Master's Thesis on Electronic Breakout Unit for Vehicle Control and Data Logging

MASTER'S THESIS
Electronic Breakout Unit
Fredrik Häggström
Master of Science in Engineering Technology

Electrical Engineering
Luleå University of Technology

Department of Computer Science, Electrical and Space Engineering
Electronic Breakout Unit
Fredrik Häggström
Luleå University of Technology

Dept. of Computer Science, Electrical and Space Engineering
28th December 2012

A BSTRACT
This thesis studies the problem to measure and control signals on a Volvo L110G wheel
loader without interfering with the original Electronic Control Units. The aim is to
develop an Electronic Breakout Unit (EBU) that can be connected to the original wiring
without damaging or altering any of the original electronics. The EBU shall be controlled
over Ethernet. This allows for data to be logged by an on-board PC while the wheel loader
is tested on the field. The on-board PC also allows the wheel loader to be controlled with
advanced remote control algorithms. In this work, the hardware design considerations
of a concept to measure and control a vehicle through an electronic add-on system is
presented. Future work for the system is to test and develop software so the wheel loader
can be controlled by an on-board PC.
iii
P REFACE
First of all, I would like to express my gratitude to my supervisor at LTU, Håkan Fredriks-
son and to my external supervisor at Volvo Construction Equipment, Jonatan Blom. For
there guidance and support. I would also like to thank Anton Videnius how helped me
with brainstorming and the layout of the Ethernet module.
This work was funded by Volvo Construction Equipment.
Fredrik Häggström
v
C ONTENTS
Chapter 1 – Introduction 1
1.1 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Chapter 2 – Material and Method 5

2.1 The Wheel Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.1 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.2 Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1.3 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.1 Analog-to-Digital-Converter . . . . . . . . . . . . . . . . . . . . . 14
2.2.2 Digital . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3.1 Microcontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3.2 SPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.3 DAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3.4 Power electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Safety and Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4.1 Emergency shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4.2 Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4.3 EMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chapter 3 – Result 27
3.1 Relay Card schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1.1 Digital in and Digital out . . . . . . . . . . . . . . . . . . . . . . 29
3.1.2 Analog in and Analog out . . . . . . . . . . . . . . . . . . . . . . 29
3.1.3 Solenoid out and Load Resistor . . . . . . . . . . . . . . . . . . . 30
3.1.4 PWM out and Load Resistor . . . . . . . . . . . . . . . . . . . . 31
3.1.5 CAN and J1708 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1.6 Relay drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 Relay Card layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3 Control Card schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.3.2 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3.3 Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.3.4 Microcontroller and peripherals . . . . . . . . . . . . . . . . . . . 42
3.4 Control Card layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Chapter 4 – Conclusions 47
4.1 Future work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2 Fields of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Appendix A – Specification 51
Appendix B – Relay Card Schematic 55
Appendix C – Relay Card Layout 65
Appendix D – Control Card Schematic 75
Appendix E – Control Card Layout 125
viii
C HAPTER 1
Introduction
In this work, the considerations of designing hardware to measure and control a vehicle
through an electronic add-on system is presented. The add-on system should not take
up any space from the driver in the driver’s compartment and all electrical wiring should
be kept intact.
Such a system can be used to log data during tests on the field to find problems in
the vehicle’s control loops that can’t be found in the test-bench. Alternatively, it can be
used to control the vehicle remotely or autonomously, which can improve the security for
personnel that work in a hazardous environment. Volvo Construction Equipment has lent
a wheel loader to Luleå University of Technology as a test platform, seen in Figure 1.1.
Figure 1.1: Volvo L110G wheel loader.
1
2 Introduction
1.1 Background
The department of Computer Science, Electrical and Space Engineering at Luleå Univer-
sity of Technology (LTU) is collaborating with Volvo Construction Equipment (VCE) in
projects regarding driver assistance systems and unmanned vehicles. The focus of this
master thesis is directed towards Volvos L110G wheel loader. Both VCE and LTU want
to be able to log and interact with the signals on the wheel loader to test and develop
new algorithms and features.
There are other systems on the market that can monitor and control the wheel loader.
However they are bulky, expensive and needs to be patched in to the original wiring that
will damage the original wiring harness. VCE have done some testing with such systems
but are not satisfied with their interface and that they have to damage the wiring on the
vehicle [1, 2, 3, 4].
1.2 Problem
VCE requested a system that could log most of the signals on the Electronic Control Units
on the wheel loader at a rate of at least 50Hz. It should be able to take over signals and
control sub systems of the wheel loader. It should not take up any space from the driver
in the driver compartment and it shold be easy to install without damaging the original
wiring harness. See Appendix A for the requirements specification.
1.3. System 3
1.3 System
The box named EBU in Figure 1.2 is the Electronic Breakout Unit that this thesis is
focused upon. It should be able to log all signals that is going in and out of the ECU
and transmit them via Ethernet to an on-board computer (L110G-PC). The EBU should
also be able take over part of the signals without disturbing the original ECUs.
The on-board computer (L110G-PC) has both connection with the Electronic Breakout
Units (EBUs) and the outside world via Wi-Fi. This enables the wheel loader to be
controlled by some external source or to let the on-board computer directly control the
wheel loader. Extra sensors can be connected to the on-board computer if needed.
The layout of the system was given at the start of this project and is not part of the
thesis. Several other student projects are running in parallel with this thesis, where all
the projects are focused upon extending the wheel loaders awareness to its surrounding
System overview
environment and controlling the wheel loader.
Original wiring
CAN
Original
Original EBU PWR
Original
ECU EBU
ECU EBU Sensors
ECU Actuators
and valves
Dedicated eth
L110G-PC Router
(industrial PC
with dual eth)
WLAN
Extra-
PC Multi purpose eth
Other Router
network
equipment
Figure 1.2: System overview.

4 Introduction
1.4 Abbreviations
Acronym Description
ADC Analog-to-Digital Converter
CAN Controller Area Network
CLK Clock
CMOS Complementary Metal–Oxide–Semiconductor
CPU Central Processing Unit
CS Chip Select
DAC Digital-to-Analog Converter
EBU Electronic Breakout Unit
ECU Electronic Control Unit (Engine Control Unit)
EMC Electromagnetic Compatibility
EMI Electromagnetic Interference
I/O Input/Output
LED Light-Emitting Diode
LTU Luleå University of Technology
MCU Microcontroller
MISO Master Input, Slave Output
MOSFET Metal–Oxide–Semiconductor Field-Effect Transistor
MOSI Master Output, Slave Input
NTC Negative Temperature Coefficient
PCB Printed Circuit Board
PWM Pulse-Width Modulation
RAM Random Access Memory
SPI Serial Peripheral Interface Bus
UART Universal Asynchronous Receiver Transmitter
VCE Volvo Construction Equipment
VDD Positive supply voltage
Table 1.1: Acronyms and description.

C HAPTER 2
Material and Method
This chapter presents the wheel loader, its sensors, actuators and communication buses.
It also describes how the sensors can be measured and how the actuators can be con-
trolled.
2.1 The Wheel Loader

The L110G is an all-round front end bucket loader that has a wide range of work areas.
It can be equipped with several different buckets and attachments that suit the work
load. The operating weight is 19840kg and it can lift around 12000kg dependent on the
attachment[5]. Figure 2.1 show how the wheel loader looks and how its boom and tilt
angles can be maneuvered.
The electrical system on the wheel loader runs on two 12V batteries in series, giving a
24V supply voltage. The batteries are continuously charged through an alternator when
the engine is running. However, when cranking the engine in cold weather the supply
voltage can go down to 9V . That is why all the electrical devices on the wheel loader
are specified to operate down to 9V .
The wheel loader is equipped from factory with sensors and actuators that can monitor
and control its movements. It has several Electronic Control Units (ECU) which the
sensors and actuators are connected to. The ECUs can monitor and control sensors that
are not connected locally by communicating to other ECUs via communication buses.
The L110G wheel loader has two CAN buses and one J1708 bus.
2.1.1 Sensors
A control system gathers physical information about the system through sensors. Sensors
transform quantities of physical properties to voltages and currents that can be measured
in an electrical system. Some sensors have an digital interface that converts the physical
property to a digital value. The sensor enables to control processes, give information to
5
6 Material and Method
Figure 2.1: Volvo L110G wheel loader.
the driver and help the driver. However the sensor data must be trustworthy and be
failsafe. If a wire to a sensor disconnects or shorts, it should be detected and the control
system should react accordingly.
The wheel loader uses sensors that are designed to give out an analog signal between
0.5 − 4.5V . If the sensor signal is outside of the approved range it will be regarded as
faulty data. If the wire is disconnected or broken the ECU has internal pull-up or pull-
down resistors so the signal will go out of the accepted range. This ensures that if a wire
to a sensor is damaged, the ECU will detect an error.
Angle sensor
Angle sensors are used to measure the angle of the tilt, boom and other links on the wheel
loader, and also to get the input from the levers in the driver’s compartment. Volvo uses
Hall Effect sensors which are reliable and uses a non-contact technique to measure the
angle between two links. Since there is no electrical contact between the links it reduces
the wear and tear on the sensor.
Hall Effect sensors measure the absolute magnetic field through the sensor by using the
Hall voltage. It is an effect from the Lorenz force, which says that an electron traveling
through a magnetic field will have a force acting on it which is perpendicular to both the
current and magnetic field [6].
Figure 2.2a shows how the force is applied on an electron which is traveling in a
magnetic field. If a free electron enters a magnetic field as Figure 2.2b shows, the force
acting on the electron will curve its path.
If the electron is traveling in a conductive material as Figure 2.3 shows, the Lorenz
2.1. The Wheel Loader 7
e
B v
F
v B
(a) (b)
Figure 2.2: (a) The force is perpendicular to the velocity and magnetic flux. (b) Free
electrons path is curved by the Lorenz force as it enters a magnetic field.
force will push the electrons more to one side of the convictive material and create a
voltage potential over the two sides.
i
e
v
Figure 2.3: Lorenz force contributing to Hall effect voltage in a conductor.
By subjecting a conductive material to a current and magnetic field which is perpen-

dicular to each other, the voltage across the conductor can be measured and the strength
of the magnetic field can be determined. By having two or three Hall Effect sensors
perpendicular to each other, the direction of the magnetic field can be determined in two
respective three dimensions.
Pressure sensor
The wheel loader uses piezoresistive sensors for measuring pressures in its liquids at lo-
cations of interest such as the hydraulic pressure in cylinders and the brakes. A piezore-
sistive material changes its resistance dependent on the strain it is subjected to.
Monocrystalline silicon, the material used for building transistors and semiconductor
circuitry, has a much greater piezoresistive effect on resistance than what a geometrical
change has. This property is used to integrate the sensing element on the same silicon
chip as the amplification and temperature compensation circuitry.
The sensing element consists of a thin diaphragm of monocrystalline silicon which have
four resistors built on the edges of the diaphragm. Two of the resistors are oriented so
they will increase in resistance when a pressure is applied and two is oriented so they
will decrease in resistance when pressure is applied.
The four resistive elements are coupled as a Wheatstone bridge and the signal is ampli-
fied as in Figure 2.4. The amplified signal is processed to make it linear to the pressure
and it is then sent as an analog signal to the control unit.
Rp1 Rl1
+
U −
−
Rl2 Rp2
+
Figure 2.4: The Resistive elements is coupled as a Wheatstone bridge and the voltage
difference in the legs is amplified.
Temperature sensor
The wheel loader uses negative temperature coefficient (NTC) thermistors for measuring
temperatures. A thermistor is a resistor which changes its resistance dependent on the
temperature it is exposed to. The NTC thermistor gets a lower resistance the higher tem-
perature it has. The relationship between resistance and temperature can be described
by Steinhart-Hart equation [7].
1
= a + b ln(R) + c ln3 (R)
T
Where a, b and c are called the Steinhart-Hart parameters and are dependent on which
thermistor is used. T is temperature in kelvin and R is the resistance in ohms over the
thermistor.
One end of the thermistor is often coupled to ground and the other end to a pull up
resistor. This will give a voltage potential vt over the thermistor that varies with the
temperature as seen in Figure 2.5.
5V
Rp
+
Rt wires vt
−
Figure 2.5: Thermistor with pull up resistor.
Inductive sensor
Inductive sensors are used to measure the velocity of moving parts on the wheel loader.
They use the changes in the magnetic flux through the sensor to generate a sinusoidal
voltage, where the amplitude and frequency depends on the velocity.
Inductive sensors or commonly known as variable reluctance sensors are composed of
a permanent magnet, a ferromagnetic pole piece and a pickup coil. This sensor is then
mounted pointing towards a toothed wheel made of a ferromagnetic material as Figure 2.6
shows.
Permanent magnet
S Pick up coil
N
+
–
Ferromagnetic toothed wheel Ferromagnetic pole piece
Figure 2.6: Inductive sensor and toothed wheel.

As the toothed wheel turns, the magnetic flux through the pickup coil changes and
generates a voltage which can be described by Faraday’s law of induction.
dΦ
U (t) = −n ·
dt
Where U is the generated voltage, n is number of turns in the pickup coil and Φ is the
magnetic flux in webers through the pickup coil [6].
By knowing how many tooths the wheel has and the frequency of the signal, the velocity
can be calculated. The calculated velocity has to be seen as the absolute velocity, because
the rotation direction of the wheel cannot be determined with only one sensor.
2.1.2 Actuators
The main actuators on the wheel loader are hydraulic valves which are controlled by
solenoids. It has two different types of solenoids, one that only can open fully and one
that can open proportionally.
Solenoids are composed of one coil around a movable ferromagnetic armature. The
induced force on the armature is proportional to the change in inductance in the coil
with respect to the change in position of the armature, and the current flowing through
the coil.
The force that is acting on the armature is always in the direction that will increase
the induction of the coil. If the armature is asymmetrically placed inside the coil, as in
Figure 2.7, the force acting on the armature will strive to center the armature to the coil,
because then it has the largest inductance [6].
The armature is connected to the hydraulic valve and as the armature moves, the valve
will open and the fluid can pass through it. By controlling the current in the solenoid the
force on the valve can be controlled, thus enabling control of flow through the hydraulic
valve.
2.1.3 Communication
The wheel loader has several ECUs that have to exchange data with each other. It uses
two CAN buses and one J1708 bus to connect all the ECUs.
CAN
Controller Area Network is a protocol developed by Bosch [8]. It is designed to connect
electronic units with a prioritized and robust network which can handle data rates up
to 1Mbit/s. There are also sensors that uses CAN to transmit their data and there can
be over 100 devices on the same bus. A generic view of a CAN-bus system can be seen
in Figure 2.8, it uses 120Ω terminating resistors in each end of the bus to attenuate
reflections.
Spring
Coil
+
–
Armature
Figure 2.7: A solenoids internal parts.
Device 1 Device 2 Device 3 Device 4
CAN High CAN High
120Ω 120Ω
CAN Low CAN Low
Figure 2.8: CAN network.
The physical implementation of CAN is built on an open drain basis with two differ-
ential wires, one that is idle high and the other is idle low. If the transceiver sends out
a ’1’ on the bus, it does so by turning off the transistors that is coupled to the wires
and letting some internal pull up/down currents go out on the wires and setting them
to its idle state. If on the other hand it is going to transmit a ’0’ the transistors are
turned on and the two differential wires are pulled in the other direction. This enables
the transmissions to be prioritized without any collisions [9, 10].
The priority of a sent message is based on its ID tag where a lower ID has a higher
priority. The ID is the first bits sent after the ’Start-of-frame’ bit, see Table 2.1. When
the transceiver sends a ’1’ on the bus it also listens at the same time. If the transceiver
detects that another device is sending a dominant ’0’, it will back off.
If two transceivers start to send a message at the same time they would not notice
that another transceiver is sending, until the sent bits differ from each other. For
example, consider two transceivers sending at the same time, one sending the ID tag
0x004(0b00000000100) and the other 0x00C(0b00000001100). As long as they are both
sending ’0’s the messages are not corrupted or any collisions detected. However when one
of the transceivers transmit a ’1’ and the bus stays at ’0’, it will notice that someone else
is transmitting a ’0’ and it will back off. This means that the higher prioritized message
will succeed and will be transmitted without any collisions.
There are two standards for the CAN frame, the Base frame format and Extended
frame format. Since every message on the wires has to have a unique ID tag, the Base
format was extended to allow more unique messages to be sent on the bus, see Table 2.1.
The data is sent in the Data field and it can vary from 0 to 8 bytes. After that a checksum
is sent and the sender listens if any device acknowledged it by answering in the ACK slot
[8].
Extended bits
Base bits Start-of-frame 1
Start-of-frame 1 Identifier A 11
Identifier 11 Substitute remote request 1
Remote transmission request 1 Identifier extension bit 1
Identifier extension bit 1 Identifier B 18
Reserved bit (r0) 1 Remote transmission request 1
Data length code 4 Reserved bit (r0, r1) 2
Data field 0-64 Data length code 4
CRC 15 Data field 0-64
CRC delimiter 1 CRC 15
ACK slot 1 CRC delimiter 1
ACK delimiter 1 ACK slot 1
End-of-frame 7 ACK delimiter 1
End-of-frame 7
Table 2.1: CAN frame.
J1708
SAE J1708 is a serial communication standard that is commonly used in heavy vehicles.
It is based on normal serial communication with 8 bits, no parity and one stop bit at the
rate of 9600 bit/s. The message is composed of up to 21 characters and starts with an
ID and finishes with a checksum. Messages can be longer than 21 characters when the
vehicle is not moving.
The physical implementation of J1708 uses the same hardware as the RS-485 standard,
but the transmitting part of the transceiver is connected as an open drain connection.
This enables several devices on the same bus and prioritizing like CAN, see Figure 2.9.
VDD
RS-485
4.7kΩ 47Ω
J1708 bus
Tx DE A
DI 2.2nF
Rx RO
2.2nF 47Ω
RE B
4.7kΩ
Figure 2.9: J1708 node on bus.

2.2 Measurement
The wheel loader is a heavy machine with a lot of inertia and most of the analog signals
are measured on slow processes. Raising the boom from ground level to upper endpoint
takes 5.4s and a whole lift cycle takes 10.0s [5]. This can be taken to account when
filtering a signal. Regarding Nyquist sampling rate theorem, the sampling frequency has
to be twice as high as the bandwidth of a bandwidth limited signal. Since the interesting
frequency spectrum is lower than the sampling frequency, the sampling frequency can set
the upper bandwidth limit for the hardware filters. It can then be digitally filtered to
accommodate to the individual process that the sensor is monitoring.
2.2.1 Analog-to-Digital-Converter
An Analog to Digital Converter (ADC) converts continuous analog signals to a discrete
digital representation. This means that an analog signal loses information as it is con-
verted, because it cannot be sampled infinity fast and it does not have infinity many
steps. However, this is a necessary step to be able to perform digital calculations with
respect to the signal data.
Figure 2.10 shows how an analog sinusoidal signal is sampled and represented in digital
form. In this case it is done in even intervals and the values on the samples are discrete
integers varying from 0 to 8.
Voltage/value
8
7
6
5
4
3
2
1
0 t
Figure 2.10: Discrete digital representation of a analog signal.
2.2.2 Digital
A digital signal is either high or low (one or zero). In an ideal case for the wheel loader it
would mean that 24V is high and 0V (ground) is low. However, all the electrical devices
on the wheel loader are specified to operate on a supply voltage down to 9V . This means
2.3. Control 15
that a 9V digital signals should also be regarded as high with some hysteresis. That
is why 8V and higher is regarded as high and 6V and lower is regarded as low, see
Appendix A.
2.3 Control
The controlling device has to have outputs so it can affect a process. This sets require-
ments on the electronics to each output so it can handle the load of its actuator. The
output channel should also handle faults that can occur on the wiring without damaging
the electronics.
If, for example the output is going to control a solenoid, it sets requirements on the
electronics that it can deliver enough current and voltage to open the solenoid. However
it has to have protection so it handles a short circuit, ESD discharge or other scenarios
that can damage the electronics. It should also be able to detect faults on its wiring and
actuator.
In the case of the wheel loader, actuators can be controlled in two different ways. One
way is to fake inputs to the ECU and let the ECU control the actuator. Another is
to drive the actuator directly. The two different strategies can be useful in different
scenarios. Driving the actuator directly may be more suitable in an control loop to avoid
unwanted filtering of the signal. Faking an analog voltage to the ECU may be more
suitable for remote control applications, to get the same filtering on the signal as you get
when driving in the cabin.
2.3.1 Microcontroller
A microcontroller (MCU) is a small computer with integrated memory and peripherals
on the same chip. It has non-volatile memory where it can store programs and param-
eters that will not be erased when the unit is turned off, and it has a RAM memory
which it uses for temporary storage during program execution. Common peripherals in
a microcontroller are hardware timers and serial communication.
This small computer is the center of a system. It takes in data from its peripherals,
computes data according to the programs instructions and performs tasks to monitor
and control the environment.
Hardware timers
Hardware timers enable control and monitoring of tasks with high precision. They can
either contribute to an internal event in the MCU or interact with the environment
through its in- and outputs, see pinin and pinout in Figure 2.11. Timers count at a
given clockrate (clkin ) that can be prescaled. The clock source can either be the main
clock, external crystal or external event. The timer will keep counting at a given rate
independent of what tasks the CPU is preforming.

