICK UPS used in parallel.

Section ❿:
The button „save config“ saves the defined settings. Those settings are not discarded after the BRICK

UPS is powered down.

If there is any trouble with a wrong network configuration, the BRICK UPS is able to start
with default network settings by toggling the “OPT signal” on the “CTRL switch” to on. See
chapter 9.6 CTRL Switch for more detailed information.

13 Commissioning and Maintenance

In order to avoid injuries and damage caused by direct or indirect contact with hot surfaces
the following instructions must be observed:

Die BRICK UPS must be positioned and installed in a maintenance area or in an operating
facility of limited access.

The users having permission to enter the maintenance area or the operating facility must have
received adequate instructions regarding the risks.

Important instructions!
For positioning and installation or removal of the BRICK UPS System, please observe the

relevant instructions given in this user manual.
The device must only be positioned and installed by maintenance personnel responsible in

this area (that is familiar with the associated risks).
The device can be operated in all positions except with the upper side downwards.
In order to avoid overheating of the platform, keep a distance of at least 100 mm to the upper

cooling fins of the chassis.
In case of installation in a housing (e.g. a control cabinet): The housing (control cabinet) must

have enough space for the BRICK UPS System and the corresponding spaces for air
circulation and cable connections. Moreover, the housing must have sufficient, possibly
active, ventilation to avoid overheating.

The cooling fins and the inlet and discharge openings of the housing must not be blocked
(covered).

Initial Commissioning Insert Battery Pack

The accessories of the BRICK UPS include an appropriate table power pack with 2 Smart battery
packs and a 2-pole connection cable.

CAUTION!

If the BRICK UPS is used in a vehicle's power network, it is necessary to protect the
device with a suitable fuse according to the specific input power.

1. Insert the provided batteries in the battery slots (1) and (2). There is no preferred order.

Figure 21: BRICK UPS battery slots

• Make sure the system is completely disconnected from power and switched OFF

• Remove cover by open the 3 knurled screw on the front

• Insert battery 1 and batterie 2 in slot 1 and slot 2

• Make sure to insert properly in the right direction

• Close front cover by fixing the 3 knurled screw on the front

❶

❷

❶

❷

2. Connect the Power supply line to a suitable power supply unit and to the rear side (3) of the

BRICK UPS.

Figure 22: BRICK UPS Power In connector

3. Connect the CARCTRL Cable to the power supply and the rear side (4) of the BRICK UPS.

Figure 23: BRICK UPS CARCTRL connector

4. Connect the load to the rear side (5) of the BRICK UPS.

Figure 24: BRICK UPS Power Out connector

5. Turn the BRICK UPS on by toggling the power switch (6) to “on”.

Figure 25: BRICK UPS Power switch

Please note, for proper operation make sure to fully load the batteries before first time use.
Batterie Status is shown on front LEDs (see chapter 9.2 for more details)

❸

❺

❻

❹

14 Installation

Typical Application

Figure 26: BRICK UPS typical application

Example Setup with a BRICK CORE COM

The following setup demonstrates a configuration with a BRICK UPS and a BRICK CORE COM.
Please note, that it shows a minimalist possibility of operation.

Figure 27: Example Setup with BRICK CORE COM

Follow these steps to get a setup for the first-time operation:

Step

Description

❶

Connect the BRICK-Power-Cable to the UPS Input and to a suitable power supply

❷

Connect the BRICK-CARCTRL-Cable to the CARCTRL Connector and connect both signals (LOAD and IGN_IN)
to the power supply

❸

Connect the BRICK-B2B-Power-Cable to the Output of the BRICK UPS and the Power Input of the BRICK CORE
COM

❹

Connect the BRICK-B2B-Power-Cable to the SYSCTRL Connector of the BRICK UPS and to the SYSCTRL
Connector of the BRICK CORE COM

❺

Turn the BRICK UPS on by toggling the power switch to “on”.

❸

❹

❶

❷

Handling of internal components

This section contains important information about the safe handling of internal components. Please
follow the instructions when handling all internal components of the BRICK UPS systems.

When installing or removing additional plug-in cards, please follow the following instructions:

Please observe the “general safety instructions for IT equipment” and installation
instructions.

The installation and removal of additional plug-in cards may only be made by a
qualified trained employee in accordance with the instructions of this manual.

Before removing the device cover please make sure that your system is switched off
and disconnected from the voltage supply.

Please observe the safety instructions regarding electrostatically sensitive
components (ESC). Failure to observe this warning may cause damage to the
device or components of the device.

The BRICK CORE UPS system might get hot during operation and should not be
touched without adequate precautions. There is danger of burning.

15 Valid for:

Item number

Description

Revision

BRICK UPS 200

>C01