The control block controls the counter through the three signals Count, Direction and
Clear. The value of the counter is stored in the Counter Reg and compared with the
T OP Reg, Compare Reg and ’zero’ for every cycle. If the comparators get a match they
will send out signals to the Control block and W ave gen. The settings in the Control
Reg determine how the W ave gen should react to the T OP and compare signal and
generate an output accordingly, see “Hardware timers as PWM output”.
When the Edge detect block detects a change on the signal coming from pinin it can
send a write signal to the Capture Reg and the value of the Counter Reg will be stored
in Capture Reg, see “Hardware timers as event capture”.
write
Capture Reg. Edge detect pinin

compare
Compare Reg. = Wave gen. pinout

T OP
TOP Reg. = =0
data bus
Counter Reg.
BOT T OM
T OP
Direction
Count
Clear
Control
clkcnt
Control Reg. Prescaler clkin
Figure 2.11: Overview of a hardware timer.
Hardware timers as PWM output
By setting a counting rate and top value, the timer will wrap around after a defined time.
By also setting a compare value and some conditions for the wave generator, a PWM
signal can be generated. Figure 2.12 shows a timer that sets the output when it wrap
2.3. Control 17
around and clears the output when the compare value is equal to the timer value. By
setting a counting rate and top value the frequency of the PWM signal is defined and
changing the compare value changes the duty cycle. The PWM signal will be generated
without disturbing the CPU which can perform other tasks meanwhile.
Counter value
Compare value
t
Voltage output
Figure 2.12: Hardware timer as PWM output.
Hardware timers as event capture
External events can be registered by a MCU in different ways. One is to let the MCU
poll a pin and check if the pins state has changed. This uses a lot of the MCUs resources
and the resolution on when the event arrived is limited to how often the pin is polled. To
get higher resolution, more of the MCUs resources have to be spent on polling the pin.
Another way is to connect the event to a pin that can invoke an interrupt. The inter-
rupt will make the MCU stop executing its current function and jump to the interrupts
handler. The time of the arriving event can be registered and the MCU can jump back to
the code it was executing before the interrupt arrived. If the frequency of the incoming
event is high, the overhead created as the MCU jumps back and forth to the interrupt
handler will consume the MCUs resources. The MCUs resource usage is dependent on
the frequency of the incoming event.
There is a more effective way to capture incoming events. It is to use a hardware timer
to capture external events. Hardware timers can do it with high timing precision and
low CPU usage. Setting a timer to count at a defined rate and letting the hardware
timer save the timer value when an event arrives and then report to the CPU. Thus can
the CPU process the event when there is no other prioritized tasks, and know when it
arrived by reading the register where it stored the time for the incoming event.
2.3.2 SPI
Serial Peripheral Interface is used for communications between digital devices in the same
system. It is a clocked bus which uses four wires to communicate. One master and several
slave devices can be connected to the same bus. There are two different ways to connect
slaves to the master. One is independent slave SPI configuration as seen in Figure 2.13a.
And the other is Daisy chain SPI configuration as seen in Figure 2.13b.
SPI Master SPI Slaves Master Slaves

MOSI MOSI MOSI MOSI
MISO MISO MISO MISO
CLK CLK CLK CLK
CS1 CS CS1 CS
CS2
CS3
MOSI MOSI
MISO MISO
CLK CLK
CS CS
MOSI MOSI
MISO MISO
CLK CLK
CS CS
(a) Independent. (b) Daisy chain.
Figure 2.13: SPI configurations.
The communication is initiated when the chip select (CS) goes low. After that the
master sends one bit on the MOSI pin for every clock (CLK) cycle and the slave answers
at the same time on its MISO pin from the previous command it was given. If an 8
bit-command is sent to the slave, the master has to send 8 more bits so the slave can
answer to the sent command.
Figure 2.14 shows how the master initiates the communication and sends the command
’14’ to the slave, and the slave answers from the previously sent command with the value
’67’.
2.3.3 DAC
To convert a Digital value to an analog voltage, a Digital to Analog Converter is used. It
represents a digital value as a discrete analog voltage. This makes it possible to recreate
signals previously sampled by a ADC. But as Figure 2.15 shows, the signal is not identical
to the one sampled in Figure 2.10.
The analog output can be used to fake input signals to the ECU. However the analog
signal has to be buffered so it can deliver enough current to handle the pull up and
pull down resistors in the ECU. It can be done through an operational amplifier that is
coupled as a voltage follower.
2.3. Control 19
CLK
MOSI 0 0 0 0 1 1 1 0
MISO 0 1 0 0 0 0 1 1
CS
t
Figure 2.14: Bit timing between master and slave.
Voltage/value
8
7
6
5
4
3
2
1
0 t
Figure 2.15: Discrete analog representation of a digital value.
2.3.4 Power electronics

To control the solenoids on the wheel loader four different techniques was evaluated. As
it turned out, only two could handle the specification in appendix A. Concept 3 and 4
had enough fault detection and could handle short circuits to ground, however concept
4 had too many components and was too expensive. Therefore concept 3 was chosen for
both PWM out and Solenoid out.
The transistors for the power electronics should control loads that have an internal
resistance of around 20Ω. The load is the coil in the solenoids that controls the hydraulic
valves. Inductive loads such as a coil needs a freewheel diode Df that bypasses the current
as the transistor is turned off, see Figures 2.16 - 2.19. Without the diode the current that
is flowing through the coil will generate a voltage that is high enough to either charge the
parasitic capacitances, creating a short circuit by exceeding the breakthrough voltage of
the transistor or generate a spark which can damage the electronics.
When using PWM to drive an inductive load, the transistor is often turned on while
the freewheel diode is still conducting a current. If the reverse recovery time of the free
wheel diode is longer than the ramp times on the transistor it will create a short circuit
just as the transistor is turned on. This will generate transients on the power lines that
can radiate to other electronic circuits. To minimize the short circuit time the reverse
recovery time on the free wheel diode should be kept to a minimum. For normal PN-
junction diode it takes some time before the charges in the junctions is dissipated and the
diode is turned off [11]. However, Schottky diodes does not have to deplete any charge
for it to turn off. This gives Schottky diodes shorter reverse recovery time than normal
PN-junction diodes. That is why Schottky diodes are used in PWM applications.
Concept 1
Figure 2.16 shows a concept that uses a P-channel MOSFET to control the Load, where
one end of the load is connected to the transistor and the other to ground.
P-channel MOSFETs are less effective than N-channel MOSFETs because the nature
of physics that make them conduct. Electrons in the substrate moves easier than ’holes’,
thus giving P-channels a higher resistance [12].
This concept uses few components but it is ineffective, has no protection against a
short circuit in the outgoing wires and no current measurement.
+24V
PWM in
Df Load
Figure 2.16: Concept 1 PWM out schematic.
Concept 2
Figure 2.17 shows a concept that connects one end of the load to +24V and the other
end to a N-channel MOSFET. To draw current through the load, the transistor is turned
on and sinks it to ground.
This concept is cheap, effective and uses few components but it has no protection if
the wires are short circuited and it has no current measurement.
Concept 3
Figure 2.18 shows a concept that uses a smart high side switch that has internal protection
against short circuit and high temperatures. It also measures the current that is flowing
2.3. Control 21
+24V
Df Load
PWM in
through the transistor and can detect if the circuit is open.

This smart high side switch is connected to one end of the load and the other end of
the load is connected to ground.
This concept uses few components, measures the current and has protection against a
short circuit on the transistor side, but is has no protection if the outgoing ground wire
is short circuited to +24V .
+24V
Smart high side switch
PWM in
Status/i
Df Load
Concept 4
Figure 2.19 shows a concept that uses a smart high side switch that has internal protection
against short circuit and high temperatures. It also measures the current that is flowing
through the transistor and can detect if the circuit is open.
This smart high side switch is connected to one end of the load and the other to an
N-channel MOSFET that has a shut resistor Rs . The current flowing through the shunt
resistor is continuously measured and if it exceeds a threshold level it will shut off the
lower N-channel transistor.
This concept has short circuit protection on all outgoing wires and measures the current
but it is expensive and uses many components
The third concept that was shown in Figure 2.18 was used in the final design, see
+24V
PWM in
Status/i
Protection logic Df Load
on/off
Dp
+
− Rs
Result. It meets the requirements of the specification and uses less components than
concept four (Figure 2.19).
2.4. Safety and Regulations 23
2.4 Safety and Regulations

Since the unit is only a prototype it does not need to comprehend all the demands in the
“ISO 26262 Achieving Functional Safety in the Automotive Industry“. But some sort of
security is needed to not endanger people or other property.
2.4.1 Emergency shutdown

If the EBU is going to take over the movement of the wheel loader, there has to be some
sort of fail-safe so it can be stopped if something goes wrong. The EBU has to be able to
shutdown remotely and from on board the wheel loader. Both the remote and on board
shutdown switches can be coupled in series so if any of them opens their circuit, it will
cut the power to the EBU.
2.4.2 Watchdog
One way to monitor that the MCU is not in any undefined state is to have the operating
system control an external pin that pokes an external watchdog. The watchdogs job is
to reset the MCU if the system crashes.
If the watchdog is windowed (WWDT), it means that the MCU cannot poke the watch-
dog to often or to seldom as Figure 2.20 shows. That will be regarded as faulty behavior
Hardware Security
and the watchdog will reset the system by pulling the reset pin on the MCU.
Window
U
Figure 2.20: How a windowed watchdog operates.

2.4.3 EMI
Electromagnetic Interference, it is when unwanted signals/transients radiate to other
circuitry. This can cause problems and even destroy other circuitry, especially in a
vehicle where several different systems are connected to each other and exposed to a
harsh environment. Thats why there are several different Electromagnetic Compatibility
(EMC) standards that defines how much interference each system is allowed to radiate,
and how immune the system should be for incoming interference [13].
All digital circuits are composed of several transistors, often CMOS transistors. When
these transistors changes state, like when a gate changes output from low to high, there
will be some short circuit current when both the upper and lower transistor is on. Another
problem is the gate capacitance in the transistors, it has to be dissipated and this will
consume a current when the transistor change state. Hence, switching a transistor will
generate a current spike that will lower the voltage over the circuit just when the switching
takes place [11].
When a digital circuit is clocked, saying that it will change state continually with even
intervals. It will generate current spikes on its power lines with even intervals. Each spike
can be approximated as a square wave impulse. Since a square wave can be described
with the sum of infinity many sinusoidal harmonics, the circuit will radiate infinity many
sinusoidal harmonics on the power lines.
∞
4 X sin (2π(2k − 1)ωt)
xsquare (t) =
π k=1 (2k − 1)
Figure 2.21 shows how the current spikes on the power lines can be reduced. The
decoupling capacitor Cd is physically placed close to the power pins on the MCU giving
it low resistance and inductance. This will keep the voltage level steady as the CMOS
circuitry draws current in even intervals shown as i3 . To minimize the RF radiation from
the spiky current loops, the loop area should be as small as possible.
The capacitor Ce is further away from the MCU so the power lines are longer, this will
give stray resistance Rs and inductance Ls . Rs , Ls and Ce can be seen as a low-pass
filter and smoothes out the spikes in the current loop i2 . This current loop area should
also be kept to a minimum to minimize the RF radiation.
The EMI filter in this case is shown by Lemi and Cemi . They are designed to attenuate
the high frequency harmonics that comes from switching devices so they will not spread
to other circuitry. The area of i1 is dependent on the distance between the power source
and the device, in the case of a vehicle it is the length of the wires between the battery
and device.
2.4. Safety and Regulations 25
i1 i2 i3
t t t
Lemi Lemi Rs Ls
Cemi
+
ut − i1 Ce i2 Cd i3 MCU
Rs Ls
Figure 2.21: How decoupling and EMI filters attenuate current spikes on power lines.
C HAPTER 3
Result
The result of this thesis is an Electronic Breakout Unit that can be connected directly
onto the original wiring on the wheel loader. The system monitor and control all signals
that are going through the wires. Communication with the outside world, i.e. a PC, is
done through Ethernet. As seen in Figure 3.1, the system consist of two separate Printed
Circuit Boards (PCB) that are stacked upon each other.
The topmost card is the Relay Card. All the original wiring is connected directly to
this card. This gives the EBU access to all the sensors and actuator signals on the wheel
loader. To provide a good interface to the original wiring it uses the same connectors as
the original ECUs. It also has the capability to disconnect itself from the wires to ensure
that it will not interfere with unwanted signals. The functionality of the Relay Card is
further explained in Section 3.1.
The card at the bottom in Figure 3.1 is the Control Card of the EBU. Its purpose is to
monitor and control the signals that are connected to the Relay Card, and communicate
that information to the outside world through Ethernet. How the monitoring and control
of the signals are dealt with is further explained in Section 3.3.
27
28 Result
3.1 Relay Card schematic

The Relay Card is connected in between the wheel loaders wiring and the ECU. This
makes it possible to monitor and control signals in both directions. To do so the incoming
and outgoing wire through the EBU has to be disconnected from each other. Otherwise
two control sources will be connected on to the same wire and they will short circuit each
other.
To disconnect the incoming and outgoing wire, and at the same time connect the wire
to the Control Card, a relay used. This enables for example monitoring of a sensor
while sending an emulated sensor signal to the ECU. It also ensures that the EBU can
not interfere with signals it’s not supposed to control and that the whole EBU can be
disconnected from the wiring by cutting the power to the relays. When the power to the
relays are cut they return to their idle state, this disables the EBU to control the wheel
loader and is used as a safety precaution. If a malfunction in the system takes place and
the wheel loader has to be stopped the power to the relays can be cut and the whole EBU
will be just like a straight through cable, connecting the wheel loaders wiring directly to
the ECU.
The Relay Card is stacked upon the Control Card as seen in Figure 3.1. If a signal
is to be controlled, the Relay Card switches the relays so the Control Card is connected
to the wire. Then the Control Card can send and receive information to both the wheel
loader and to the original ECU. This setup does allow the EBU to both listen, as well
as take full control of all the different signals on the wheel loader. One example is for
instance the tilt of the bucket. Normally the tilt is controlled by an electrical lever in the
cabin. Using the EBU, the signal from this lever could be emulated and in turns, the tilt
of the bucket may be controlled without touching the lever.
Signals from
EBU Signals from
sensors and
original ECU
actuators
Relay card
Control card
Ethernet
Figure 3.1: The Electronic Breakout Unit is divided into two printed circuit boards, a
Relay Card, and a Control Card.
3.1. Relay Card schematic 29
3.1.1 Digital in and Digital out

Digital signals are widely used on the wheel loader. Such signals can come from interface
buttons, digital sensors or other digital electronics.
As seen in Figure 3.2 the original wiring is connected to the EBU, and the EBU is
connected to the ECU. The Relay Card connects the signal to the ’Digital in’ port on
the Control Card, so the Control Card can always listen to the signal. To be able to
tamper with the signal that is going to the ECU a relay has to be switched, connecting
the ’Digital out’ port on the Control Card to the wire that is going to the ECU.
Some of the digital signals require a pull up or down resistor. Therefore, there are
empty soldering pads where pull up and pull down resistors can be mounted, shown as
gray in Figure 3.2. These are meant to customize each input on the Relay card so they
match the ECU its monitoring. The resistor is then connected to the wire as the relay
switches, and the EBU takes control of that signal.
ECU EBU
Ru Relay
Rd
Original wiring
Digital out Digital in
Figure 3.2: The relay connects the pull up/down resistors to the wire at the same time
the Digital out is connected to the ECU.
3.1.2 Analog in and Analog out

There are several analog signals connected to the EBU. They are either generated by user
interface sensors or sensors that measure some physical property of the wheel loader. All
the sensors are designed to deliver an analog output between 0.5V to 4.5V .
As seen in Figure 3.3 the original wiring is connected to the EBU, and the EBU is
connected to the ECU. The Relay Card connects the signal to the ’Analog in’ port on
the Control Card, so the Control Card can always listen to the signal. To be able to
tamper with the signal that is going to the ECU a relay has to be switched. When
switched, the ’Analog out’ port on the Control Card is connected to the wire that is
going to the ECU. This enables to send emulated input to the ECU, like tilting the
bucket.
As for the Digital in and out ports there are resistor pads that allows the input to
customized dependent on which signal its monitoring. The resistor (shown as gray in
30 Result
Figure 3.3) are then connected to the wire as the relays switches.
ECU EBU
Ru Relay
Rd
Original wiring
Analog out Analog in
Figure 3.3: The relay connects the pull up/down resistors to the wire at the same time
the Analog out is connected to the ECU.
3.1.3 Solenoid out and Load Resistor
The main actuators on the wheel loader are hydraulic valves which are controlled by
solenoids. As seen in Figure 3.4 the original wiring is connected to the EBU, and the
EBU is connected to the ECU.
The ’Solenoid in’ port on the Control Card is always connected to the wire so the EBU
can listen what the ECU sends out. However the EBU cannot send out any signal to the
original wiring unless the relay is switched. With the relay switched, the ’Solenoid out’
port is connected to the outgoing wire and the EBU can control the solenoid. The relay
also connects a load resistor to the ECU so it will not detect any faulty wiring.
ECU EBU
Original wiring
Relay
Rl
Solenoid in Solenoid out
Figure 3.4: The relay connects the load resistor to the ECU and bypasses the signal to
the Control Card.
3.1. Relay Card schematic 31
3.1.4 PWM out and Load Resistor

Some of the hydraulic valves on the wheel loader are of a proportional type, i.e. it is
possible to proportionally control the flow of fluid through them. The solenoids in those
valves are controlled by a PWM signal which both has an outgoing wire and a return
wire as seen in Figure 3.5. The original wiring is connected to the EBU, and the EBU is
connected to the ECU.
The ’PWM in’ port on the Control Card is always connected to the outgoing wire so the
EBU can listen what the ECU sends out. However the EBU cannot send out any signal
to the original wiring unless the relay is switched. By doing so, both the outgoing and
return wire is connected to the ’PWM out’ port and the EBU can control the solenoid.
The relay also connects a load resistor to the ECU so it will not detect any faulty wiring.
ECU EBU
Rl Original wiring
Relay
PWM in PWM out
Figure 3.5: The relays connects the load resistor to the ECU and bypasses the signal to
the Control Card.
3.1.5 CAN and J1708

For every CAN and J1708 bus on the ECU, the EBU has two transceivers. One that is
always connected to the original wiring and one that can be connected to the ECU. This
enables filtering of messages and control of other peripheral equipment.
The transceiver that is connected to the ECU always has a terminating resistor con-
nected between the two wires. The transceiver that is connected to the outgoing wires
has a terminating resistor that can be connected as the relay is switched as Figure 3.6
shows.
3.1.6 Relay drivers

All the relays on the Relay Card are controlled by an I/O-extension through a SPI bus,
which is explained further in Section 3.3.4 “Internal buses”. Figure 3.7 shows how the
output from the shift register IC1 is connected to the relay driver IC4 ULN2803. The
1 2 3 4 5 6
32 Result
A
ECU EBU
Rt Original wiring
Relay
B
CAN/J1708 CAN/J1708
Figure 3.6: The relay connects the terminating resistor to the original wiring and connects
VDD
the ECU to the Control Card at the same time.
16
16
16
16
16
VCC
VCC
VCC
VCC
VCC
C257IC1P C258IC2P C259IC3P C268IC7P C269IC9P
GND
GND
GND
GND
GND
100n 100n 100n 100n 100n
8
GND
C
relay driver ULN2803 has internal freewheel diodes which can drain 500mA [14], therefore
external freewheeling diodes are unnecessary.
BATT
K15 K2 K16 K3 K9 K17

C261 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
1
1
100n/50V
8
8
IC4
D K_DI 14 15 1 18
SER QA I1 O1
1 2 17
QB I2 O2
K_CLK 11
SCK QC
2 3
I3 O3
16 K_CLK
K_RST 10
SCL QD
3 4
I4 O4
15 K_RST
4 5 14
QE I5 O5
K_STORE 12
RCK QF
5 6
I6 O6
13 K_STORE
6 7 12
QG I7 O7
7 8 11
QH I8 O8
9 10
GND CD+
K_DISABLE 13
G QH*
9 K_DISABLE
ULN2803AA
74HC595D GND
Figure 3.7: Relay driver schematic.

E
K4 K10 K18 K5 K11 K19 K6

C260 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
1
100n/50V
8
IC5
14 15 1 18
SER QA I1 O1
1 2 17
QB I2 O2
11 2 3 16
SCK QC I3 O3
10 3 4 15
SCL QD I4 O4
4 5 14
QE I5 O5
12 5 6 13
RCK QF I6 O6
6 7 12
QG I7 O7
7 8 11
QH I8 O8
9 10
GND CD+
13 9
G QH*
F ULN2803AA
74HC595D GND
C262 K12 K20 K7 K13 K21 K8 K14

IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
1
100n/50V
8
IC6
14 15 1 18
SER QA I1 O1
1 2 17
QB I2 O2
G 11
SCK QC
2 3
I3 O3
16
10 3 4 15
SCL QD I4 O4
4 5 14
QE I5 O5
12 5 6 13
RCK QF I6 O6
6 7 12
QG I7 O7
7 8 11
QH I8 O8
9 10
GND CD+
13 9
G QH*
ULN2803AA
74HC595D GND
I
3.2. Relay Card layout 33
3.2 Relay Card layout

The connectors in the upper part of Figure 3.8 connects the EBU to the wiring on the
wheel loader. The connectors on the bottom connect the EBU to the original ECU. The
main relay can cut the power to the power electronics and relays.
All analog signals is kept as far as possible from the switching power signals to minimize
interference. The pull up/down and load resistors are all placed on the bottom of the
card. This makes it easy to distinguish the customizable resistors from the permanent
static resistors.
The PCB card has 6 layers of copper which connects the pads on the components. The
routing of each layer can be seen in Appendix C.
Wheel loader connector A Wheel loader connector B

Main relay
Power relays
Analog Digital
&
relays relays
Load resistors
Relay drivers & Shift registers
ECU connector A ECU connector B
Figure 3.8: Layout of the Relay Card and its internal blocks.
34 Result
3.3 Control Card schematic

The Control Card is stacked upon the Relay Card as Figure 3.1 shows. One task for the
Control Card is to monitor electrical signals and transmit data over Ethernet. It can also
control some of the signals that are going to the wheel loader and to the ECU.
The tasks of the Control Card is divided over three Microcontrollers (MCU). The main
reason why three MCUs had to be used is the number of CAN buses to be monitored,
and the numbers of hardware input captures.
As Figure 3.9 shows, there is one master and two slave MCUs. The one in the middle
is the master MCU, it has one SPI bus that is connected to the lower speed peripherals
e.g. ADC, DAC, ’Digital in/out’, ’Solenoid out’ and the relays. The master handles
the Ethernet communication and streams the data to and from the two slaves through
dedicated SPI buses and transmit them over Ethernet.
The slave MCUs are connected to the master through SPI buses. The slaves share
the high speed peripherals e.g. CAN communication, Frequency in and PWM out and
transmits there data to the master on the masters request.
Control card
CAN/ PWM Power
Freq. in Ethernet
J1708 out supply
SPI SPI
MCU MCU MCU
Analog Analog
ADC DAC
in out
SPI
Digital Shift Shift Solenoid
Drivers
in reg reg out
Shift Shift Digital

Relays Drivers Drivers
reg reg out
Figure 3.9: System overview of the Control Card.
3.3.1 Power supply

The in-coming power first goes through a protection circuit as Figure 3.10 shows. It
protects the EBU from incoming transients and load dumps (Appendix A). The input
power is then divided into ’24V power’, ’24V regulated’ and power to the digital circuitry.
The ’24V power’ is the supply that drives the hydraulic valves. The switching frequency
of the power electronics is 200Hz and it is switched softly. Softly implies that the rise
and fall times on the transistor that is controlling the signal is limited. This lowers the
radiated harmonics so no EMI filter should be necessary. The ’24V power’ supply can
3.3. Control Card schematic 35
be turned on and off through a N-channel MOSFET.

The ’24V regulated’ is used to supply the Digital out ports. The Digital out ports does
not change its state more often than the sampling rate, which is 50Hz. Hence, no EMI
filter should be needed for this signal. The allowed current limit is below 1A so a linear
regulator LM317HV was chosen.
The internal digital components demands two different voltage supplies, one 3.3V and
one 5V . The specification in Appendix A states that the EBU should be able to operate
at a battery voltage between 9 − 60V . To comprehend with such a large voltage span
and still keep the energy losses to a minimum, a switched regulator had to be used. The
switched voltage regulator is behind an EMI filter and it regulates the voltage down to
8V and sends it to two linear regulators. One that regulates the voltage to 3.3V to supply
the MCUs with power, and another one that regulates the voltage to 5V to supply the
peripherals on the board.
The analog voltage supply is taken from the analog supply output from the ECU and
has the same ground reference as the analog ground on the ECU. The analog circuitry
is galvanically separated from the EBU. This setup should decrease the interference and
potential grounding loops. All communication to the analog circuitry is done through
galvanically separated transceivers. However, if the analog circuits draw to much current
from the ECU, the circuit board is prepared for adding a filtered 5V analog voltage
supply that can be generated through the 5V supply as Figure 3.10 shows.
Power supply
Battery
-Operational: 6-60V
-Clamping: 60V
Protection
EMI filter
Power on
MOSFET
Lin. reg Switch reg 2 x Lin. reg Filter
Power
24V 32V 8V 3.3V 5V 5V Analog
24V (Battery + 8)
(Battery)
GND AGND
Figure 3.10: Overview of the power supply.
Emergency shutdown
If the EBU is going to take over the movement of the wheel loader there has to be some
sort of fail-safe so it can be stopped if something goes wrong. That is why an external
emergency switch will be mounted on the wheel loader. The emergency switch can be
36 Result
controlled from inside the cabin and remotely through wireless communication. By using
this emergency switch to cut the power to units that control the wheel loader will bring
the wheel loader to a halt.
The wheel loader can be shut down in two ways when it’s controlled remotely. One way
is to cut the power to the whole wheel loader, this will shutdown all electronic equipment
on the wheel loader and it will eventually come to an abrupt halt. Another way is to
just cut the power to the relays in the EBU as Figure 3.11 shows. If only the power to
the relays is cut off, the unit will not be able to control any signals but it will still be
possible to monitor and log data.
Hardware Security
Battery
Emergency
switch
Power Emergency
supply Switch
Reset
WWDT MCU Relays

WDI
Figure 3.11: Overview over the built in safety features. The emergency switch is external
equipment and not included in this thesis.
Power in
The main battery is connected to ’BATTF’ in figure 3.12 through a main relay. ’BATT
ON’ is the net that supplies the power transistors and can be turned off and on by the
MOSFET Q1. The MOSFET Q1 is controlled by the signal ’ON’ from the master MCU.
The D5 diode is a reverse protection diode that will blow the fuse to the EBU if the
battery poles are switched.
1 The diodes D32 and D4 supplies
3 the voltage regulators
4 for 5
the digital circuits.
Power in
A 32V
BATT to 24V
R28
1k
Q2 KEY_SUPPLY IN OUT
D8
BSR33,115 S5BC
C63
C64
ADJ
+
R30
R25
1k
Q3 IC6
BSR43 LM317HV
100n
120u
10k
R31
ON
VSS
VSS
1k
BUK663R7-75C
R26
18k
C65
VSS
100n
S5BC-13-F
Q1
Place caps close to pin
B
VSS
BATTF BATT_ON
C66
C67
D5
B3100-13-F
D3
100n/60V
R29
1n/60V
10k
BZX84C15
VSS
VSS
VSS
D7
D4
KEY KEY_SUPPLY
B3100-13-F
C69
C70
100n/60V
1n/60V
C
VSS
VSS
Figure 3.12: Power in schematic.
BATT to 32V and 8V

D Place close to pin
BAS70-04
1u/60V
D6
Switched regulator 8V and 32V Place caps close to pin 100
R27
100n
1n
C71
IC56
VSS
Place caps close to inductor

C61
C57
100n
C62 VSS
A switched regulator was chosen to be able to deliver enough current to all the digital
+
KEY_SUPPLY L3 3
VIN VCC
1 C48
7427512 1u/16V
C68
C60
C59
C58
VSS
circuits and keeping the energy losses to a minimum as the voltage is lowered. The 2
SD BST
16
1u/16V
C52
100n
100n
VSS
1n
switched regulator ’LM5575MH’ has an internal P-channel MOSFET that can either C49 10 SS SW
14 L2
B3100-13-F
10n/16V
E
VSS
VSS
VSS
7447709680
C55
C53
C54
C56
turn on or off the current flowing from pin3 to pin14, see Figure 3.13. This MOSFET is C50 6 15
+
FB PRE
10n/16V
D2
R22 33p
120u
100n
49.9k
10u
5 13
controlled by the internal logical circuits inside the ’LM5575MH’ chip. The frequency of COMP
10
IS
R15
VSS 21k 7 12
how fast the regulator should switch this MOSFET is determined by the resistor R16 on 680p
C51
R16 8
RT
RAMP
PGND
AGND
9
VSS
17
EPAD
4 11
SYNC OUT
pin7. A value of 21kΩ on R16 should give a frequency of 300kHz [15]. How long time
LM5575MH Place caps close to inductor
the MOSFET should be on during each cycle is determined by the voltage on pin6. The 10k
R23
current values ofF the two resistors R23 = 10k and R24 = 1.8k should give a duty cycle
R24
1.8k
that keeps a steady 8V output from the pin on inductance L2 that is connected to the
VSS
’8V’ net.
The 32V is needed to drive the N-channel MOSFET that delivers the power to the
power electronics. It is generated through a charge pump. As pin14 switches and goes
1k
BUK663R7-75
V
R26
18k
C65
VSS
100n
S5BC-13-F
Q1
B
VSS
BATTF BATT_ON
C66
C67
D5
B3100-13-F
D3
100n/60V
R29
1n/60V
10k
BZX84C15
VSS
VSS
VSS
D7
38 KEY
D4
KEY_SUPPLY
Result
B3100-13-F
C69
C70
100n/60V
1n/60V
C below 8V the capacitor C68 is charged through the diode D6. When pin14 rises back up 8V
VSS
VSS
to the battery voltage, the charge in C68 is pumped to C71 through the other diode in
D6. Thus giving a voltage potential that is 8V above the battery voltage. The regulator
is behind an EMI filter L3 that attenuates the harmonics on the power line.
BATT to 32V and 8V
D Place close to pin
BAS70-04
32V
1u/60V
D6
100
R27
100n
1n
C71
IC56
Place caps close to inductor VSS
C61
C57
100n
C62
VSS
+
KEY_SUPPLY L3 3
VIN VCC
1 C48
7427512 1u/16V
C68
C60
C59
C58
VSS
2
SD BST
16 C52
1u/16V
100n
100n
VSS 8V
1n
C49 10 SS SW
14 L2 8V
B3100-13-F
10n/16V
E
VSS
VSS
VSS
7447709680
C55
C53
C54
C56
C50 6 15
+
FB PRE
10n/16V
D2
R22 33p
120u
100n
49.9k
10u
5 13
COMP
10
IS
R15
VSS 21k 7 12
RT PGND
C51
R16 8
RAMP AGND
9
680p
VSS
17
EPAD
4 11
SYNC OUT

10k
R23
F
R24
1.8k
VSS
Figure 3.13: Switched regulator 8V and 32V schematic.
3.3.2 Inputs
Analog in
The ’Analog in’ ports samples the analog voltage signals from the sensors on the wheel
loader. If the signal is to be controlled from the EBU, a pull up/down resistor, shown in
gray in Figure 3.14, is mounted on the Relay Card.
To attenuate interference a low pass filter between R1 and C1 is designed. This gives
a cutoff frequency of:
1
fc =
2πR1 C1
To protect the ADC two external protection diodes is placed rail-to-rail with the signal
net. The signal is then measured by the ADC and read by the master MCU through a
SPI bus.
D1 D2
+5V
+5V
Ru
R1
To ADC.
In
Rd C1
Figure 3.14: Analog in schematic.
Digital in
The Digital in ports both listens to the digital output that the wheel loader is providing
and to the solenoid outputs from the ECU. If the signal is to be controlled from the EBU,
a pull up/down resistor, shown in gray in Figure 3.15, is mounted on the Relay Card. A
digital ’High’ should be considered as ’High’ even if the battery voltage varies between
9 − 60V . That sets the condition for the voltage division between R1 and R2 :
R2
Vout = Vin ·
R1 + R2
To reduce influence of button bounce and other interference a low pass filter between
R1 , R2 and C1 is designed. The cutoff frequency of the filter is calculated as:
1
fc =
2π(R1 ||R2 )C1
To protect the logical circuit two external protection diodes is placed rail-to-rail with
the signal net. The signal is then sent to a shift register that is controlled by the master
MCU, this is further explained in Section 3.3.4 “Internal Buses“ on page 43.
D1 D2
+24V
VDD
Ru
R1 To shift reg.
In
Rd R2 C1
Figure 3.15: Digital in schematic.

40 Result
Frequency in
The velocity sensors on the wheel loader are all of the inductive type described in Chap-
ter 2. These sensors induce a sinusoidal voltage signal of which the frequency is directly
proportional to the measured velocity. However, the amplitude of the signal does also
vary with the velocity hence a special designed circuit, the LM1815, is used to amplify
and detect the signal. The LM1815 uses an adaptive hysteresis to reduces the errors if
the signal is interfered and adapts the hysteresis to the amplitude of the sinusoidal signal.
If C1 >> C2 then the circuit in Figure 3.16 can be considered a band-pass filter. This
filters is designed to let through the wanted mid frequency spectrum and attenuate the
unwanted low and high frequencies. Unwanted frequencies in this case can be DC offset
and high frequencies from switching electronics.
The bandpass filter has a lower cutoff frequency of:
1
fL =
2πR2 C1
And an upper cutoff frequency of:
1
fH =
2πR1 C2
R1 C1
To LM1815
In
C2 R2
Figure 3.16: Frequency in schematic.
The LM1815 chip measures the zero crossing of the sinusoidal signal and represents it
as a digital signal. The digital signal is then sent to a pin on the MCU that can use
hardware timers to measure the frequency of the signal, see ”Hardware timers as event
capture“.
3.3.3 Outputs
Analog out
The ’Analog out’ ports sends analog signals to the wheel loader’s ECU emulating sensors
or driver input. It is done through a DAC that is controlled by the master MCU. The
maximum output current from the DAC is highly limited so an operational amplifier (op
amp) is connected as a buffer on the signal. The resistance R1 connected in series with
the output of the op amp is there to protect the op amp from high currents that might
occur if the output for some reason is short circuited. R1 and C1 creates a low pass filter
that limits the high frequency output.
− R1
Out
From DAC +
C1
Figure 3.17: Analog out schematic.
Digital out
The ’Digital out’ port is used to send digital signals to the wheel loader ECU to be able
to emulate driver and sensor input. It is controlled by the master MCU through a shift
register, this setup is further explained in Section 3.3.4 ”Internal Buses” on page 43.
The digital signal from the shift register is represented as 0V or 5V , it has to be
amplified so it can go from 0V to 24V . It is done through a buffer. The series resistance
R1 is there to protect the buffer from breaking by drawing to much current if the outgoing
wire is shorted, see Figure 3.18. The resistor R1 and the capacitor C1 also constructs a
low pass filter that limits the outgoing frequency output from the port. This is done for
lowering the amount of interference that the EBU is radiating.
+24V
R1
From shift reg. Out
C1
Figure 3.18: Digital out schematic.

42 Result
PWM out
The ’PWM out’ ports are controlled by output pins on the MCU. These pins generate
a PWM signal by using a hardware timer which is further explained in Section 2.3.1
“Hardware timers as PWM output”.
Figure 3.19 shows the design of the ’PWM out’ port, it uses a smart high side switch
that has internal protection against short circuit and high temperatures. Besides that,
it measures the current that is flowing through the transistor and it can detect if the
circuit is open.
This smart high side switch is then connected to one end of the load and the other end
of the load is connected to ground.
+24V
PWM in
Status/i
Df Load
Solenoid out
’Solenoid out’ uses the same power electronics as ’PWM out’ but the controlling signal
comes from a shift register instead of a pin from the MCU, see Figure 3.19. It also
measures the current that is flowing through the transistor and can detect if the circuit
is open.
3.3.4 Microcontroller and peripherals

The microcontroller (MCU) LPC1768 from NXP semiconductors is used to control the
EBU. It has CAN, Ethernet, PWM output, SPI and many more peripherals and can
execute instructions at 100M Hz [16]. Since it only has two CAN modules and six PWM
out, several MCUs has to be used to be able to control and monitor all signals that is
connected to the EBU.
1 2 3 4
A Watchdog
The external watchdog MAX6753 is used to reset the MCUs if they come in some unde-
fined state. It also resets the relays so that they are switched to their idle state. This
disconnects the Control Card from the original wiring, thus ensuring that the EBU will
not come in some undefined state and controlling the wheel loader.
The MAX6753 chip has a windowed watchdog which needs to be reseted with even
intervals. If the watchdog is reseted to fast or slow it will reset the MCUs [17]. The
B interval that the watchdog has to be reseted is set to 100ms by the capacitor C79 as seen
in Figure 3.20. The window for a successful reset is set by the pull up/down resistors on
pin 1 and 5.
Watchdog
IC55
+3V3
VSS DNP
8 7 RESET_N
VCC ~RESET
C78 100n R41
WDI 6
WDI
3
SRT
2 Watchdog slow timeout set to 100ms
C 1
SWT
SET0 Twd2=0.65x10⁹xCswt
VSS C80 22n
C79 150p
5
SET1
Reset Timeout set to 100ms
4 Trp=5.06x10⁶xCsrt
GND
SET0 SET1 Ratio

VSS
MAX6753KA29+T 0 0 8
DNP
R39
R40
0 1 16
DNP
1k
R37
R38
1 0 Disabled
1k
+3V3 1 1 64
VSS
Figure 3.20: Watchdog schematic.

D
JTAG
Internal buses
+3V3
1
R34
2
3
10k
The internal and external digital in TMS_SWDIO
and out ports on the EBU far exceeds the input and
TCK_SWDCLK
4
output pins on the MCUs, hence anRESET_N
5
6
I/O-extension is needed. This is done by using shift
TDI
E 7
registers, where the output to the shift registers is shifted out from a SPI bus on the
8
+5V
MCU. As the MCU SV1 shifts out the output it also reads the values that is shifted to it
VSS
from the input shift registers.

1
To connect
TDO_SWO
this I/O-extension to a SPI bus where several
2
other devices can be connected,
3 a 2TDO_SWOX
tri-state gate has to be placed on the MISO pin as
Figure 3.21 shows. The SV4 MISO pin from the I/O-extension should be at high impedance
state when the I/O-extension is inactive (Chip Select, CS high).

The shift registers are coupled in series, and as CS is enabled the input shift registers +3V
stores the input. As the MCU starts the clock pulses on SCK and writes on MOSI to the VSS
F output shift register, the input register starts to shift out their input to the MCU. At the VSS
same time as the new output is written to the output shift register, the input registers
VSS
VSS
G
A
44 Result
answers with their input. When the CS is disabled the output registers changes state to
what is written in their internal registers.
B
IC51
Shift out reg. Shift out reg.
100n C394
100n C387
+5VA
+3V3
1 16
VDD1A VDD2A
2 15
GND1 GND2
AGND
VSS
SPI_CS0 3 14 A_SPI_CS0
SCK VIA VOA
SPI_SCK 4 13 A_SPI_SCK
VIB VOB
SPI_MOSI 5 12 A_SPI_MOSI
VIC VOC
SPI_MISO 6 11 A_SPI_MISO
VOD VID
100n C393
100n C388
+5VA
+3V3
MOSI 7 10
VDD1B VDD2B
C
8 9
GND1* GND2_2
AGND
MISO
VSS
ADUM7441ARQZ
IC54
CS
100n C391
100n C389
+5VA
+3V3
1 16
VDD1A VDD2A
2 15
GND1 GND2
AGND
Shift in reg.14 Shift in reg.

VSS
SPI_CS1 3 A_SPI_CS1
VIA VOA
VIB VOB
VIC VOC
6 11
VOD VID D
100n C392
100n C390
+5VA
+3V3
7 10
VDD1B VDD2B
Figure 3.21: Tri-state gates and shift registers expand the digital I/O.
8 9
GND1* GND2_2
AGND
VSS
ADUM7441ARQZ
+3V3
R367
5988160107F
220
+5V
RN25B1k
LED1
U1
E
+3V3
VSS
2
100n C395 14 VCC 1Y

3 D_CLK
6 SPI_MISO
2Y
SPI_SCK 2 8 D_CS
1A 3Y
9 11 DO_SER
3A 4Y
DI_SER8 5
2A
SPI_MOSI 12
4A
1
1~OE
RN25A1k
RN25C1k
RN25D1k
SPI_CS4 4
8
2~OE
10
3~OE
13
4~OE
1
7
GND
VSS
VSS
3 6 SN74LVC125AD
R336
RN21C1k RSTOUT_N D_RST F
4 5
0
RN21D1k
Figure 3.22: SPI I/O Extension schematic.

+5V
RN26B1k
7
U2
To measure the analog signals with the same reference as the original ECU, the analog
+3V3
VSS
2
100n C396 14 VCC 1Y

3 K_CLK
devices in the EBU must be on the 2
same ground
2Y
6 as the analog ground on the ECU. To
8
SPI_SCK 1A 3Y K_STORE
9 11 K_DI
5
3A
2A
4Y G
SPI_MOSI 12
4A
1
1~OE
RN26A1k
RN26C1k
RN26D1k
SPI_CS5 4
8
2~OE
10
3~OE
13
4~OE
1
7
GND
VSS
VSS
SN74LVC125AD
R335
RSTOUT_N K_RST
8 9 10 11
ensure that no ground loops are created which can pick up interface, the communication A
between the analog devices and the rest of the EBU had to be isolated. The ADUM7441
uses internal transformers to isolate the communication and can handle speeds up to
25M bit [18]. As seen in Figure 3.23 the ADUM7441 isolates the communication between
the MCU and analog devices.
The ADCs cannot be connected in daisy chain so each of the devices has to have one
separate CS net. But the DACs can be connected in daisy chain, so it reduces the number
of nets that has to be isolated.
B
IC51
100n C394
100n C387
+5VA
+3V3
1 16
VDD1A VDD2A
2 15
GND1 GND2
AGND
VSS
VIA VOA
SPI_SCK 4 13 A_SPI_SCK
VIB VOB
SPI_MOSI 5 12 A_SPI_MOSI
VIC VOC
SPI_MISO 6 11 A_SPI_MISO
VOD VID
100n C393
100n C388
+5VA
+3V3
7 10
VDD1B VDD2B
C
8 9
GND1* GND2_2
AGND
VSS
ADUM7441ARQZ
IC54
100n C391
100n C389
+5VA
+3V3
1 16
VDD1A VDD2A
2 15
GND1 GND2
AGND
VSS
VIA VOA
VIB VOB
VIC VOC
D0 6 11
VOD VID D
100n C392
100n C390
D1
+5VA
+3V3
EN 7 10
VDD1B VDD2B
S
D0
D1 8 9
GND1* GND2_2
ER
AGND
VSS
F_CLK
C ADUM7441ARQZ
O
+3V3
Figure 3.23: SPI Isolated schematic.

R367
5988160107F
220
O
+5V
SI
RN25B1k
LED1
U1
E
+3V3
VSS
2
100n C395 14 VCC 1Y

3 D_CLK
6 SPI_MISO
2Y
SPI_SCK 2 8 D_CS
1A 3Y
9 11 DO_SER
3A 4Y
DI_SER8 5
2A
SPI_MOSI 12
4A
1
1~OE
RN25A1k
RN25C1k
RN25D1k
SPI_CS4 4
8
2~OE
10
3~OE
13
4~OE
1
7
GND
VSS
EINT0
VSS
EINT1
EINT2 3 6 SN74LVC125AD
R336
EINT3 RN21C1k RSTOUT_N D_RST F
4 5
0
CUR_SEL0 RN21D1k
CUR_SEL1
18p 18p 7p 7p
+5V
8KHZ-7-T
RN26B1k
7
U2
+3V3
0MHZ-B2-T VSS
2
100n C396 14 VCC 1Y

3 K_CLK
VSS
6
2Y
SPI_SCK 2 8 K_STORE
1A 3Y
9 11 K_DI
5
3A
2A
4Y G
46 Result
3.4 Control Card layout

Figure 3.24 show how the input and output circuits are placed on the board. The analog
side to the left is galvanically separated from the rest of the board and is placed as far
as possible from the high current switching electronics.
The blocks that handle high frequency signals are placed closer to the MCU. This is
to keep the path between the devices as short as possible to minimize the current loop
which lowers the intensity on the radiated frequencies.
Frequency in
Ethernet
ADC PWM out
PWM in
Digital out
Digital in
MCU
CAN/J1708
Solenoid
JTAG out
DAC
Backup Power
battery supply
Figure 3.24: Layout of the Control Card and its internal blocks.
C HAPTER 4
Conclusions
The EBU system presented in this thesis allows signals on the wheel loader to be con-
trolled over Ethernet. It makes it possible to send driver-input remotely and control
actuators directly. This makes it easy to test and develop new functionality and driver
support systems on the wheel loader. It allows new ideas and concepts to be tested with-
out having to make any changes on the wheel loader except from connecting the EBU.
All software on the ECUs can be untouched and the add-on system can be installed in a
short time and it is easy to remove. With the EBU removed the wheel loader is back to
its original state without any damages on its original systems.
I hope that my work will improve the testing and developing phase at Volvo Construc-
tion Equipment, and come in good use to them.
4.1 Future work

Hardware
There are still things that has to be done until the EBU can be mounted and used in the
wheel loader.
• Stress test, inputs, outputs, power supply and the safety features so they can handle
the specifications in Appendix A.
• The PCB cards are designed to fit in a aluminum casing which protects the elec-
tronics, and dissipates heat from the transistors. However, the casing has to be
machined to fit the connectors and mounting brackets.
• The system has to be mounted and tested in the wheel loader.
47
48
Software
• Software has to be developed for the individual MCUs. The two slave MCUs should
have the same software and shouldn’t be too complex to write. However the master
MCU probably needs to use its DMA to be able to stream everything over Ethernet.
• Develop an protocol to transmit/receive data to/from the on-board PC.
• Software testing and debugging.
Interface
• Develop a interface to Matlab and Simulink so VCE and LTU can use it to easily
develop and test functions and control algorithms on the wheel loader.
4.2 Fields of application

The main use for the EBU is to monitor and control the wheel loader. It allows testing
of new prototypes and functions on the wheel loader and has the capability to stream
large amounts of data to an on-board PC. When testing and developing new ideas and
concepts on the wheel loader, the original electronics be untouched and just let the EBU
control the new function. Since the EBU monitors all the sensors on the wheel loader
the original sensor data can be used to control the new function.
LTU is going to use the EBU to develop and test new techniques to lower the fuel
consumption on a four wheel drive vehicle with articulated angle, like the wheel loader.
It is also going to be used to develop advanced remote control and driver assistance
systems.
Several student projects are going to use it to gather data from the wheel loader. The
projects are going to focus on building new sensors and features for the wheel loader, to
increase the knowledge of the surrounding environment.
The Electronic Breakout unit is a general purpose device that can be used for other
Volvo vehicles as well. However, the pinout of the connectors are matched to the L110G
wheel loader. The EBU can be used to control and log other systems over Ethernet that
is within the specifications in Appendix A.
R EFERENCES
[1] R. Lilja, “A Localisation and Navigation System for an Autonomous Wheel Loader,”
Master’s thesis, Mälardalen University, 2011.
[2] A. Bergdahl, “Autonomous bucket emptying on hauler,” Master’s thesis, Linköpings

universitet, 2011.
[3] P. Stener and R. Snabb, “Körbarhetskvantifiering hjullastare,” Master’s thesis,

Linköpings universitet, 2008.
[4] D. Gunstad and P. Alnefelt, “Autonomous Machine,” Master’s thesis, Mälardalen

University, 2008.
[5] Volvo Construction Equipment, “Volvo wheel loader L110G, L120G.”

http://www.volvoce.com/SiteCollectionDocuments/VCE/Documents\
%20Global/wheel\%20loaders/Volvo\_L110G-L120G\%20Product\%20Brochure\
_NA\_2210009239.pdf, 2012.
[6] H. D. Young and R. A. Freedman, University Physics. Pearson Addison-Wesley,

2008.
[7] Agilent Technologies, “Practical Temperature Measurements.” http://cp.

literature.agilent.com/litweb/pdf/5965-7822E.pdf, 2012.
[8] BOSCH, “CAN Specification v2.0.” http://www.semiconductors.bosch.de/

media/pdf/canliteratur/can2spec.pdf, 1991.
[9] Texas Instruments, “Choosing an Appropriate Pull-up/Pull-down Resistor for Open

Drain Outputs.” http://www.ti.com/lit/an/slva485/slva485.pdf, 2011.
[10] Texas Instruments, “Introduction to the Controller Area Network (CAN).” http:
//www.ti.com/lit/an/sloa101a/sloa101a.pdf, 2011.
[11] N. Mohan, T. M. Undeland, and W. P. Robbins, Power Electronics Converters,

Applications and Design. John Wiley & Sons, inc, third ed., 2003.
49
50
[12] R. J. Baker, CMOS circuit design, layout and simulation. John Wiley & Sons, inc,
2008.
[13] T. Williams, EMC for Product Designers. Newnes, third ed., 2001.
[14] Texas Instruments, “ULN2803A datasheet, Darlington transistor array.” http://

www.ti.com/lit/ds/symlink/uln2803a.pdf, 2006.
[15] Texas Instruments, “LM5575MH datasheet, 75V, 1.5A Step-Down Switching Regu-
lator.” http://www.ti.com/lit/ds/snvs471f/snvs471f.pdf, 2009.
[16] NXP Semiconductors, “LPC1769 datasheet, 32-bit ARM Cortex-M3 microcon-

troller.” http://www.nxp.com/documents/data\_sheet/LPC1769\_68\_67\_66\
_65\_64\_63.pdf, 2012.
[17] MAXIM, “MAX6753 datasheet, µP Reset Circuits with Capacitor-Adjustable Re-

set/Watchdog Timeout Delay.” http://www.datasheetcatalog.org/datasheet/
maxim/MAX6746-MAX6753.pdf, 2003.
[18] Analog Devices, “ADuM7441 datasheet, 1kV RMS Quad-Channel Digi-

tal Isolator.” http://www.analog.com/static/imported-files/data\_sheets/
ADuM7440\_7441\_7442.pdf, 2012.
A PPENDIX A
Specification
51
52 Appendix A
Specification
Sheet1
The unit shall monitor and take over selected channels to and from the ECU
without disturbing the original electronics and damaging the original wiring.
Type EBU
Analog IN 20
Digital IN 38 + 22
Frequency IN 6 + 16
Analog OUT 20
Digital OUT 38
Frequency OUT 6
Solenoid OUT 22
PWM OUT 16
Load resistor 22 + 16
J1708 2x1
CAN 2x2
Ethernet 1
KEY 1
BATT 2
24V 2
5V 3
PWM Ret 16
misc. ?
FGND 1
AGND 2
GND 2
NC 3
Power Supply
Operating range 9 - 60 V
Security
Manual emergency shutdown
Remote emergency shutdown
Windowed Watchdog
Analog IN
Measure range 0-5V
Max range -100 - 100 V
Resolution Min 12 bit
Bandwidth 0 - 1k Hz
Page 1
53
Sheet1
Digital IN
High 8 – 100 V
Low -100 - 6 V
Bandwidth Min 50 Hz
Interrupts No
Frequency IN
Bandwidth 1 – 10k Hz
Analog OUT
Update freq. Min 50 Hz
Output range 0–5V
Short circuit prot. Yes to Ground
Output current Max 80 mA
Impendance 47 ohm
Digital OUT
Output range 0 – 24 V
Short circuit prot. Yes
Output current Max 0.6 A
Impendance 150 ohm
Solenoid OUT
Output current 5A
Impendance Max 0.5 ohm
PWM OUT
Swiching freq. 10 – 1k Hz
Output current 5A
Impendance Max 0.5 ohm
CAN
Baudrate 250k bit/s
Page 2
54 Appendix A
Sheet1
J1708
Baudrate 9600 bit/s
Ethernet
Baudrate 10 – 100M bit/s
Protocol UDP
Page 3
A PPENDIX B
Relay Card Schematic
55
F
E
B
A
D
C
1
1n/100V 1n/100V 1n/100V

1n/100V
2
PE
PE
PE
PE
VARISTORCN0603
VARISTORCN0603
VARISTORCN0603
GND
PE
1n/100V
3
4
ES2D
40.61
1n/100V 1n/100V
PE
PE
PE
AGND
VARISTORCN0603
VARISTORCN0603
5
MOUNT-PAD-ROUND4.1
GND
GNDI
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
The names on pins and nets have been erased on request from the customer.
6
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
7
1n/100V 1n/100V
PE
PE
VARISTORCN0603
VARISTORCN0603
8
9
F
E
B
A
D
C
Power and Ground
Appendix B 56
1 2 3 4 5 6 7 8 9
Analog
A A
* *
+5V +5V
B B
* *
AGND PE AGND PE
1n/100V
1n/100V
1n/100V
1n/100V
* PE * * PE
+5V +5V +5V
* * *
AGND PE AGND PE AGND PE
1n/100V
1n/100V
1n/100V
1n/100V
1n/100V
1n/100V
* PE * PE * PE
+5V +5V +5V
* * *
1n/100V
1n/100V
1n/100V
1n/100V
1n/100V
1n/100V
C C
* PE * PE * PE
+5V +5V +5V
* * *
1n/100V
1n/100V
1n/100V
1n/100V
1n/100V
1n/100V
* PE * PE * PE
+5V +5V +5V
* * *
1n/100V
1n/100V
1n/100V
1n/100V
1n/100V
1n/100V
D * PE * PE * PE D
+5V +5V +5V
* * *
1n/100V
1n/100V
1n/100V
1n/100V
1n/100V
1n/100V
* PE * PE * PE
+5V +5V +5V
* * *
1n/100V
1n/100V
1n/100V
1n/100V
1n/100V
1n/100V
PE PE PE
E E
F F
57
I
F
E
B
A
H
D
C
G
1
GND GND GND GND GND GND GND

*
*
*
*
*
*
*
*
*
*
*
*
*
*
1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V

PE
PE
PE
PE
PE
PE
PE
2
PE
PE
PE
PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V

3
GND GND GND GND GND GND GND GND GND GND GND GND GND
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
4
GND
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V
5
GND GND GND GND GND GND GND GND GND GND GND GND
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
6
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V
7
GND GND GND GND GND GND

*
*
*
*
*
*
*
*
*
*
*
*
1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V

8
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V

9
GND GND GND GND GND GND
*
*
*
*
*
*
*
*
*
*
*
*
10
1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
PE
11
1n/100V 1n/100V 1n/100V 1n/100V 1n/100V 1n/100V
I
F
E
B
A
H
D
C
G
Digital
Appendix B 58
1 2 3 4 5 6 7 8 9
Solenoid
A A
GND GND GND

1n/100V 1n/100V 1n/100V
PE PE PE
1n/100V
1n/100V
1n/100V
B PE PE PE
B
GND GND GND

1n/100V 1n/100V 1n/100V
PE PE PE
1n/100V
1n/100V
1n/100V
PE PE PE
GND GND GND

1n/100V 1n/100V 1n/100V
PE PE PE
1n/100V
1n/100V
1n/100V
C C
PE PE PE
GND GND GND

1n/100V 1n/100V 1n/100V
PE PE PE
1n/100V
1n/100V
1n/100V
PE PE PE
D GND GND GND D

1n/100V 1n/100V 1n/100V
PE PE PE
1n/100V
1n/100V
1n/100V
PE PE PE
GND GND GND

1n/100V 1n/100V 1n/100V
PE PE PE
1n/100V
1n/100V
1n/100V
PE PE PE
E E
GND GND GND
1n/100V 1n/100V 1n/100V
PE PE PE
1n/100V
1n/100V
1n/100V
PE PE PE
F F
59
60 Appendix B
PWM
1 2 3 4 5 6 7 8 9
A A
1n/100V 1n/100V 1n/100V 1n/100V

PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V
PE
PE
PE
PE
B B
1n/100V 1n/100V 1n/100V 1n/100V

PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V

PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V
PE
PE
PE
PE
C 1n/100V 1n/100V 1n/100V 1n/100V C

PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V

PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V

PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V

PE
PE
PE
PE
D D
1n/100V 1n/100V 1n/100V 1n/100V
PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V

PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V

PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V

PE
PE
PE
PE
E E
1n/100V 1n/100V 1n/100V 1n/100V

PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V

PE
PE
PE
PE
1n/100V 1n/100V 1n/100V 1n/100V

PE
PE
PE
PE
F F
61
Communication
1 2 3 4 5 6
A The names on pins and nets have been erased on request from the customer. A
27p/100V
1n/100V
PE
PE
B82790
B82790
B B
27p/100V
1n/100V
PE
PE
27p/100V
1n/100V
PE
PE
C C
B82790 B82790
120
27p/100V
1n/100V
PE
PE
27p/100V
1n/100V
D D
PE
PE
B82790 B82790
120
1n/100V 27p/100V
1n/100V
PE
PE
E E
PE
VARISTORCN0603
1 2 3 4 5 6 7 8 9 10 11 62
A A
I/O ports
B B
C C
SSW-116-02-S-D SSW-116-02-S-D
SSW-116-02-S-D
SSW-116-02-S-D
SSW-116-02-S-D
D D
+5V
+5V
E E
SSW-116-02-S-D
SSW-116-02-S-D
SSW-116-02-S-D
SSW-116-02-S-D SSW-116-02-S-D
F F
G G
H H
I I
Appendix B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A A
B B
Relay drivers
VDD
16
16
16
16
16
16
16
16
16
16
16
16
16
16
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
VCC
C257IC1P C258IC2P C259IC3P C268IC7P C269IC9P C270IC11P C271IC13P C272IC15P C273IC17P C275IC21P C276IC23P C277IC25P C278IC27P C279IC29P
100n 100n 100n 100n 100n 100n 100n 100n 100n 100n 100n 100n 100n 100n
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
8
8
8
8
8
8
8
8
8
8
8
8
8
8
GND
C C
BATT
BATT BATT
K75 K106 K107 K108 K109 K110 K67 K68 K76 K77
1
1
1
1
1
1
1
1
1
1
K15 K2 K16 K3 K9 K17 K60 K42 K22 K29 K43 K23 K30 K44 C263 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
1
1
1
1
1
1
1
1
1
1
1
1
1
1
C261 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" C280 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
100n/50V
8
8
8
8
8
8
8
8
8
8
100n/50V 100n/50V
8
8
8
8
8
8
8
8
8
8
8
8
8
8
IC22
IC4 IC8 14 15 1 18
D SER QA I1 O1 D
K_DI 14 15 1 18 14 15 1 18 1 2 17
SER QA I1 O1 SER QA I1 O1 QB I2 O2
1 2 17 1 2 17 K_CLK 11 2 3 16
QB I2 O2 QB I2 O2 SCK QC I3 O3
K_CLK 11 2 3 16 K_CLK 11 2 3 16 K_RST 10 3 4 15
SCK QC I3 O3 SCK QC I3 O3 SCL QD I4 O4
K_RST 10 3 4 15 K_RST 10 3 4 15 4 5 14
SCL QD I4 O4 SCL QD I4 O4 QE I5 O5
4 5 14 4 5 14 K_STORE 12 5 6 13
QE I5 O5 QE I5 O5 RCK QF I6 O6
K_STORE 12 5 6 13 K_STORE 12 5 6 13 6 7 12
RCK QF I6 O6 RCK QF I6 O6 QG I7 O7
6 7 12 6 7 12 7 8 11
QG I7 O7 QG I7 O7 QH I8 O8
7 8 11 7 8 11 9 10
QH I8 O8 QH I8 O8 GND CD+
9 10 9 10 K_DISABLE 13 9
GND CD+ GND CD+ G QH*
K_DISABLE 13 9 K_DISABLE 13 9 ULN2803AA
G QH* G QH*
ULN2803AA ULN2803AA 74HC595D GND
74HC595D GND 74HC595D GND
K111 K112 K78 K79 K80 K81 K113 K114 K82 K83 K84 K85
1
1
1
1
1
1
1
1
1
1
1
1
K24 K31 K25 K45 K32 K26 K46 K33 C264 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
1
1
1
1
1
1
1
1
C281 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
100n/50V
8
8
8
8
8
8
8
8
8
8
8
8
100n/50V
8
8
8
8
8
8
8
8
IC24
IC10 14 15 1 18
SER QA I1 O1
14 15 1 18 1 2 17
E SER QA I1 O1 QB I2 O2 E
1 2 17 11 2 3 16
QB I2 O2 SCK QC I3 O3
11 2 3 16 10 3 4 15
SCK QC I3 O3 SCL QD I4 O4
10 3 4 15 4 5 14
SCL QD I4 O4 QE I5 O5
K4 K10 K18 K5 K11 K19 K6 4 5 14 12 5 6 13
QE I5 O5 RCK QF I6 O6
1
1
1
1
1
1
1
C260 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" 12 5 6 13 6 7 12
RCK QF I6 O6 QG I7 O7
6 7 12 7 8 11
QG I7 O7 QH I8 O8
100n/50V 7 8 11 9 10
QH I8 O8 GND CD+
8
8
8
8
8
8
8
9 10 13 9
IC5 GND CD+ G QH*
13 9 ULN2803AA
G QH*
14 15 1 18 ULN2803AA 74HC595D GND
SER QA I1 O1
1 2 17 74HC595D GND
QB I2 O2
11 2 3 16 K115 K116 K86 K87 K88 K89 K117 K118 K90 K91 K92 K93
SCK QC I3 O3
1
1
1
1
1
1
1
1
1
1
1
1
10 3 4 15 K27 K47 K34 K28 K48 K35 K49 K36 C265 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
SCL QD I4 O4
1
1
1
1
1
1
1
1
4 5 14 C282 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
QE I5 O5
12 5 6 13 100n/50V
RCK QF I6 O6
8
8
8
8
8
8
8
8
8
8
8
8
6 7 12 100n/50V
QG I7 O7
8
8
8
8
8
8
8
8
7 8 11 IC26
QH I8 O8 IC12
9 10 14 15 1 18
GND CD+ SER QA I1 O1
13 9 14 15 1 18 1 2 17
G QH* SER QA I1 O1 QB I2 O2
ULN2803AA 1 2 17 11 2 3 16
F QB I2 O2 SCK QC I3 O3 F
74HC595D GND 11 2 3 16 10 3 4 15
10 3 4 15 4 5 14
4 5 14 12 5 6 13
12 5 6 13 6 7 12
6 7 12 7 8 11
QG I7 O7 QH I8 O8
7 8 11 9 10
QH I8 O8 GND CD+
9 10 13 9
GND CD+ G QH*
13 9 ULN2803AA
G QH*
ULN2803AA 74HC595D GND
74HC595D GND
K119 K120 K94 K95 K96 K97 K121 K122 K98 K99 K100 K101
1
1
1
1
1
1
1
1
1
1
1
1
C262 K12 K20 K7 K13 K21 K8 K14 K50 K37 K51 K38 K52 K39 K53 K40 C266 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" C283 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
100n/50V 100n/50V
8
8
8
8
8
8
8
8
8
8
8
8
100n/50V
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
IC28
IC6 IC14 14 15 1 18
SER QA I1 O1
14 15 1 18 14 15 1 18 1 2 17
SER QA I1 O1 SER QA I1 O1 QB I2 O2
1 2 17 1 2 17 11 2 3 16
QB I2 O2 QB I2 O2 SCK QC I3 O3
11 2 3 16 11 2 3 16 10 3 4 15
G SCK QC I3 O3 SCK QC I3 O3 SCL QD I4 O4 G
10 3 4 15 10 3 4 15 4 5 14
SCL QD I4 O4 SCL QD I4 O4 QE I5 O5
4 5 14 4 5 14 12 5 6 13
QE I5 O5 QE I5 O5 RCK QF I6 O6
12 5 6 13 12 5 6 13 6 7 12
RCK QF I6 O6 RCK QF I6 O6 QG I7 O7
6 7 12 6 7 12 7 8 11
QG I7 O7 QG I7 O7 QH I8 O8
7 8 11 7 8 11 9 10
QH I8 O8 QH I8 O8 GND CD+
9 10 9 10 13 9
GND CD+ GND CD+ G QH*
13 9 13 9 ULN2803AA
G QH* G QH*
ULN2803AA ULN2803AA 74HC595D GND
74HC595D GND 74HC595D GND
K123 K124 K103 K102 K105 K104 K125
1
1
1
1
1
1
1
K41 K56 K57 K54 K55 K58 K59 K61 K62 K69 K63 C267 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
1
1
1
1
1
1
1
1
1
1
1
C284 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
100n/50V
8
8
8
8
8
8
8
100n/50V
8
8
8
8
8
8
8
8
8
8
8
IC30
IC16 14 15 1 18
SER QA I1 O1
14 15 1 18 1 2 17
SER QA I1 O1 QB I2 O2
1 2 17 11 2 3 16
QB I2 O2 SCK QC I3 O3
11 2 3 16 10 3 4 15
H 10 3 4 15 4 5 14 H
4 5 14 12 5 6 13
12 5 6 13 6 7 12
6 7 12 7 8 11
QG I7 O7 QH I8 O8
7 8 11 9 10
QH I8 O8 GND CD+
9 10 13 9
GND CD+ G QH*
13 9 ULN2803AA
G QH*
ULN2803AA 74HC595D GND
74HC595D GND
K70 K64 K71 K65 K72 K66 K73 K74
1
1
1
1
1
1
1
1
C285 IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR" IM*GR"
100n/50V
8
8
8
8
8
8
8
8
IC18
14 15 1 18
SER QA I1 O1
1 2 17
QB I2 O2
11 2 3 16
SCK QC I3 O3
10 3 4 15
SCL QD I4 O4
I 4 5 14 I
QE I5 O5
12 5 6 13
RCK QF I6 O6
6 7 12
QG I7 O7
7 8 11
QH I8 O8
9 10
GND CD+
13 9
G QH*
ULN2803AA
74HC595D GND
J J
K K
63
64 Appendix B
A PPENDIX C
Relay Card Layout
65
66
Top components
D1
R10 R6
ADC DO1 DI1 DI3 PWM1
AI3_RU AI11_RU DI24_RU DI26_RU DI15_RU DI32_RU

R4
R7 6
AI3_RD AI11_RD DI24_RD DI26_RD DI15_RD DI32_RD
AI14_RU AI9_RU AI19_RU DI22_RU DI4_RU DI13_RU DI29_RU DI19_RU DI34_RU FI3_RU
R4 R5 R5 R5 R5 R5 R6 R6 R6
AI14_RD AI9_RD AI19_RD DI22_RD DI4_RD DI13_RD DI29_RD DI19_RD DI34_RD FI3_RD 7 1 3 5 7 9 1 3 5
AI1_RU AI17_RU AI6_RU DI2_RU DI11_RU DI7_RU DI16_RU DI33_RU DI35_RU DI38_RU
AI1_RD AI17_RD AI6_RD DI2_RD DI11_RD DI7_RD DI16_RD DI33_RD DI35_RD DI38_RD
R4 R5 R5 R5 R5 R6 R6 R6 R4
8 2 4 6 8 0 2 4 4
AI15_RU AI4_RU AI12_RU DI9_RU DI5_RU DI27_RU DI30_RU DI20_RU FI1_RU FI4_RU
AI15_RD AI4_RD AI12_RD DI9_RD DI5_RD DI27_RD DI30_RD DI20_RD FI1_RD FI4_RD
R4 R8 R2 R2 R2 R3 R3 R4 R4
DAC DO2 DI2 DI4 9 0 4 8 2 6 0 2 SO1
AI2_RU AI10_RU AI20_RU DI23_RU DI25_RU DI14_RU DI17_RU DI21_RU DI36_RU DI39_RU
R9
AI2_RD AI10_RD AI20_RD DI23_RD DI25_RD DI14_RD DI17_RD DI21_RD DI36_RD DI39_RD
AI8_RU AI18_RU AI7_RU DI3_RU DI12_RU DI8_RU DI31_RU FI2_RU FI5_RU R5

0
R4 R1
8
R2
2
R2
6
R3
0
R3
4
R3
8
AI8_RD AI18_RD AI7_RD DI3_RD DI12_RD DI8_RD DI31_RD FI2_RD FI5_RD
AI16_RU AI5_RU AI13_RU DI10_RU DI6_RU DI28_RU DI18_RU DI37_RU FI6_RU
AI16_RD AI5_RD AI13_RD DI10_RD DI6_RD DI28_RD DI18_RD DI37_RD FI6_RD
EBU Relay Card 2012 v0.2

Fredrik Häggström
Appendix C
67
Bottom components
3 1 2C
5 1 2C
6 5 2C
4 1 2C
6 1 2C
5 5 2C
9 0 2C
1 1 2C
4 5 2C
0 1 2C 201K 401K 521K 501K 301K
2 1 2C
3 5 2C
5 0 2C
7 0 2C
2 5 2C
6 0 2C
8 0 2C
1 5 2C
1 0 2C
3 0 2C
0 5 2C
2 0 2C
89K 001K 321K 421K 101K 99K 4 0 2C
9 4 2C
7 9 1C
9 9 1C
8 4 2C
8 9 1C
0 0 2C
7 4 2C
3 9 1C
5 9 1C
6 4 2C
4 9 1C
6 9 1C
5 4 2C
9 8 1C
49K 69K 121K 221K 79K 59K 1 9 1C
4 4 2C
0 9 1C
2 9 1C
3 4 2C
5 8 1C
7 8 1C
2 4 2C
7 6 2C
0 3 CI
6 8 1C
8 8 1C
1 4 2C
1 8 1C
3 8 1C
0 4 2C 09K 29K 911K 021K 39K 19K
2 8 1C
9 2 CI
4 8 1C
9 3 2C
7 7 1C
9 7 1C
8 3 2C
6 6 2C
8 2 CI
8 7 1C
3 7 1C 9720C8 1C
7 3 2C
5 7 1C
6 3 2C
4 7 1C 68K 88K 711K 811K 98K 78K
7 2 CI
6 7 1C
5 3 2C
9 6 1C
1 7 1C
0 7 1C
5 6 2C
4 3 2C
6 2 CI
2 7 1C
5 6 1C 8 7 2C 3 3 2C
7 6 1C
6 6 1C
8 6 1C
2 3 2C
28K 48K 511K 611K 58K 38K
5 2 CI
1 6 1C
3 6 1C
1 3 2C
2 6 1C
4 6 1C
4 6 2C
0 3 2C
4 2 CI
7 5 1C 7729C5 1C
9 2 2C
8 5 1C
0 6 1C
8 2 2C
9 3 1C
3 2 CI
87K 08K 311K 411K 18K 97K 1 4 1C
0 4 1C 7 2 2C
2 4 1C
6 2 2C
3 6 2C
2 2 CI
3 5 1C
4 2 2C 6 7 2C 5 2 2C
1 5 1C 4 5 1C
7 3 1C 3 2 2C
1 2 CI
2 2 2C 76K 67K 111K 211K 77K 86K 2 5 1C
9 4 1C 8 3 1C
5 3 1C 1 2 2C
0 2 2C 5 7 2C 0 5 1C
7 4 1C 6 3 1C
3 3 1C 9 1 2C
8 1 2C 8 4 1C
5 4 1C 57K 601K 701K 801K 901K 011K 4 3 1C
1 3 1C 7 1 2C
6 5 1C 6 4 1C
251L
451L
651L
3 4 1C 2 3 1C
7 2 1C
5 5 1C
FFO_NIAM
9 2 1C
151L
351L
551L
4 4 1C
0 3 1C
2 2NR 1 1NR 2 1NR 3 1NR 4 1NR 5 1NR 6 1NR 7 1NR 8 1NR 9 1NR 0 2NR 1 2NR 8 2 1C
95L
NIAM_K
2NR 3NR 4NR 5NR 6NR 7NR 8NR 9NR 1NR 0 1NR
-NIAM
62L
5216C1R
5 8 2C
17K 56K 27K 66K 37K 47K

8 1 CI
6012CR
+NIAM
9 7C 0 8C
52L
4215C1R 8 1 1C
7 1 1C
7 1 CI
8 7C
7 7C 4 0 1C
3 0 1C 16K 26K 96K 36K 07K 46K
4 8 2C
6 1 1C
426L1CI
5 1 1C 6 7C
5 7C 3 7 2C
2 0 1C
1 0 1C 4 1 1C
3 1 1C 4 7C
5 1 CI
37C 65K 75K 45K 55K 85K 95K 0 0 1C

9 9C 2 1 1C
3 8 2C
1 1 1C
4312CLI
12L
22L
2 7C
1 7C 2 7 2C 8 9C
7 9C 0 1 1C
901C 25K 93K 35K 04K 14K 0 7C
3 1 CI
9 6C 6 9C
5 9C 8 0 1C
2 8 2C
7 0 1C
2 1 CI
8 6C
7 6C 1 7 2C 4 9C
3 9C 4 5C
35C 53K 94K 63K 05K 73K 15K 83K
6 6C
5 6C
1 1 CI
2 9C
1 9C 2 5C
1 5C
1 8 2C
4 6C
0 1 CI
3 6C 0 9C
98C 64K 33K 72K 74K 43K 82K 84K 0 7 2C
0 5C
9 4C 2 6C
1 6C
9 CI
8 8C
7 8C 8 4C
7 4C 0 6C
0 8 2C
8 CI
95C 44K 42K 13K 52K 54K 23K 62K 6 4C

5 4C 9 6 2C
6 8C
5 8C 8 5C
7 5C 4 4C
7 CI
3 4C 4 8C
3 8C 6 5C
06K 24K 22K 92K 34K 32K 03K
241L
441L
641L
841L
051L
411L
611L
811L
021L
221L
421L
621L
821L
031L
231L
431L
631L
831L
041L
5 5C 2 4C
1 4C 8 6 2C
311L
511L
711L
911L
121L
321L
521L
721L
921L
131L
331L
531L
731L
931L
141L
341L
541L
741L
941L
2 8C
1 8C 9 1 1C
6 2 1C
1 2 1C
3 2 1C 6 2C
0 2 1C 4 1C
5 0 1C
21R 0 4C
2 2 1C
41R 4 2C
52C11R
2 6 2C
2 1C
6 CI
31C3R 8 3C
93C31R 2 2C
3 2C 0 1C
1 1C
3 CI
6 3C
7 3C 0 2C
1 2C 8C
0 6 2C
21K 02K 7K 31K 12K 8K 41K

5 CI
9C
5 3C 9 5 2C 4 3C
8 1C
9 1C 6C
7C 2 3C
2 CI
3 3C 6 1C
71C 4K 01K 81K 5K 11K 91K 6K 4C
1 6 2C
5C
4 CI
0 3C
1 3C 8 5 2C 2C
5 1C 8 2C
3C
2 1 1 L 1 CI
9 2C 51K 2K 61K 3K 9K 71K

1C
39L
001L
101L
201L
301L
401L
501L
601L
701L
801L
901L
011L
111L
7 2C
49L
59L
69L
79L
89L
99L
1L
2L
3L
4L
5L
6L
7L
8L
9L
01L
11L
21L
31L
41L
51L
61L
71L
81L
91L
02L
7 5 2C
68 Appendix C
Layer 1 (Top)
147
344
69
Layer 2
147
344
70 Appendix C
Layer 3
147
344
71
Layer 14
147
344
72 Appendix C
Layer 15
147
344
73
Layer 16 (Bottom)
147
344
A PPENDIX D
Control Card Schematic
75
1 2 3 4 5 6 7 8 9 10 11 76
A A
I/O ports
B B
AGND AGND
TSW-116-02-S-D
AGND ADC-1 AGND ADC-2
VSS VSS VSS
TSW-116-02-S-D
AI1_HA1 ADC-3 AI2_HA2 ADC-4 DO1-1 VSS DO1-2 DO1_HA9 VSS DI1-1 DI1_EA15 DI1-2 VSS DI3-1 VSS DI3-2 TSW-116-02-S-D
TSW-116-02-S-D VSS PWM1-1PO1_HB32 PWM1-2
AI3_HA3 AI4_HA4 VSS
DO2_EA14 DO3_EA13 DI2_HA10
TSW-116-02-S-D DI3_HA11 FI1_HB26 FI2_HB27
ADC-5 ADC-6 DO1-3 DO1-4 DI1-3 DI1-4 DI3-3 DI3-4
VSS PWM1-3PO2_HB33 PWM1-4
AI5_HA5 ADC-7 AI6_HA6 ADC-8 DO1-5 DO4_EA12 DO1-6 DO5_EA11 DI4_HA12 DI1-5 DI5_HA13 DI1-6 FI3_HB28 DI3-5 FI4_HB29 DI3-6
AI7_HA7 ADC-9 ADC-10 DO1-7 DO6_EA10 DO1-8 DO7_EA9 DI6_HA14 DI1-7 DI7_HA15 DI1-8 FI5_HB30 DI3-7 FI6_HB31 DI3-8
AGND AGND VSS PWM1-7PO4_HB35 PWM1-8
AGND ADC-11 AGND ADC-12 DO1-9 DO8_EA8 DO1-10 DO9_EA37 DI8_HA16 DI1-9 DI9_HA34 DI1-10 FO1_EB45 DI3-9 FO2_EB44 DI3-10
AI8_HA26 ADC-13 AI9_HA27 ADC-14 DO1-11 DO10_EA36 DO1-12 DO11_EA35 DI10_HA35 DI1-11 DI11_HA36 DI1-12 FO3_EB43 DI3-11 FO4_EB42 DI3-12
C VSS PO6_HB37
PWM1-11 PWM1-12
C
AI10_HA28 ADC-15 AI11_HA29 ADC-16 DO1-13 DO12_EA34 DO1-14 DO13_EA33 DI12_HA37 DI1-13 DI13_HA38 DI1-14 FO5_EB41 DI3-13 FO6_EB40 DI3-14
VSS VSS PO7_HB38
PWM1-13 PWM1-14
AI12_HA30 ADC-17 AI13_HA31 ADC-18 DO1-15 DO14_EA32 DO1-16 VSS DI14_HA39 DI1-15 VSS DI1-16 PI1_EB39 DI3-15 PI2_EB38 DI3-16
AGND AGND VSS PO8_HB39
PWM1-15 PWM1-16
AGND AGND DO15_EA31 VSS
DO16_EA30 DI15_HA40 DI16_HA41 PI3_EB37 PI4_EB36
ADC-19 ADC-20 DO1-17 DO1-18 DI1-17 DI1-18 DI3-17 DI3-18
VSS PO9_HB40
PWM1-17 PWM1-18
AI14_HA48 ADC-21 AI15_HA49 ADC-22 DO1-19 DO17_EA29 DO1-20 DO18_EA28 DI17_HA42 DI1-19 DI18_HA43 DI1-20 PI5_EB35 DI3-19 PI6_EB34 DI3-20
VSS PO10_HB41
PWM1-19 PWM1-20
VSS PO11_HB42
PWM1-21 PWM1-22
VSS PO12_HB43
PWM1-23 PWM1-24
AI20_HA54 ADC-27 ADC-28 DO1-25 DO23_EA60 DO1-26 DO24_EA59 DI23_HA58 DI1-25 DI24_HA59 DI1-26 PI11_EB29 DI3-25 PI12_EB28 DI3-26
AGND AGND VSS PO13_HB44
PWM1-25 PWM1-26
AGND ADC-29 AGND ADC-30 DO1-27 DO25_EA58 DO1-28 DO26_EA57 DI25_HA60 DI1-27 DI26_HA61 DI1-28 PI13_EB27 DI3-27 PI14_EB26 DI3-28
R364 R365 VSS PO14_HB45
PWM1-27 PWM1-28
ADC-31 ADC-32 DO1-29 DO27_EA56 DO1-30 DO28_EA55 DI27_HA62 DI1-29 DI28_HA63 DI1-30 PI15_EB25 DI3-29 PI16_EB24 DI3-30
VSS VSS VSS VSS PO15_HB46
PWM1-29 PWM1-30
D +5VA 0 +5VA 0 DO29_EA54 VSS DI29_HA64 VSS VSS VSS D
DO1-31 DO1-32 DI1-31 DI1-32 DI3-31 DI3-32
VSS PO16_HB47
PWM1-31 PWM1-32
VSS
VSS
VSS
TSW-116-02-S-D
DO2-1 DO30_EA53 DO2-2 VSS DI30_HA65 DI2-1 VSS DI2-2
TSW-116-02-S-D DI4-1 VSS DI4-2 VSS
DO31_EA52 VSS
DO32_EA51 DI31_HA66 DI32_HA67 VSS VSS
DO2-3 DO2-4 DI2-3 DI2-4 TSW-116-02-S-D SO1-1 SO1-2
DAC-1 AGND DAC-2 AGND DI4-3 SI1_EB68 VSS
DI4-4 SI2_EB67 VSS TSW-116-02-S-D
TSW-116-02-S-D DO2-5 DO33_EA50 DO2-6 DO34_EB23 DI33_HA68 DI2-5 DI34_HB1 DI2-6 SO1-3 SO1_HB50 VSSSO1-4 SO2_HB51 VSS
AGND
AO1_EA23 AGND
AO2_EA22 SI3_EB66 SI4_EB65
DAC-3 DAC-4 DI4-5 DI4-6
DO2-7 DO35_EB22 DO2-8 DO36_EB21 DI35_HB2 DI2-7 DI36_HB3 DI2-8 SO1-5 SO3_HB52 SO1-6 SO4_HB53
DAC-5 AO3_EA21 DAC-6 AO4_EA20 DI4-7 SI5_EB64 DI4-8 SI6_EB63
DO2-9 DO37_EB20 DO2-10 DO38_EB19 DI37_HB4 DI2-9 DI38_HB5 DI2-10 SO1-7 SO5_HB54 SO1-8 SO6_HB55
DAC-7 AO5_EA19 DAC-8 AO6_EA18 VSS DI4-9 SI7_EB62 DI4-10 SI8_EB61
E DO2-11 DO39_EB18 DO2-12 VSS DI39_HB6 DI2-11 VSS DI2-12 SO1-9 SO7_HB56 SO1-10 SO8_HB57 E
DAC-9 AO7_EA17 DAC-10 DI4-11 SI9_EB60 DI4-12 SI10_EB59
DO2-13 K_DI DO2-14 K_CLKVSS DI2-13 DI2-14 SO1-11 SO9_HB58 SO1-12 SO10_HB59
DAC-11 AGND DAC-12 AGND DI4-13 SI11_EB58 DI4-14 SI12_EB57
DO2-15 K_RST DO2-16 K_STORE DI2-15 DI2-16 SO1-13 SO11_HB60 SO1-14 SO12_HB61
AGND
AO8_EA45 AGND
AO9_EA44 VSS VSS VSS SI13_EB56
DAC-13 DAC-14 DI4-15 DI4-16
DO2-17 K_DISABLE DO2-18 VSS DI2-17 VSS DI2-18 SO1-15 VSS SO1-16 SO13_HB62
DAC-15 AO10_EA43 DAC-16 AO11_EA42 DI4-17 SI14_EB55 VSS
DI4-18 SI15_EB54
DO2-19 RST DO2-20 SYNC J1708A_IN_HA17 DI2-19 J1708B_IN_HA18 DI2-20 SO1-17 SO14_HB63VSS
SO1-18 SO15_HB64
DAC-17 AO12_EA41 DAC-18 AO13_EA40 DI4-19 SI16_EB53 DI4-20 SI17_EB52
DO2-21 DO2-22 J1708A_OUT_EA7 DI2-21 J1708B_OUT_EA6 DI2-22 SO1-19 SO16_HB65 SO1-20 SO17_HB66
DAC-19 AGND DAC-20 AGND DI4-21 SI18_EB51 DI4-22 SI19_EB50
DO2-23 DO2-24 CAN1_L_IN_HA19 DI2-23 CAN1_H_IN_HA20 DI2-24 SO1-21 SO18_HB67 SO1-22 SO19_HB68
AGND
AO14_EA70 AGND
AO15_EA69 SI21_EB48
DAC-21 DAC-22 DI4-23 SI20_EB49 DI4-24
DO2-25 VSS DO2-26 VSS CAN1_L_OUT_EA5 DI2-25 CAN1_H_OUT_EA4 DI2-26 SO1-23 SO20_HB69 SO1-24 SO21_HB70
DAC-23 AO16_EA68 DAC-24 AO17_EA67 DI4-25 KEY DI4-26 BATT
VSS VSS
POW_5V1 CAN2_L_IN_HA21 CAN2_H_IN_HA22 VSS VSS
DO2-27 DO2-28 DI2-27 DI2-28 SO1-25 SO1-26
DAC-25 AO18_EA66 DAC-26 AO19_EA65 DI4-27 BATTF DI4-28 BATTF
POW_5V2 POW_5V3 CAN2_L_OUT_EA3 VSS VSS
DO2-29 DO2-30 DI2-29 CAN2_H_OUT_EA2 DI2-30 SO1-27 SO1-28
F DAC-27 AO20_EA64 DAC-28 VSS VSS DI4-29 BATTF DI4-30 BATTF F
DO2-31 POW_24V1 DO2-32 POW_24V2 VSS DI2-31 VSS DI2-32 SO1-29 SO1-30
DAC-29 AGND DAC-30 AGND DI4-31 BATTF DI4-32 BATTF
AGND AGND SO1-31 SO1-32
DAC-31 DAC-32
H1
H2
H3
H4
H5
H6
H7
H8
H9
H10
G G
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
MOUNT-PAD-ROUND4.1
H H
I I
Appendix D
1 2 3 4 5 6 7 8 9 10 11
A A
B B
Master MCU
IC51
Watchdog 1
VDD1A VDD2A
16
+3V3
+5VA
IC55 2 15
100n C394
100n C387
GND1 GND2
+3V3
VSS SPI_CS0 3 14 A_SPI_CS0
DNP VIA VOA
VSS
AGND
8 7 RESET_N SPI_SCK 4 13 A_SPI_SCK
VCC ~RESET VIB VOB
C78 100n SPI_MOSI 5 12 A_SPI_MOSI
R41 VIC VOC
WDI 6 SPI_MISO 6 11 A_SPI_MISO
WDI VOD VID
3
SRT
2 Watchdog slow timeout set to 100ms 7 10
SWT VDD1B VDD2B
+3V3
+5VA
C 1 Twd2=0.65x10⁹xCswt C
SET0
5
SET1
Reset Timeout set to 100ms 8 9
100n C393
100n C388
GND1* GND2_2
4 Trp=5.06x10⁶xCsrt
GND
C79 150p
VSS
AGND
SET0 SET1 Ratio ADUM7441ARQZ
MAX6753KA29+T 0 0 8
VSS C80 22n

VSS
0 1 16 IC54
R39
DNP
R40
1k
1 0 Disabled
R37
1k
R38
DNP
+3V3 1 1 64
1 16
VDD1A VDD2A
+3V3
+5VA
2 15
100n C391
GND1 GND2 100n C389
VSS
VIA VOA
VSS
AGND
LPC1768 IC1 VIB VOB
VIC VOC
UART3_TX 46 95 ENET_TXD0 6 11
D P0[0]/RD1/TXD3/SDA1 P1[0]/ENET_TXD0 VOD VID D
UART3_RX 47 94 ENET_TXD1
P0[1]/TD1/RXD3/SCL1 P1[1]/ENET_TXD1
AD0[7] 98 93 ENET_TX_EN 7 10
P0[2]/TXD0/AD0[7] P1[4]/ENET_TX_EN VDD1B VDD2B
+3V3
+5VA
AD0[6] 99 92 ENET_CRS
P0[3]/RXD0/AD0[6] P1[8]/ENET_CRS
CAP2[0] 81 91 ENET_RXD0
P0[4]/I2SRX_CLK/RD2/CAP2[0] P1[9]/ENET_RXD0
CAP2[1] 80 90 ENET_RXD1 8 9
100n C392
100n C390
P0[5]/I2SRX_WS/TD2/CAP2[1] P1[10]/ENET_RXD1 GND1* GND2_2

SSP1_CS 79 89 ENET_RX_ER
P0[6]/I2SRX_SDA/SSEL1/MAT2[0] P1[14]/ENET_RX_ER
SSP1_SCK 78 88 ENET_REF_CLK
P0[7]/I2STX_CLK/SCK1/MAT2[1] P1[15]/ENET_REF_CLK
VSS
AGND
SSP1_MISO 77 87 ENET_MDC
P0[8]/I2STX_WS/MISO1/MAT2[2] P1[16]/ENET_MDC ADUM7441ARQZ
SSP1_MOSI 76 86 ENET_MDIO
JTAG P0[9]/I2STX_SDA/MOSI1/MAT2[3] P1[17]/ENET_MDIO
UART2_TX 48 32 CAP1[0]
P0[10]/TXD2/SDA2/MAT3[0] P1[18]/USB_UP_LED/PWM1[1]/CAP1[0]
+3V3
UART2_RX 49 33 CAP1[1]
P0[11]/RXD2/SCL2/MAT3[1] P1[19]/MCOA0/USB_PPWR/CAP1[1]
SPI_SCK 62 34 SSP0_SCK
R34 P0[15]/TXD1/SCK0/SCK P1[20]/MCI0/PWM1[2]/SCK0
+3V3
1 SPI_CS0 63 35 SSP0_CS
P0[16]/RXD1/SSEL0/SSEL P1[21]/MCABORT/PWM1[3]/SSEL0
2 TMS_SWDIO SPI_MISO 61 36
R367
220
10k P0[17]/CTS1/MISO0/MISO P1[22]/MCOB0/USB_PWRD/MAT1[0]
3 TCK_SWDCLK SPI_MOSI 60 37 SSP0_MISO
P0[18]/DCD1/MOSI0/MOSI P1[23]/MCI1/PWM1[4]/MISO0
+5V
4 SPI_CS1 59 38 SSP0_MOSI
P0[19]/DSR1/SDA1 P1[24]/MCI2/PWM1[5]/MOSI0
7
5 TDI SPI_CS2 58 39
P0[20]/DTR1/SCL1 P1[25]/MCOA1/MAT1[1]
6 RESET_N CAN1_RD 57 40 CAP0[0] U1
P0[21]/RI1/RD1 P1[26]/MCOB1/PWM1[6]/CAP0[0]
LED1
5988160107F
7 CAN1_TD 56 43 CAP0[1]
P0[22]/RTS1/TD1 P1[27]/CLKOUT/USB_OVRCR/CAP0[1]
2
E E
RN25B1k
8 CAP3[0] 9 44 ON VSS
+5V P0[23]/AD0[0]/I2SRX_CLK/CAP3[0] P1[28]/MCOA2/PCAP1[0]/MAT0[0]
+3V3
CAP3[1] 8 45 100n C395 14 3 D_CLK

P0[24]/AD0[1]/I2SRX_WS/CAP3[1] P1[29]/MCOB2/PCAP1[1]/MAT0[1] VCC 1Y
SV1 AD0[2] 7 21 AD0[4] 6 SPI_MISO
P0[25]/AD0[2]/I2SRX_SDA/TXD3 P1[30]/VBUS/AD0[4] 2Y
AD0[3] 6 20 AD0[5] SPI_SCK 2 8 D_CS
P0[26]/AD0[3]/AOUT/RXD3 P1[31]/SCK1/AD0[5] 1A 3Y
VSS
SPI_CS3 25 9 11 DO_SER
P0[27]/SDA0/USB_SDA 3A 4Y
1 TDO_SWO SPI_CS4 24 75 PWM1[1] DI_SER8 5
P0[28]/SCL0/USB_SCL P2[0]/PWM1[1]/TXD1 2A
2 SPI_CS5 29 74 PWM1[2] SPI_MOSI 12
P0[29]/USB_DPLUS P2[1]/PWM1[2]/RXD1 4A
3 2TDO_SWOX SPI_CS6 30 73 PWM1[3]
P0[30]/USB_DMINUS P2[2]/PWM1[3]/CTS1/TRACEDATA[3]
70 PWM1[4] 1
P2[3]/PWM1[4]/DCD1/TRACEDATA[2] 1~OE
8
6
5
SV4 RESET_N 17 69 PWM1[5] SPI_CS4 4

RESET P2[4]/PWM1[5]/DSR1/TRACEDATA[1] 2~OE
RSTOUT_N 14 68 PWM1[6] 10
RSTOUT P2[5]/PWM1[6]/DTR1/TRACEDATA[0] 3~OE
67 13
P2[6]/PCAP1[0]/RI1/TRACECLK 4~OE
1
3
4
RN25A1k
RN25C1k
RN25D1k
28 66 CAN2_RD
VDD(3V3)1 P2[7]/RD2/RTS1
54 65 CAN2_TD 7
+3V3 VDD(3V3)2 P2[8]/TD2/TXD2/ENET_MDC GND
71 64
VDD(3V3)3 P2[9]/USB_CONNECT/RXD2/ENET_MDIO
96 53 4 5 EINT0
VDD(3V3)4 P2[10]/EINT0/NMI
VSS
42 52 3 6 EINT1
100n C26
100n C25
100n C24
VDD(REG)(3V3)1 P2[11]/EINT1/I2STX_CLK RN22D1k
VSS
VSS 84 51 2 7 EINT2 3 6 SN74LVC125AD
100n C27
100n C29
100n C28
VDD(REG)(3V3)2 P2[12]/EINT2/I2STX_WS RN22C1k R336
F 50 1
RN22B8
1k EINT3 RN21C1k RSTOUT_N D_RST F
P2[13]/EINT3/I2STX_SDA
VSS VBAT 19 RN22A1k 4 5
VBAT 0
C30 100n 27 1 8 CUR_SEL0 RN21D1k
P3[25]/MAT0[0]/PWM1[2]
10 26 2
RN21A7
1k CUR_SEL1
VDDA P3[26]/STCLK/MAT0[1]/PWM1[3]
VSS C31 100n 11 RN21B1k
+3V3 VSSA
82
P4[28]/RX_MCLK/MAT2[0]/TXD3
12 85 WDI
VREFP P4[29]/TX_MCLK/MAT2[1]/RXD3
X5
15
VREFN
VSS 16
RTCX1
31 18
VSS1 RTCX2
+5V
41 ABS07-32.768KHZ-7-T
VSS2
7
X2
55 22
VSS3 XTAL1
72 23 U2
C16 C17 C22 C23
18p 18p 7p 7p
VSS4 XTAL2
97
VSS5
2
RN26B1k
83 ABM3B-12.000MHZ-B2-T VSS
VSS6
+3V3
100n C396 14 3 K_CLK

VCC 1Y
TDO_SWO 1 6
TDO/SWO 2Y
VSS
TDI 2 SPI_SCK 2 8 K_STORE

TDI 1A 3Y
TMS_SWDIO 3 9 11 K_DI
R8 TMS/SWDIO 3A 4Y
G 4 5 G
TRST 2A
TCK_SWDCLK 5 SPI_MOSI 12
+3V3 10k TCK/SWDCLK 4A
100 13
RTCK NC
1
1~OE
8
6
5
SPI_CS5 4
2~OE
10
3~OE
13
4~OE
1
3
4
RN26A1k
RN26C1k
RN26D1k
7
GND
VSS
VSS
SN74LVC125AD
R335
RSTOUT_N K_RST
0
R337
K_DISABLE
0
H H
VSS
I I
77
78
1 2 3 4 5 6 7 8 9
A A
Slave MCU 1
LPC1768 IC2
46 95
P0[0]/RD1/TXD3/SDA1 P1[0]/ENET_TXD0
47 94
1AD0[7] 98 93
P0[2]/TXD0/AD0[7] P1[4]/ENET_TX_EN
1AD0[6] 99 92
1CAP2[0] 81 91
1CAP2[1] 80 90
B P0[5]/I2SRX_WS/TD2/CAP2[1] P1[10]/ENET_RXD1 B
79 89
78 88
P0[7]/I2STX_CLK/SCK1/MAT2[1] P1[15]/ENET_REF_CLK
77 87
P0[8]/I2STX_WS/MISO1/MAT2[2] P1[16]/ENET_MDC
76 86
P0[9]/I2STX_SDA/MOSI1/MAT2[3] P1[17]/ENET_MDIO
48 32 1CAP1[0]
49 33 1CAP1[1]
SSP0_SCK 62 34
P0[15]/TXD1/SCK0/SCK P1[20]/MCI0/PWM1[2]/SCK0
+3V3
SSP0_CS 63 35
SSP0_MOSI 61 36
P0[17]/CTS1/MISO0/MISO P1[22]/MCOB0/USB_PWRD/MAT1[0]
SSP0_MISO 60 37
59 38
R368
220
58 39
1CAN1_RD 57 40 1CAP0[0]
1CAN1_TD 56 43 1CAP0[1]
1CAP3[0] 9 44 1MCOA2
P0[23]/AD0[0]/I2SRX_CLK/CAP3[0] P1[28]/MCOA2/PCAP1[0]/MAT0[0]
LED2
5988160107F
1CAP3[1] 8 45 1MCOB2
P0[24]/AD0[1]/I2SRX_WS/CAP3[1] P1[29]/MCOB2/PCAP1[1]/MAT0[1]
1AD0[2] 7 21 1AD0[4]
P0[25]/AD0[2]/I2SRX_SDA/TXD3 P1[30]/VBUS/AD0[4]
1AD0[3] 6 20 1AD0[5]
C P0[26]/AD0[3]/AOUT/RXD3 P1[31]/SCK1/AD0[5] C
25
P0[27]/SDA0/USB_SDA
24 75 1PWM1[1]
P0[28]/SCL0/USB_SCL P2[0]/PWM1[1]/TXD1
29 74 1PWM1[2]
P0[29]/USB_DPLUS P2[1]/PWM1[2]/RXD1
30 73 1PWM1[3]
70 1PWM1[4]
P2[3]/PWM1[4]/DCD1/TRACEDATA[2]
1RESET_N 17 69 1PWM1[5]
RESET P2[4]/PWM1[5]/DSR1/TRACEDATA[1]
1RSTOUT_N 14 68 1PWM1[6]
RSTOUT P2[5]/PWM1[6]/DTR1/TRACEDATA[0]
67
P2[6]/PCAP1[0]/RI1/TRACECLK
+3V3 28 66 1CAN2_RD
54 65 1CAN2_TD
+3V3 VDD(3V3)2 P2[8]/TD2/TXD2/ENET_MDC
71 64
96 53 4 5 EINT0
42 52 3 6 EINT1
100n C34
100n C33
100n C32
VSS 84 51 2 7 EINT2
100n C35
100n C37
100n C36
VDD(REG)(3V3)2 P2[12]/EINT2/I2STX_WS RN23C1k
50 1
RN23B8
1k EINT3
VSS 19 RN23A1k
VBAT
C38 100n 27
P3[25]/MAT0[0]/PWM1[2]
10 26
D VDDA P3[26]/STCLK/MAT0[1]/PWM1[3] D
VSS C39 100n 11
+3V3 VSSA
82
P4[28]/RX_MCLK/MAT2[0]/TXD3
12 85
15
VREFN
VSS 16
RTCX1
31 18
VSS1 RTCX2
41
VSS2
55 22
VSS3 XTAL1 X3
72 23
R35 VSS4 XTAL2
+3V3
2 1 97 ABM3B-12.000MHZ-B2-T
VSS5
TMS_SWDIO 4 3 1TMS_SWDIO 83 C18 C19
10k VSS6
TCK_SWDCLK 6 5 1TCK_SWDCLK
8 7 1TDO_SWO 1TDO_SWO 1 18p 18p
TDO/SWO
TDO_SWO 10 9 1TDI 1TDI 2
TDI
RESET_N 12 11 1RESET_N 1TMS_SWDIO 3
R9 TMS/SWDIO
14 13 4
TRST
16 15 1TCK_SWDCLK 5
+5V +3V3 10k TCK/SWDCLK
VSS
100 13
E RTCK NC E
SV3
VSS
F F
Appendix D
1 2 3 4 5 6 7 8 9
A A
Slave MCU 2
LPC1768 IC3
46 95
P0[0]/RD1/TXD3/SDA1 P1[0]/ENET_TXD0
47 94
2AD0[7] 98 93
P0[2]/TXD0/AD0[7] P1[4]/ENET_TX_EN
2AD0[6] 99 92
2CAP2[0] 81 91
2CAP2[1] 80 90
P0[5]/I2SRX_WS/TD2/CAP2[1] P1[10]/ENET_RXD1
79 89
78 88
B P0[7]/I2STX_CLK/SCK1/MAT2[1] P1[15]/ENET_REF_CLK B
77 87
P0[8]/I2STX_WS/MISO1/MAT2[2] P1[16]/ENET_MDC
76 86
P0[9]/I2STX_SDA/MOSI1/MAT2[3] P1[17]/ENET_MDIO
48 32 2CAP1[0]
49 33 2CAP1[1]
+3V3
SSP1_SCK 62 34
P0[15]/TXD1/SCK0/SCK P1[20]/MCI0/PWM1[2]/SCK0
SSP1_CS 63 35
SSP1_MOSI 61 36
P0[17]/CTS1/MISO0/MISO P1[22]/MCOB0/USB_PWRD/MAT1[0]
SSP1_MISO 60 37
R369
220
59 38
58 39
2CAN1_RD 57 40 2CAP0[0]
2CAN1_TD 56 43 2CAP0[1]
LED3
5988160107F
2CAP3[0] 9 44 2MCOA2
P0[23]/AD0[0]/I2SRX_CLK/CAP3[0] P1[28]/MCOA2/PCAP1[0]/MAT0[0]
2CAP3[1] 8 45 2MCOB2
P0[24]/AD0[1]/I2SRX_WS/CAP3[1] P1[29]/MCOB2/PCAP1[1]/MAT0[1]
2AD0[2] 7 21 2AD0[4]
P0[25]/AD0[2]/I2SRX_SDA/TXD3 P1[30]/VBUS/AD0[4]
2AD0[3] 6 20 2AD0[5]
P0[26]/AD0[3]/AOUT/RXD3 P1[31]/SCK1/AD0[5]
25
P0[27]/SDA0/USB_SDA
24 75 2PWM1[1]
C P0[28]/SCL0/USB_SCL P2[0]/PWM1[1]/TXD1 C
29 74 2PWM1[2]
P0[29]/USB_DPLUS P2[1]/PWM1[2]/RXD1
30 73 2PWM1[3]
70 2PWM1[4]
P2[3]/PWM1[4]/DCD1/TRACEDATA[2]
2RESET_N 17 69 2PWM1[5]
RESET P2[4]/PWM1[5]/DSR1/TRACEDATA[1]
2RSTOUT_N 14 68 2PWM1[6]
RSTOUT P2[5]/PWM1[6]/DTR1/TRACEDATA[0]
67
P2[6]/PCAP1[0]/RI1/TRACECLK
+3V3 28 66 2CAN2_RD
54 65 2CAN2_TD
+3V3 VDD(3V3)2 P2[8]/TD2/TXD2/ENET_MDC
71 64
96 53 4 5 EINT0
42 52 3 6 EINT1
100n C42
100n C41
100n C40
VSS 84 51 2 7 EINT2
100n C43
100n C45
100n C44
VDD(REG)(3V3)2 P2[12]/EINT2/I2STX_WS RN24C1k
50 1
RN24B8
1k EINT3
VSS 19 RN24A1k
VBAT
C46 100n 27
P3[25]/MAT0[0]/PWM1[2]
10 26
VDDA P3[26]/STCLK/MAT0[1]/PWM1[3]
VSS C47 100n 11
+3V3 VSSA
82
D P4[28]/RX_MCLK/MAT2[0]/TXD3 D
12 85
15
VREFN
VSS 16
RTCX1
31 18
VSS1 RTCX2
41
VSS2
55 22
VSS3 XTAL1 X4
72 23
VSS4 XTAL2
97 ABM3B-12.000MHZ-B2-T
R36 VSS5
+3V3
2 1 83 C20 C21
VSS6
1TMS_SWDIO 4 3 2TMS_SWDIO
10k
1TCK_SWDCLK 6 5 2TCK_SWDCLK 2TDO_SWO 1 18p 18p
TDO/SWO
2TDO_SWOX 8 7 2TDO_SWO 2TDI 2
TDI
1TDO_SWO 10 9 2TDI 2TMS_SWDIO 3
R10 TMS/SWDIO
1RESET_N 12 11 2RESET_N 4
TRST
14 13 2TCK_SWDCLK 5
+3V3 10k TCK/SWDCLK
VSS
16 15 100 13
+5V RTCK NC
E SV2 E
VSS
F F
79
80
1 2 3 4 5 6 7 8 9
Power in Battery
BATT to 24V BAS70-04 R32 R33 BAS70-04
+5V
A 32V VBAT A
1k
D1 47 47 D9
R28
Q2 KEY_SUPPLY IN OUT
D8 +24V
+
BSR33,115 S5BC-13-F
+
ADJ
C63
C64
1k
R30
Q3 IC6
R25
G1
BSR43 10k LM317HV
B2430UNI
100n
120u
-
R31
Power supply
ON
1k
VSS
VSS
VSS
18k
R26
C65
VSS
100n
Q1
BUK663R7-75C
B B
BATTF BATT_ON
VSS
D5
S5BC-13-F
D3
C66
C67
R29
10k
1n/60V
100n/60V
BZX84C15
B3100-13-F
D7 8V to 3.3V
VSS
VSS
VSS
D4
KEY KEY_SUPPLY
B3100-13-F
Place caps close to reg pins
C69
C70
+3V3
IC8
NX1117C33Z
1n/60V
100n/60V
8V 3 2
C VIN VOUT C
VSS
VSS
GND
1
C76
C77
R370
220
10u
10u
LED4
5988160107F
VSS
VSS
VSS
VSS
BATT to 32V and 8V

D Place close to pin D
BAS70-04
32V
D6
1u/60V
1n
8V to 5V and 5V analog
100
R27
C71
100n
IC56
Place caps close to inductor
VSS
C62
C61
C57
100n
VSS
KEY_SUPPLY L3 3 1 C48
VIN VCC
7427512 1u/16V Place caps close to reg pins Place caps close to inductor
VSS
+5V
C68
C60
C59
C58
+5VA
2 16 C52 IC7
SD BST
1u/16V NX1117C50Z
3 2
R366
VSS 8V L4
100n
1n
100n
VIN VOUT
C49 10 14 L2 8V 7447709680
SS SW DNP
GND
10n/16V 7447709680
E E
VSS
VSS
VSS
C55
+
C50 6 15
1
C72
C73
C74
C75
C53
C54
C56
FB PRE
10n/16V
10u
10u
10u
10u
D2
B3100-13-F
49.9k 5 13
120u
10u
100n
COMP IS
10
R22 33p
R15
VSS
VSS
VSS
VSS
AGND
VSS 21k 7 12
RT PGND
C51 8 9
R16 RAMP AGND
680p 17
EPAD
VSS
4 11
SYNC OUT

10k
R23
F F
R24
1.8k
VSS
Appendix D
1 2 3 4 5 6 Ethernet
A A
+3V3
L1
+3V3_8720A
BLM18PG121SN1D
C5 C6 C7
+3V3
C1 C2
10u 100n 100n
10u 100n
VSS
C3 C4
R3
49.9R/1%
R4
49.9R/1%
R5
49.9R/1%
R6
49.9R/1%
VSS
LED_RXTX
R20
1K5
R21
10K
1u 100n
IC4 Place close to LAN8720 LED_10/100
19
1
9
6
B LAN8720A B
17 J1
ENET_TXD0 TXD0
VSS
ENET_TXD1 18 1 9
TXD1 TD+ LA
ENET_TX_EN 16 10
TXEN LC
VDDIO
VDD1A
VDD2A
VDDCR
ENET_RXD0 8 21 RJ45_TXP 4
R11 22R RXD0/MODE0 TXP CTT
ENET_RXD1 7 12
R12 22R RXD1/MODE1 RA
ENET_CRS 11 20 RJ45_TXN 2 11
R13 22R CRS_DV/MODE2 TXN TD- RC
ENET_RX_ER 10
R14 22R RXER/PHYAD0
ENET_MDIO 12 23 RJ45_RXP
MDIO RXP
ENET_REF_CLK ENET_MDC 13 3
MDC RD+
14 22 RJ45_RXN
R17
R18
NINT/REFCLKO RXN
220R
220R
RSTOUT_N 15 5
NRST CTR
R1
3 C9 C10 C11 C12 RJ45
LED_RXTX
22R
LED1/REGOFF
XTAL1/CLKIN
XTAL2
RBIAS
GND
LED_10/100 2 6
LED2/NINTSEL RD-
DNP DNP DNP DNP
5
4
74LVC1G04DBV
24
7 S1
NC S1
GND
4 2 8 S2
C14
18p
R19
10K
C CG S2 C
IC5A J0011D01B
VSS
C13
R7
R2
12.1K/1%
VSS
DNP Place close to CTR 22n
X1
C15
18p
VSS
+3V3
VSS
VSS
VSS
5
VCC
IC5P C8
100n
3
GND
ABM3B-25.000MHZ-B2-T
D D
VSS
81
1 2 3 4 5 6
82 Appendix D
Solenoid out
1 2 3 4 5 6
A A
BATT_ON
C81
1u
IC9
1*2
VSS
B3100-13-F
VCC
6 SO1_HB50
OUT1
DO_SER5 14
SER QA
15 1 8 9
IN1
C243
1
D10
QB RN1A 10k
D_CLK 11
SCK QC
2 1n/100V
D_RST 10 3 2 7 10
SCL QD IN2
4 RN1B 10k
QE
B3100-13-F
VSS
D_CS 12 5
RCK QF
6 3 6 11 5 SO2_HB51
QG IN3 OUT2
QH
7 RN1C 10k C244
D11
13 9 SO_SER1 4 5 12 1n/100V
B G QH*
RN1D 10k
IN4 B
74HC595D
VSS
8 16 2 7 15
+5V
SEL_A
B3100-13-F
IC11P
GND VCC
RN2B 10k
3 6 16 3 SO3_HB52
SEL_B OUT3
RN2C 10k C245
1 8 14
D12
+5V
SENS_E
100n
C85
1n/100V
VSS
RN2A 10k
13
CURRENT
10n
B3100-13-F
VSS
2.7k
R42
C82 OUT4
2 SO4_HB53
8
GND
C246
D13
1n/100V
VNQ05XSP16
VSS
VSS
BATT_ON
C83
C 1u C
IC10
1*2
VSS
B3100-13-F
VCC
6 SO5_HB54
OUT1
1 8 9
IN1
C279
D14
RN3A 10k
1n/100V
2 7 10
IN2
RN3B 10k
B3100-13-F
VSS
3 6 11 5 SO6_HB55
IN3 OUT2
RN3C 10k C280
D15
4 5 12
IN4
1n/100V
RN3D 10k
VSS
2 7 15
SEL_A
B3100-13-F
RN4B 10k
3 6 16 3 SO7_HB56
SEL_B OUT3
D RN4C 10k C281 D
1 8 14
D16
+5V
SENS_E
RN4A 10k 1n/100V
13
CURRENT
10n
B3100-13-F
VSS
2.7k
R43
C84 OUT4
2 SO8_HB57
8
GND
C282
D17
1n/100V
VNQ05XSP16
VSS
VSS
E E
83
1 2 3 4 5 6
A A
BATT_ON
C86
1u
IC12
1*2
VSS
B3100-13-F
VCC
6 SO9_HB58
OUT1
SO_SER1 14
SER QA
15 1 8 9
IN1
C247
1
D18
QB RN5A 10k
D_CLK 11
SCK QC
2 1n/100V
D_RST 10 3 2 7 10
SCL QD IN2
4 RN5B 10k
QE
B3100-13-F
VSS
D_CS 12 5
RCK QF
6 3 6 11 5 SO10_HB59
B QG
7 RN5C 10k
IN3 OUT2
C248 B
QH
D19
13
G QH*
9 SO_SER2 4 5 12
IN4
1n/100V
RN5D 10k
74HC595D
VSS
8 16 2 7 15
+5V
SEL_A
B3100-13-F
IC14P
GND VCC
RN6B 10k
3 6 16 3 SO11_HB60
SEL_B OUT3
RN6C 10k C249
1 8 14
D20
+5V
SENS_E
100n
C90
1n/100V
VSS
RN6A 10k
13
CURRENT
10n
B3100-13-F
VSS
2.7k
R44
C87 OUT4
2 SO12_HB61
8
GND
C250
D21
1n/100V
VNQ05XSP16
VSS
VSS
C BATT_ON
C88
C
1u
IC13
1*2
VSS
B3100-13-F
VCC
6 SO13_HB62
OUT1
1 8 9
IN1
C251
D22
RN7A 10k
1n/100V
2 7 10
IN2
RN7B 10k
B3100-13-F
VSS
3 6 11 5 SO14_HB63
IN3 OUT2
RN7C 10k C252
D23
4 5 12
IN4
1n/100V
RN7D 10k
D D
VSS
2 7 15
SEL_A
B3100-13-F
RN8B 10k
3 6 16 3 SO15_HB64
SEL_B OUT3
RN8C 10k C253
1 8 14
D24
+5V
SENS_E
RN8A 10k 1n/100V
13
CURRENT
10n
B3100-13-F
VSS
2.7k
R45
C89 OUT4
2 SO16_HB65
8
GND
C254
D25
1n/100V
VNQ05XSP16
VSS
VSS
E E
84 Appendix D
1 2 3 4 5 6
A A
BATT_ON
C91
1u
IC15
1*2
VSS
B3100-13-F
VCC
6 SO17_HB66
OUT1
SO_SER2 14
SER QA
15 1 8 9
IN1
C255
1
D26
QB RN9A 10k
D_CLK 11
SCK QC
2 1n/100V
D_RST 10 3 2 7 10
SCL QD IN2
4 RN9B 10k
QE
B3100-13-F
VSS
D_CS 12 5
RCK QF
6 3 6 11 5 SO18_HB67
B QG
7 RN9C 10k
IN3 OUT2
C256 B
QH
D27
13
G QH*
9 SO_SER3 4 5 12
IN4
1n/100V
RN9D 10k
74HC595D
VSS
8 16 2 7 15
+5V
SEL_A
B3100-13-F
IC17P
GND VCC
RN10B10k
3 6 16 3 SO19_HB68
SEL_B OUT3
RN10C10k C257
1 8 14
D28
+5V
SENS_E
100n
C95
1n/100V
VSS
RN10A10k
13
CURRENT
10n
B3100-13-F
VSS
2.7k
R46
C92 OUT4
2 SO20_HB69
8
GND
C258
D29
1n/100V
VNQ05XSP16
VSS
VSS
C BATT_ON
C93
C
1u
IC16
1*2
VSS
B3100-13-F
VCC
6 SO21_HB70
OUT1
1 8 9
IN1
C259
D30
RN11A10k
1n/100V
2 7 10
IN2
RN11B10k
B3100-13-F
VSS
3 6 11 5 EXTRA_SO1
IN3 OUT2
RN11C10k C260
D31
4 5 12
IN4
1n/100V
RN11D10k
D D
VSS
2 7 15
SEL_A
B3100-13-F
RN12B10k
3 6 16 3 EXTRA_SO2
SEL_B OUT3
RN12C10k C261
1 8 14
D32
+5V
SENS_E
RN12A10k 1n/100V
13
CURRENT
10n
B3100-13-F
VSS
2.7k
R47
C94 OUT4
2 EXTRA_SO3
8
GND
C262
D33
1n/100V
VNQ05XSP16
VSS
VSS
E E
85
PWM out
1 2 3 4 5 6
A A
BATT_ON
C96
1u
IC18
1*2
VSS
B3100-13-F
VCC
6 PO1_HB32
OUT1
PWM1[1] 1 8 9
IN1
C263
D34
RN13A10k
1n/100V
PWM1[2] 2 7 10 VSS
IN2
RN13B10k
B3100-13-F
VSS
PWM1[3] 3 6 11 5 PO2_HB33
IN3 OUT2
RN13C10k C264
D35
PWM1[4] 4 5 12 1n/100V
B RN13D10k
IN4
VSS B
VSS
CUR_SEL0 2 7 15
SEL_A
RN14B10k B3100-13-F
CUR_SEL1 3 6 16 3 PO3_HB34
SEL_B OUT3
RN14C10k C265
1 8 14
D36
+5V
SENS_E
RN14A10k 1n/100V
CUR1 13 VSS
CURRENT
10n
B3100-13-F
VSS
2.7k
R48
C97 OUT4
2 PO4_HB35
8
GND
C266
D37
1n/100V
VNQ05XSP16
VSS
VSS
VSS
BATT_ON
C98
C 1u C
IC19
1*2
VSS
B3100-13-F
VCC
6 PO5_HB36
OUT1
PWM1[5] 1 8 9
IN1
C267
D38
RN15A10k
1n/100V
PWM1[6] 2 7 10 VSS
IN2
RN15B10k
B3100-13-F
VSS
1PWM1[1] 3 6 11 5 PO6_HB37
IN3 OUT2
RN15C10k C268
D39
1PWM1[2] 4 5 12
IN4
1n/100V
RN15D10k VSS
VSS
CUR_SEL0 2 7 15
SEL_A
B3100-13-F
RN16B10k
CUR_SEL1 3 6 16 3 PO7_HB38
SEL_B OUT3
D RN16C10k C269 D
1 8 14
D40
+5V
SENS_E
RN16A10k 1n/100V
CUR2 13 VSS
CURRENT
10n
B3100-13-F
VSS
2.7k
R49
C99 OUT4
2 PO8_HB39
8
GND
C270
D41
1n/100V
VNQ05XSP16
VSS
VSS
VSS
E E
86 Appendix D
1 2 3 4 5 6
A A
BATT_ON
C100
1u
IC20
1*2
VSS
B3100-13-F
VCC
6 PO9_HB40
OUT1
1PWM1[3] 1 8 9
IN1
C271
D42
RN17A10k
1n/100V
1PWM1[4] 2 7 10 VSS
IN2
RN17B10k
B3100-13-F
VSS
1PWM1[5] 3 6 11 5 PO10_HB41
IN3 OUT2
RN17C10k C272
D43
1PWM1[6] 4 5 12
IN4
1n/100V
VSS
B RN17D10k B
VSS
CUR_SEL0 2 7 15
SEL_A
B3100-13-F
RN18B10k
CUR_SEL1 3 6 16 3 PO11_HB42
SEL_B OUT3
RN18C10k C273
1 8 14
D44
+5V
SENS_E
RN18A10k 1n/100V
CUR3 13 VSS
CURRENT
10n
B3100-13-F
VSS
2.7k
R50
C101 OUT4
2 PO12_HB43
8
GND
C274
D45
1n/100V
VNQ05XSP16
VSS
VSS
VSS
BATT_ON
C102
1u
C C
IC21
1*2
VSS
B3100-13-F
VCC
6 PO13_HB44
OUT1
2PWM1[1] 1 8 9
IN1
C275
D46
RN19A10k
1n/100V
2PWM1[2] 2 7 10 VSS
IN2
RN19B10k
B3100-13-F
VSS
2PWM1[3] 3 6 11 5 PO14_HB45
IN3 OUT2
RN19C10k C276
D47
2PWM1[4] 4 5 12
IN4
1n/100V
RN19D10k VSS
VSS
CUR_SEL0 2 7 15
SEL_A
B3100-13-F
RN20B10k
CUR_SEL1 3 6 16 3 PO15_HB46
SEL_B OUT3
RN20C10k C277
D 1 8 14 D
D48
+5V
SENS_E
RN20A10k 1n/100V
CUR4 13 VSS
CURRENT
10n
B3100-13-F
VSS
2.7k
R51
C103 OUT4
2 PO16_HB47
8
GND
C278
D49
1n/100V
VNQ05XSP16
VSS
VSS
VSS
E E
1 2 3 4 5 6
A A
Digital out
IC23
+5V
C104
100n/60V
C105
100n
+24V
10 20
VS VSS
2 3
R52
DO1_HA9
C283
B IN1 OUT1 B
VSS
VSS
1 150
EN1 R53
9 8 DO2_EA14
C284
+5V IN2 OUT2 VSS
150
12 13
R54
DO3_EA13
C285
1n/100V 1n/100V
IN3 OUT3 VSS
11 150
EN2 R55
19 18 DO4_EA12
C286
1n/100V 1n/100V
IN4 OUT4 VSS
150
4 17
GND GND VSS
5 16
GND GND
6 15 Place caps close to port
GND GND
7 14
GND GND
DO_SER 14 15
SER QA
1 L293DD
QB
D_CLK 11 2
SCK QC
VSS
VSS
D_RST 10 3
SCL QD
4
QE
C D_CS 12 5 C
RCK QF IC24
+5V
6
C106
100n/60V
C107
100n
QG
+24V
7 10 20
QH VS VSS
13 9 2 3
R56
DO_SER1 DO5_EA11
C287
G QH* IN1 OUT1
VSS
VSS
1 150
EN1 R57
74HC595D 9 8 DO6_EA10
+5V IN2 OUT2
150 C288 VSS
8 16
GND VCC R58
+5V
12 13 DO7_EA9
C289
1n/100V 1n/100V
IN3 OUT3 VSS
11 150
IC22P
EN2 R59
19 18 DO8_EA8
C290
1n/100V 1n/100V
IN4 OUT4 VSS

150
4 17
GND GND
100n
C108
VSS
VSS
5 16
GND GND
GND GND
7 14
GND GND
D L293DD
D
VSS
VSS
E E
87
88
1 2 3 4 5 6
A A
IC26
+5V
C109
100n/60V
C110
100n
+24V
10 20
VS VSS
2 3
R60
DO9_EA37
C291
IN1 OUT1
VSS
VSS
1 150
EN1 R61
9 8 DO10_EA36
C292
+5V IN2 OUT2 VSS
B 150 B
12 13
R62
DO11_EA35
C293
1n/100V 1n/100V
IN3 OUT3 VSS
11 150
EN2 R63
19 18 DO12_EA34
C294
1n/100V 1n/100V
IN4 OUT4 VSS
150
4 17
GND GND VSS
5 16
GND GND
GND GND
7 14
GND GND
DO_SER1 14 15
SER QA
1 L293DD
QB
D_CLK 11 2
SCK QC
VSS
VSS
D_RST 10 3
SCL QD
4
QE
D_CS 12 5
RCK QF IC27
+5V
6
C111
100n/60V
C112
100n
QG
+24V
7 10 20
QH VS VSS
C R64
C
13 9 DO_SER2 2 3 DO13_EA33
C295
G QH* IN1 OUT1
VSS
VSS
1 150
EN1 R65
74HC595D 9 8 DO14_EA32
C296
+5V IN2 OUT2 VSS
8 16 150
GND VCC R66
+5V
12 13 DO15_EA31
C297
IN3 OUT3 1n/100V 1n/100V VSS
11 150
IC25P
EN2 R67
19 18 DO16_EA30
C298
1n/100V 1n/100V
IN4 OUT4 VSS

150
4 17
GND GND
100n
C113
VSS
VSS
5 16
GND GND
GND GND
7 14
GND GND
L293DD
VSS
VSS
D D
E E
Appendix D
1 2 3 4 5 6
A A
IC29
+5V
C114
100n/60V
C115
100n
+24V
10 20
VS VSS
2 3
R68
DO17_EA29
C299
IN1 OUT1
VSS
VSS
1 150
EN1 R69
9 8 DO18_EA28
C300
+5V IN2 OUT2 VSS
B 150 B
12 13
R70
DO19_EA27
C301
1n/100V 1n/100V
IN3 OUT3 VSS
11 150
EN2 R71
19 18 DO20_EA26
C302
1n/100V 1n/100V
IN4 OUT4 VSS
150
4 17
GND GND VSS
5 16
GND GND
GND GND
7 14
GND GND
DO_SER2 14 15
SER QA
1 L293DD
QB
D_CLK 11 2
SCK QC
VSS
VSS
D_RST 10 3
SCL QD
4
QE
D_CS 12 5
RCK QF IC30
+5V
6
C116
100n/60V
C117
100n
QG
+24V
7 10 20
QH VS VSS
C R72
C
13 9 DO_SER3 2 3 DO21_EA25
C303
G QH* IN1 OUT1
VSS
VSS
1 150
EN1 R73
74HC595D 9 8 DO22_EA61
C304
+5V IN2 OUT2 VSS

8 16 150
GND VCC R74
+5V
12 13 DO23_EA60
C305
1n/100V 1n/100V
IN3 OUT3 VSS

11 150
IC28P
EN2 R75
19 18 DO24_EA59
C306
1n/100V 1n/100V
IN4 OUT4 VSS

150
4 17
GND GND
100n
C118
VSS
VSS
5 16
GND GND
GND GND
7 14
GND GND
L293DD
VSS
VSS
D D
E E
89
90
1 2 3 4 5 6
A A
IC32
+5V
C119
100n/60V
C120
100n
+24V
10 20
VS VSS
2 3
R76
DO25_EA58
C307
IN1 OUT1
VSS
VSS
1 150
EN1 R77
9 8 DO26_EA57
C308
+5V IN2 OUT2 VSS
B 150 B
12 13
R78
DO27_EA56
C309
1n/100V 1n/100V
IN3 OUT3 VSS
11 150
EN2 R79
19 18 DO28_EA55
C310
1n/100V 1n/100V
IN4 OUT4 VSS
150
4 17
GND GND VSS
5 16
GND GND
GND GND
7 14
GND GND
DO_SER3 14 15
SER QA
1 L293DD
QB
D_CLK 11 2
SCK QC
VSS
VSS
D_RST 10 3
SCL QD
4
QE
D_CS 12 5
RCK QF IC33
+5V
6
C121
100n/60V
C122
100n
QG
+24V
7 10 20
QH VS VSS
C R80
C
13 9 DO_SER4 2 3 DO29_EA54
C311
G QH* IN1 OUT1
VSS
VSS
1 150
EN1 R81
74HC595D 9 8 DO30_EA53
C312
+5V IN2 OUT2 VSS
8 16 150
GND VCC R82
+5V
12 13 DO31_EA52
C313
1n/100V 1n/100V
IN3 OUT3 VSS
11 150
IC31P
EN2 R83
19 18 C314 DO32_EA51
1n/100V 1n/100V
IN4 OUT4 VSS

150
4 17
GND GND
100n
C123
VSS
VSS
5 16
GND GND
GND GND
7 14
GND GND
L293DD
VSS
VSS
D D
E E
Appendix D
1 2 3 4 5 6
A A
IC35
+5V
C124
100n/60V
C125
100n
+24V
10 20
VS VSS
2 3
R84
DO33_EA50
C315
IN1 OUT1
VSS
VSS
B 1 150 B
EN1 R85
9 8 DO34_EB23
C316
+5V IN2 OUT2 VSS
150
12 13
R86
DO35_EB22
C317
1n/100V 1n/100V
IN3 OUT3 VSS
11 150
EN2 R87
19 18 DO36_EB21
C318
1n/100V 1n/100V
IN4 OUT4 VSS
150
4 17
GND GND VSS
5 16
GND GND
GND GND
7 14
GND GND
DO_SER4 14 15
SER QA
1 L293DD
QB
D_CLK 11 2
SCK QC
VSS
VSS
D_RST 10 3
SCL QD
4
QE
D_CS 12 5
RCK QF IC36
+5V
C 6 C
C126
100n/60V
C127
100n
QG
+24V
7 10 20
QH VS VSS
13 9 2 3
R88
DO_SER5 DO37_EB20
C319
G QH* IN1 OUT1
VSS
VSS
1 150
EN1 R89
74HC595D 9 8 DO38_EB19
C320
+5V IN2 OUT2 VSS

8 16 150
GND VCC R90
+5V
12 13 DO39_EB18
C321
1n/100V 1n/100V
IN3 OUT3 VSS

11 150
IC34P
EN2 R91
19 18 N$68
C322
1n/100V 1n/100V
IN4 OUT4 VSS

150
4 17
GND GND
100n
C128
VSS
VSS
5 16
GND GND
GND GND
7 14
GND GND
D L293DD D
VSS
VSS
E E
91
1 2 3 4 5 6 92
VCC GND
+5V
16 8
IC37P
100n
C137
Digital in
A A
VSS
BAS70-04 VSS
VSS
10
R92 SER
+5V
DI1_EA15 11 9 DI_SER1
D50 A QH
12
15k B
13
C
14 7
R93
10k
D QH
1u
3
E
C129
4
F
5
G
VSS
VSS
BAS70-04 6
H
R94
+5V
DI2_HA10 D_CLK 2
D51 CLK
VSS 15
15k INH
D_CS 1
SH/LD
R95
10k
1u
74HC165D
C130
B B
VSS
VSS
BAS70-04
R96
+5V
DI3_HA11
D52
15k
R97
10k
1u
C131
VSS
VSS
BAS70-04
R98
+5V
DI4_HA12
D53
15k
R99
10k
1u
C C
C132
VSS
VSS
BAS70-04
R100
+5V
DI5_HA13
D54
15k
R101
10k
1u
C133
VSS
VSS
BAS70-04
R102
+5V
DI6_HA14
D55
15k
D D
R103
10k
1u
C134
VSS
VSS
BAS70-04
R104
+5V
DI7_HA15
D56
15k
R105
10k
1u
C135
VSS
VSS
BAS70-04
R106
+5V
DI8_HA16
D57
E 15k E
R107
10k
1u
C136
VSS
Appendix D
1 2 3 4 5 6
VCC GND
+5V
16 8
IC38P
100n
C146
A A
VSS
BAS70-04
VSS
DI_SER1 10
R108 SER
+5V
DI9_HA34 11 9 DI_SER2
D58 A QH
12
15k B
13
C
14 7
R109
10k
D QH
1u
3
E
C138
4
F
5
G
VSS
VSS
BAS70-04 6
H
R110
+5V
DI10_HA35 D_CLK 2
D59 CLK
VSS 15
15k INH
D_CS 1
SH/LD
R111
10k
1u
74HC165D
C139
B B
VSS
VSS
VSS
BAS70-04
R112
+5V
DI11_HA36
D60
15k
R113
10k
1u
C140
VSS
VSS
BAS70-04
R114
+5V
DI12_HA37
D61
15k
R115
10k
1u
C C
C141
VSS
VSS
BAS70-04
R116
+5V
DI13_HA38
D62
15k
R117
10k
1u
C142
VSS
VSS
BAS70-04
R118
+5V
DI14_HA39
D63
15k
D D
R119
10k
1u
C143
VSS
VSS
BAS70-04
R120
+5V
DI15_HA40
D64
15k
R121
10k
1u
C144
VSS
VSS
BAS70-04
R122
+5V
DI16_HA41
D65
E 15k E
R123
10k
1u
C145
93
VSS
94
1 2 3 4 5 6
VCC GND
+5V
16 8
IC39P
100n
C155
A A
VSS
BAS70-04
VSS
DI_SER2 10
R124 SER
+5V
D66 A QH
12
15k B
13
C
14 7
R125
10k
D QH
1u
3
E
C147
4
F
5
G
VSS
VSS
BAS70-04 6
H
R126
+5V
DI18_HA43 D_CLK 2
D67 CLK
VSS 15
15k INH
D_CS 1
SH/LD
R127
10k
1u
B 74HC165D B
C148
VSS
VSS
VSS
BAS70-04
R128
+5V
DI19_HA44
D68
15k
R129
10k
1u
C149
VSS
VSS
BAS70-04
R130
+5V
DI20_HA45
D69
15k
C C
R131
10k
1u
C150
VSS
VSS
BAS70-04
R132
+5V
DI21_HA46
D70
15k
R133
10k
1u
C151
VSS
VSS
BAS70-04
R134
+5V
DI22_HA57
D71
D 15k D
R135
10k
1u
C152
VSS
VSS
BAS70-04
R136
+5V
DI23_HA58
D72
15k
R137
10k
1u
C153
VSS
VSS
BAS70-04
R138
+5V
E DI24_HA59 E
D73
15k
R139
10k
1u
C154
Appendix D
VSS
1 2 3 4 5 6
VCC GND
+5V
16 8
IC40P
100n
C164
A A
VSS
BAS70-04
VSS
DI_SER3 10
R140 SER
+5V
D74 A QH
12
15k B
13
C
14 7
R141
10k
D QH
1u
3
E
C156
4
F
5
G
VSS
VSS
BAS70-04 6
H
R142
+5V
DI26_HA61 D_CLK 2
D75 CLK
VSS 15
15k INH
D_CS 1
SH/LD
R143
10k
1u
74HC165D
C157
B B
VSS
VSS
VSS
BAS70-04
R144
+5V
DI27_HA62
D76
15k
R145
10k
1u
C158
VSS
VSS
BAS70-04
R146
+5V
DI28_HA63
D77
15k
R147
10k
1u
C C
C159
VSS
VSS
BAS70-04
R148
+5V
DI29_HA64
D78
15k
R149
10k
1u
C160
VSS
VSS
BAS70-04
R150
+5V
DI30_HA65
D79
15k
D D
R151
10k
1u
C161
VSS
VSS
BAS70-04
R152
+5V
DI31_HA66
D80
15k
R153
10k
1u
C162
VSS
VSS
BAS70-04
R154
+5V
DI32_HA67
D81
E 15k E
R155
10k
1u
C163
95
VSS
96
1 2 3 4 5 6
VCC GND
+5V
16 8
IC41P
100n
C173
VSS
A BAS70-04 A
VSS
DI_SER4 10
R156 SER
+5V
D82 A QH
12
15k B
13
C
14 7
R157
10k
D QH
1u
3
E
C165
4
F
5
G
VSS
VSS
BAS70-04 6
H
R158
+5V
DI34_HB1 D_CLK 2
D83 CLK
VSS 15
15k INH
D_CS 1
SH/LD
R159
10k
1u
74HC165D
C166
B B
VSS
VSS
VSS
BAS70-04
R160
+5V
DI35_HB2
D84
15k
R161
10k
1u
C167
VSS
VSS
BAS70-04
R162
+5V
DI36_HB3
D85
15k
R163
10k
1u
C168
C C
VSS
VSS
BAS70-04
R164
+5V
DI37_HB4
D86
15k
R165
10k
1u
C169
VSS
VSS
BAS70-04
R166
+5V
DI38_HB5
D87
15k
R167
10k
1u
D D
C170
VSS
VSS
BAS70-04
R168
+5V
DI39_HB6
D88
15k
R169
10k
1u
C171
VSS
VSS
BAS70-04
R170
+5V
EXTRA_DI1
D89
15k
E E
R171
10k
1u
C172
Appendix D
VSS
1 2 3 4 5 6
VCC GND
+5V
16 8
IC42P
100n
C182
VSS
A BAS70-04 A
VSS
DI_SER5 10
R172 SER
+5V
SI1_EB68 11 9 DI_SER6
D90 A QH
12
15k B
13
C
14 7
R173
10k
D QH
1u
3
E
C174
4
F
5
G
VSS
VSS
BAS70-04 6
H
R174
+5V
SI2_EB67 D_CLK 2
D91 CLK
VSS 15
15k INH
D_CS 1
SH/LD
R175
10k
1u
74HC165D
C175
B B
VSS
VSS
VSS
BAS70-04
R176
+5V
SI3_EB66
D92
15k
R177
10k
1u
C176
VSS
VSS
BAS70-04
R178
+5V
SI4_EB65
D93
15k
R179
10k
1u
C177
C C
VSS
VSS
BAS70-04
R180
+5V
SI5_EB64
D94
15k
R181
10k
1u
C178
VSS
VSS
BAS70-04
R182
+5V
SI6_EB63
D95
15k
R183
10k
1u
D D
C179
VSS
VSS
BAS70-04
R184
+5V
SI7_EB62
D96
15k
R185
10k
1u
C180
VSS
VSS
BAS70-04
R186
+5V
SI8_EB61
D97
15k
E E
R187
10k
1u
C181
97
VSS
98
1 2 3 4 5 6
VCC GND
+5V
16 8
IC43P
100n
C191
A A
VSS
BAS70-04
VSS
DI_SER6 10
R188 SER
+5V
D98 A QH
12
15k B
13
C
14 7
R189
10k
D QH
1u
3
E
C183
4
F
5
G
VSS
VSS
BAS70-04 6
H
R190
+5V
SI10_EB59 D_CLK 2
D99 CLK
VSS 15
15k INH
D_CS 1
SH/LD
R191
10k
1u
74HC165D
C184
B B
VSS
VSS
VSS
BAS70-04
R192
+5V
SI11_EB58
D100
15k
R193
10k
1u
C185
VSS
VSS
BAS70-04
R194
+5V
SI12_EB57
D101
15k
R195
10k
1u
C C
C186
VSS
VSS
BAS70-04
R196
+5V
SI13_EB56
D102
15k
R197
10k
1u
C187
VSS
VSS
BAS70-04
R198
+5V
SI14_EB55
D103
15k
D D
R199
10k
1u
C188
VSS
VSS
BAS70-04
R200
+5V
SI15_EB54
D104
15k
R201
10k
1u
C189
VSS
VSS
BAS70-04
R202
+5V
SI16_EB53
D105
E 15k E
R203
10k
1u
C190
Appendix D
VSS
1 2 3 4 5 6
VCC GND
+5V
16 8
IC44P
100n
C200
A A
VSS
BAS70-04
VSS
DI_SER7 10
R204 SER
+5V
D106 A QH
12
15k B
13
C
14 7
R205
10k
D QH
1u
3
E
C192
4
F
5
G
VSS
VSS
BAS70-04 6
H
R206
+5V
SI18_EB51 D_CLK 2
D107 CLK
VSS 15
15k INH
D_CS 1
SH/LD
R207
10k
1u
74HC165D
C193
B B
VSS
VSS
VSS
BAS70-04
R208
+5V
SI19_EB50
D108
15k
R209
10k
1u
C194
VSS
VSS
BAS70-04
R210
+5V
SI20_EB49
D109
15k
R211
10k
1u
C C
C195
VSS
VSS
BAS70-04
R212
+5V
SI21_EB48
D110
15k
R213
10k
1u
C196
VSS
VSS
BAS70-04
R214
+5V
KEY
D111
15k
D D
R215
10k
1u
C197
VSS
VSS
BAS70-04
R216
+5V
D112
15k
R217
10k
1u
C198
VSS
VSS
BAS70-04
R218
+5V
D113
E 15k E
R219
10k
1u
C199
99
VSS
1 2 3 4 5 6 100
A A
Analog in
B B
+5VA
D114
D115
D116
D117
D118
D119
D120
D121
IC57
AI1_HA1 R220 1
CH0
AGND
AI2_HA2 R221 1k 2
CH1
AI3_HA3 R222 1k 3
CH2
AI4_HA4 R223 1k 4 10 A_SPI_CS1
CH3 *CS/SHDN
AI5_HA5 R224 1k 5 11 A_SPI_MOSI
CH4 DIN
AI6_HA6 R225 1k 6 12 A_SPI_MISO
CH5 DOUT
AI7_HA7 R226 1k 7 13 A_SPI_SCK
CH6 CLK
AI8_HA26 R227 1k 8
CH7
C 1k C
1u
1u
1u
1u
1u
1u
1u
1u
+5VA
1u 15
VREF
C210 1u 16
C201
C202
C203
C204
C205
C206
C207
C208
VDD
C209 9
DGND
14
AGND
AGND
AGND
MCP3208-CI/SL
D D
E E
Appendix D
1 2 3 4 5 6
A A
B B
+5VA
D122
D123
D124
D125
D126
D127
D128
D129
IC58
AI9_HA27 R228 1
CH0
AGND
AI10_HA28 R229 1k 2
CH1
AI11_HA29 R230 1k 3
CH2
AI12_HA30 R231 1k 4 10 A_SPI_CS2
CH3 *CS/SHDN
AI13_HA31 R232 1k 5 11 A_SPI_MOSI
CH4 DIN
C AI14_HA48 R233 1k 6 12 A_SPI_MISO C
CH5 DOUT
AI15_HA49 R234 1k 7 13 A_SPI_SCK
CH6 CLK
AI16_HA50 R235 1k 8
CH7
1k
1u
1u
1u
1u
1u
1u
1u
1u
+5VA
1u 15
VREF
C220 1u 16
C211
C212
C213
C214
C215
C216
C217
C218
VDD
C219 9
DGND
14
AGND
AGND
AGND
MCP3208-CI/SL
D D
E E
101
102
1 2 3 4 5 6
A A
B B
+5VA
D130
D131
D132
D133
D134
D135
D136
D137
IC59
AI17_HA51 R236 1
CH0
AGND
AI18_HA52 R237 1k 2
CH1
AI19_HA53 R238 1k 3
CH2
AI20_HA54 R239 1k 4 10 A_SPI_CS3
CH3 *CS/SHDN
BATT R240 1k 5 11 A_SPI_MOSI
CH4 DIN
EXTRA_AI1 R241 1k 6 12 A_SPI_MISO
CH5 DOUT
EXTRA_AI2 R242 1k 7 13 A_SPI_SCK
CH6 CLK
EXTRA_AI3 R243 1k 8
CH7
1k
C C
1u
1u
1u
1u
1u
1u
1u
1u
+5VA
1u 15
VREF
C230 1u 16
C221
C222
C223
C224
C225
C226
C227
C228
VDD
C229 9
DGND
14
AGND
220
DNP
DNP
DNP
AGND
AGND
MCP3208-CI/SL
R376
R375
R377
R378
AGND
D D
E E
Appendix D
1 2 3 4 5 6
A A
Analog out
IC61
IC60
C231
1u
+5VA
4
VCC+ OUT1
1 R249 AO6_EA18
+5VA
AGND 7 R250 47 AO7_EA17
C233
1u
OUT2
B 16 2 3 8 R251 47 AO8_EA45 B
VCC VOUTA POS_1 OUT3
AGND
3 2 14 R248 47 AO5_EA19
VOUTB NEG_1 OUT4
A_SPI_SCK 8 4 5 47
SCK VOUTC POS_2
A_SPI_CS0 7 5 6 C323C324C325C326
R252 ~CS/LD VOUTD NEG_2
11 12 10
~CLR VOUTE POS_3
A_SPI_MOSI 9 13 9 1n/100V
1n/100V
1n/100V
1n/100V
10k SDI VOUTF NEG_3
6 14 12
REF VOUTG POS_4
15 13
VOUTH NEG_4
1
GND
+5VA
10 A_SPI_DO1 11
SDO VCC-
AGND
1u
AGND
C234
AGND
LTC2620CGNPBF TS924ID
AGND
C C
IC62
C232
1u
+5VA
4
VCC+ OUT1
1 R245 AO2_EA22
7 R246 47 AO3_EA21
OUT2
3 8 R247 47 AO4_EA20
POS_1 OUT3
AGND
2 14 R244 47 AO1_EA23
NEG_1 OUT4
5 47
POS_2
6 C327C328C329C330
NEG_2
10
POS_3
9 1n/100V
1n/100V
1n/100V
1n/100V
NEG_3
12
POS_4
13
NEG_4
D 11 D
VCC-
AGND
AGND
TS924ID
E E
103
104
1 2 3 4 5 6
A A
IC64
IC63
C235
1u
+5VA
4
VCC+ OUT1
1 R258 AO14_EA70
+5VA
AGND 7 R259 47 AO15_EA69
C237
1u
OUT2
16 2 3 8 R260 47 AO16_EA68
AGND
B 3 2 14 R257 47 AO13_EA40 B
VOUTB NEG_1 OUT4
A_SPI_SCK 8 4 5 47
SCK VOUTC POS_2
A_SPI_CS0 7 5 6 C331C332C333C334
11 12 10
~CLR VOUTE POS_3
A_SPI_DO1 9 13 9 1n/100V
1n/100V
1n/100V
1n/100V
10k SDI VOUTF NEG_3
6 14 12
REF VOUTG POS_4
15 13
VOUTH NEG_4
1
GND
+5VA
10 A_SPI_DO2 11
SDO VCC-
AGND
1u
AGND
C238
AGND
AGND
C C
IC65
C236
1u
+5VA
4
VCC+ OUT1
1 R254 AO10_EA43
7 R255 47 AO11_EA42
OUT2
3 8 R256 47 AO12_EA41
POS_1 OUT3
AGND
2 14 R253 47 AO9_EA44
NEG_1 OUT4
5 47
POS_2
6 C335C336C337C338
NEG_2
10
POS_3
9 1n/100V
1n/100V
1n/100V
1n/100V
NEG_3
12
POS_4
13
NEG_4
11
D VCC- D
AGND
AGND
TS924ID
E E
Appendix D
1 2 3 4 5 6
A A
IC67
IC66
C239
1u
+5VA
4
VCC+ OUT1
1 R267
+5VA
AGND 7 R268 DNP
C241
1u
OUT2
B 16 2 3 8 R269 DNP B
AGND
3 2 14 R266 DNP
VOUTB NEG_1 OUT4
A_SPI_SCK 8 4 5 DNP
SCK VOUTC POS_2
A_SPI_CS0 7 5 6
11 12 10
~CLR VOUTE POS_3
A_SPI_DO2 9 13 9
10k SDI VOUTF NEG_3
6 14 12
REF VOUTG POS_4
15 13
VOUTH NEG_4
1
GND
+5VA
10 A_SPI_MISO 11
SDO VCC-
1u
AGND
C242
AGND
AGND
C C
IC68
C240
1u
+5VA
4
VCC+ OUT1
1 R263 AO18_EA66
7 R264 47 AO19_EA65
OUT2
3 8 R265 47 AO20_EA64
POS_1 OUT3
AGND
2 14 R262 47 AO17_EA67
NEG_1 OUT4
5 47
POS_2
6 C343C344C345C346
NEG_2
10
POS_3
9 1n/100V
1n/100V
1n/100V
1n/100V
NEG_3
12
POS_4
13
NEG_4
D 11 D
VCC-
AGND
AGND
TS924ID
E E
105
1 2 3 4 5 6 106
A A
Frequency in
B B
+3V3
IC45
+3V3
8 14
VCC RC
C339
R273
5.6k
12
REF_OUT
100n 2 GND
+3V3
11
C341
100n/100V
R271 IN_SEL
FI1_HB26 3
VIN
VSS
18k C366
3
10 CAP0[0]
OUT
47p 2 5
MODE
C SJ1 C
1
9
R274
1k
TIME_PULSE
7
PEAK_CAP
VSS
LM1815M
VSS
C340
R272
1.6M
220n
VSS
D D
E E
Appendix D
1 2 3 4 5 6
A A
B B
+3V3
IC46
+3V3
8 14
VCC RC
C342
R277
5.6k
12
REF_OUT
100n 2 GND
+3V3
11
C348
100n/100V
R275 IN_SEL
FI2_HB27 3
VIN
VSS
18k C365
3
10 CAP0[1]
OUT
47p 2 5
MODE
C SJ2 C
1
9
R278
1k
TIME_PULSE
7
PEAK_CAP
VSS
LM1815M
VSS
C347
R276
1.6M
220n
VSS
D D
E E
107
108
1 2 3 4 5 6
A A
B B
+3V3
IC47
+3V3
8 14
VCC RC
C349
R281
5.6k
12
REF_OUT
100n 2 GND
+3V3
11
C351
100n/100V
R279 IN_SEL
FI3_HB28 3
VIN
VSS
18k C367
3
10 CAP1[0]
OUT
47p 2 5
MODE
C SJ3 C
1
9
R282
1k
TIME_PULSE
7
PEAK_CAP
VSS
LM1815M
VSS
C350
R280
1.6M
220n
VSS
D D
E E
Appendix D
1 2 3 4 5 6
A A
B B
+3V3
IC48
+3V3
8 14
VCC RC
C352
R285
5.6k
12
REF_OUT
100n 2 GND
+3V3
11
C354
100n/100V
R283 IN_SEL
FI4_HB29 3
VIN
VSS
18k C368
3
10 CAP1[1]
OUT
47p 2 5
MODE
SJ4
1
C 9 C
R286
1k
TIME_PULSE
7
PEAK_CAP
VSS
LM1815M
VSS
C353
R284
1.6M
220n
VSS
D D
E E
109
110
1 2 3 4 5 6
A A
B B
+3V3
IC49
+3V3
8 14
VCC RC
C355
R289
5.6k
12
REF_OUT
100n 2 GND
+3V3
11
C357
100n/100V
R287 IN_SEL
FI5_HB30 3
VIN
VSS
18k C369
3
10 CAP2[0]
OUT
47p 2 5
MODE
C SJ5 C
1
9
R290
1k
TIME_PULSE
7
PEAK_CAP
VSS
LM1815M
VSS
C356
R288
1.6M
220n
VSS
D D
E E
Appendix D
1 2 3 4 5 6
A A
B B
+3V3
IC50
+3V3
8 14
VCC RC
C358
R293
5.6k
12
REF_OUT
100n 2 GND
+3V3
11
C360
100n/100V
R291 IN_SEL
FI6_HB31 3
VIN
VSS
18k C370
3
10 CAP2[1]
OUT
47p 2 5
MODE
SJ6
1
9
R294
1k
TIME_PULSE
7
PEAK_CAP
C C
VSS
LM1815M
VSS
C359
R292
1.6M
220n
VSS
D D
E E
111
1 2 3 4 5 6 112
A A
Frequency out
IC52
+5V
C361
100n/60V
C362
100n
+24V
10 20
VS VSS
2 3
R295
B IN1 OUT1 FO1_EB45 B
VSS
VSS
1 150
EN1 R296
9 8 FO2_EB44
+5V IN2 OUT2
150
12 13
R297
IN3 OUT3 FO3_EB43
11 150
EN2 R298
19 18 FO4_EB42
IN4 OUT4
150
4 17
GND GND
5 16
GND GND
6 15
GND GND
7 14
GND GND
L293DD
VSS
VSS
C C
IC53
+5V
C363
100n/60V
C364
100n
+24V
10 20
VS VSS
2 3
R299
IN1 OUT1 FO5_EB41
VSS
VSS
1 150
EN1 R300
9 8 FO6_EB40
+5V IN2 OUT2
150
12 13
R301
IN3 OUT3
11 150
EN2 R302
19 18
IN4 OUT4
150
4 17
GND GND
5 16
GND GND
6 15
GND GND
7 14
GND GND
D L293DD
D
VSS
VSS
E E
Appendix D
1 2 3 4 5 6
PWM in
A A
BAS70-04
D138
+3V3 VSS
R303
PI1_EB39 2CAP0[0]
10k C371
B 47p B
R304
4.7k
BAS70-04
VSS
D139
+3V3 VSS
R305
PI2_EB38 2CAP0[1]
10k C372
47p
R306
4.7k
BAS70-04
VSS
C C
D140
+3V3 VSS
R307
PI3_EB37 2CAP1[0]
10k C373
47p
R308
4.7k
BAS70-04
VSS
D141
+3V3 VSS
R309
PI4_EB36 2CAP1[1]
10k C374
47p
R310
4.7k
D D
VSS
E E
113
114
1 2 3 4 5 6
A A
BAS70-04
D142
+3V3 VSS
R311
PI5_EB35 2CAP2[0]
10k C375
B 47p B
R312
4.7k
BAS70-04
VSS
D143
+3V3 VSS
R313
PI6_EB34 2CAP2[1]
10k C376
47p
R314
4.7k
BAS70-04
VSS
C C
D144
+3V3 VSS
R315
PI7_EB33 2CAP3[0]
10k C377
47p
R316
4.7k
BAS70-04
VSS
D145
+3V3 VSS
R317
PI8_EB32 2CAP3[1]
10k C378
47p
R318
4.7k
D D
VSS
E E
Appendix D
1 2 3 4 5 6
A A
BAS70-04
D146
+3V3 VSS
R319
PI9_EB31 1CAP0[0]
10k C379
B 47p B
R320
4.7k
BAS70-04
VSS
D147
+3V3 VSS
R321
PI10_EB30 1CAP0[1]
10k C380
47p
R322
4.7k
BAS70-04
VSS
C C
D148
+3V3 VSS
R323
PI11_EB29 1CAP1[0]
10k C381
47p
R324
4.7k
BAS70-04
VSS
D149
+3V3 VSS
R325
PI12_EB28 1CAP1[1]
10k C382
47p
R326
4.7k
D D
VSS
E E
115
116
1 2 3 4 5 6
A A
BAS70-04
D150
+3V3 VSS
R327
PI13_EB27 1CAP2[0]
10k C383
47p
R328
4.7k
B B
BAS70-04
VSS
D151
+3V3 VSS
R329
PI14_EB26 1CAP2[1]
10k C384
47p
R330
4.7k
BAS70-04
VSS
C D152
+3V3 VSS C
R331
PI15_EB25 1CAP3[0]
10k C385
47p
R332
4.7k
BAS70-04
VSS
D153
+3V3 VSS
R333
PI16_EB24 1CAP3[1]
10k C386
47p
R334
4.7k
D D
VSS
E E
Appendix D
1 2 3 4 5 6
CAN
A A
B B
IC69
+5V
VSS VSS
47p
C400
R338 8 3
RS VCC
47k
1CAN1_TD 1
TXD
7 CAN1_H_IN_HA20
R344 CANH
1CAN1_RD 4 C397
RXD
6
470 CANL
47p CAN1_L_IN_HA19
C 5 C
R345
1k
VREF
2
GND
C398 C399
ADM3051
VSS
47p 47p
VSS
D D
E E
117
118
1 2 3 4 5 6
A A
B B
IC70
+5V
VSS VSS
47p
C404
R339 8 3
RS VCC
47k
1CAN2_TD 1
TXD
7 CAN1_H_OUT_EA4
R346 CANH
1CAN2_RD 4 C401
RXD
6
470 CANL
C 47p CAN1_L_OUT_EA5 C
5
R347
1k
VREF
2
GND
C402 C403
ADM3051
VSS
47p 47p
VSS
D D
E E
Appendix D
1 2 3 4 5 6
A A
B B
IC71
+5V
VSS VSS
47p
C408
R340 8 3
RS VCC
47k
2CAN1_TD 1
TXD
7 CAN2_H_IN_HA22
R348 CANH
2CAN1_RD 4 C405
RXD
6
470 CANL
47p CAN2_L_IN_HA21
C 5 C
R349
1k
VREF
2
GND
C406 C407
ADM3051
VSS
47p 47p
VSS
D D
E E
119
120
1 2 3 4 5 6
A A
B B
IC72
+5V
VSS VSS
47p
C412
R341 8 3
RS VCC
47k
2CAN2_TD 1
TXD
7 CAN2_H_OUT_EA2
R342 CANH
C 2CAN2_RD 4 C409 C
RXD
6
470 CANL
47p CAN2_L_OUT_EA3
5
R343
1k
VREF
2
GND
C410 C411
ADM3051
VSS
47p 47p
VSS
D D
E E
Appendix D
1 2 3 4 5 6
J1708
A A
B B
R363
UART2_RX
U3
1k
470 R350
J1708A_IN_HA17
R362
VSS C414
C413
100n
47
+5V
8 1
VCC RO
2.2n
R352 +5V
4.7k
IC73A 2 6
~RE A
VSS
UART2_TX 1 2 3 7 C415
DE B
4
DI R351
VSS
74AC04D 2.2n J1708B_IN_HA18
5
R353
4.7k
DNP GND 47
R361
+5V
14
C C
VCC
VSS
VSS
ST485CDR
100n IC73P
C419
GND
7
VSS
D D
E E
121
122
1 2 3 4 5 6
A A
B B
470
UART3_RX
U4
1k
R358 R354
J1708A_OUT_EA7
R360
VSS C417
C416
100n
47
+5V
8 1
VCC RO
2.2n
R356 +5V
4.7k
IC73C 2 6
~RE A
VSS
UART3_TX 5 6 3 7 C418
DE B
4
DI R355
VSS
74AC04D 2.2n J1708B_OUT_EA6
C 5 C
R357
4.7k
DNP GND 47
R359
VSS
VSS
ST485CDR
D D
E E
Appendix D
1 2 3 4 5 6
Misc I/O
A A
B B
BAS70-04
D154
+3V3 VSS
R371
EXTRA_FI1 CAP3[0]
10k C420
47p
R372
4.7k
C422 AGND 1 2 +5V
+5VA 3 4 EXTRA_FI1 C423
1u EXTRA_AI1 5 6 EXTRA_FI2 BAS70-04
EXTRA_AI2 7 8 EXTRA_DI1 1u
VSS
EXTRA_AI3 9 10 VSS
C 11 12 D155
+3V3 VSS C
VSS VSS R373
VSS 13 14 EXTRA_SO2 EXTRA_FI2 CAP3[1]
EXTRA_SO1 15 16 EXTRA_SO3 C421
10k
SV5 47p
R374
4.7k
VSS
D D
E E
123
A PPENDIX E
Control Card Layout
125
C32 C29 C40
C33 C24 C41
C35
C43
C25
C46C47
C38C39
C30C31
C42
C34
C26
C37 C27 C45

C36 C28 C44
Top components
Appendix E 126
55R 95R
663C
372R
763C
182R
963C
982R
1 224C
501C
701C
021D
121D
1 JS
3 JS
5 JS
933C
943C
553C
043C
053C
653C
25R 65R
324C
802C
143C
153C
753C
422R
522R
622R
722R
32CI
42CI
811D 02C
9117D 5VS 61
602C 472R 282R 092R
024C
* * *
172R
502C
563C
977722RR
863C
758822RR
073C
392R
451D
12545C1D
611D
711D 402C
54CI 74CI 94CI
273R
373R
473R
302C
2 JS
4 JS
6 JS
243C
253C
853C
39R 59R
272R 743C
082R 353C
882R 953C
202C 801C
73D
63D
53D
43D
81CI
411D
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127
128 Appendix E
Layer 1 (Top)
129
Layer 2
130 Appendix E
Layer 3
131
Layer 14
132 Appendix E
Layer 15
133
Layer 16 (Bottom)

Master's Thesis on Electronic Breakout Unit for Vehicle Control and Data Logging

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Master's Thesis on Electronic Breakout Unit for Vehicle Control and Data Logging

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MASTER'S THESIS

Electronic Breakout Unit

Master of Science in Engineering Technology

Luleå University of Technology

Luleå University of Technology

28th December 2012

Chapter 2 – Material and Method 5

Appendix B – Relay Card Schematic 55

Appendix C – Relay Card Layout 65

Appendix D – Control Card Schematic 75

Appendix E – Control Card Layout 125

Figure 1.1: Volvo L110G wheel loader.

Figure 1.2: System overview.

Table 1.1: Acronyms and description.

2.1 The Wheel Loader

Figure 2.1: Volvo L110G wheel loader.

Figure 2.3: Lorenz force contributing to Hall effect voltage in a conductor.

By subjecting a conductive material to a current and magnetic field which is perpen-

temperature as seen in Figure 2.5.

Figure 2.5: Thermistor with pull up resistor.

Ferromagnetic toothed wheel Ferromagnetic pole piece

Figure 2.6: Inductive sensor and toothed wheel.

Figure 2.7: A solenoids internal parts.

Device 1 Device 2 Device 3 Device 4

CAN High CAN High

Figure 2.8: CAN network.

Table 2.1: CAN frame.

Figure 2.9: J1708 node on bus.

Figure 2.10: Discrete digital representation of a analog signal.

independent of what tasks the CPU is preforming.

Capture Reg. Edge detect pinin

Compare Reg. = Wave gen. pinout

Control Reg. Prescaler clkin

Figure 2.11: Overview of a hardware timer.

Hardware timers as PWM output

Figure 2.12: Hardware timer as PWM output.

Hardware timers as event capture

SPI Master SPI Slaves Master Slaves

(a) Independent. (b) Daisy chain.

Figure 2.13: SPI configurations.

Figure 2.14: Bit timing between master and slave.

Figure 2.15: Discrete analog representation of a digital value.

2.3.4 Power electronics

Figure 2.16: Concept 1 PWM out schematic.

Figure 2.17: Concept 2 PWM out schematic.

through the transistor and can detect if the circuit is open.

Figure 2.18: Concept 3 PWM out schematic.

Protection logic Df Load

Figure 2.19: Concept 4 PWM out schematic.

2.4 Safety and Regulations

2.4.1 Emergency shutdown

Figure 2.20: How a windowed watchdog operates.

3.1 Relay Card schematic

3.1.1 Digital in and Digital out

Digital out Digital in

3.1.2 Analog in and Analog out

Analog out Analog in

3.1.3 Solenoid out and Load Resistor

3.1.4 PWM out and Load Resistor

3.1.5 CAN and J1708

3.1.6 Relay drivers

K15 K2 K16 K3 K9 K17