syvecs X4 Expander User Manual

syvecs X4 Expander

This document is intended for use by a technical audience and describes a number of procedures that are potentially hazardous. Installations should be carried out by competent persons only.

Syvecs and the author accept no liability for any damage caused by the incorrect installation or configuration of the equipment.
Please Note that due to frequent firmware changes certain windows might not be the same as the manual illustrates.
If so please contact the Syvecs Tech Team for Assistance.
[email protected]

INSTRUCTION

The Syvecs X4 Expander is a compact but very powerful expansion unit for enhancing the Input and Output compliment of a powertrain electronics installation.
The X4 is fitted with four Half Bridges drivers which are capable of driving Low, High or joined in pairs as a full bridge motor driver. Each of the four H-Bridge Outputs is equipped with a current monitoring circuit which can be assigned in strategies on Syvecs Engine Controllers or as Current Limiting functions in other applications.
Four MagnetoResitive circuits make reading the ABS sensors found on most new automotive applications easier by just needing to connect one side of the sensor to the X4 and the other side to Ground.

The four 0-5v Analog inputs are not capable of frequency detection but are useful for monitoring of switches, pressure transducer or positional sensors.
Able to withstand the toughest of conditions and high temperatures the X4 is useful for many applications whether it’s for external Drive By Wire support, Electronic Wastegates, Fuel Pump Controller and more.
Two canbus interfaces are fitted on the X4 which are setup out of the box for Slave Control with an S7, S8, S12 Ecu or XCan Support for other Ecu’s.

Syvecs is also able to use the hardware for custom projects so if you have a requirement for a dedicated task please email [email protected]

Specification

Outputs

• 4 Half Bridge Outputs (Support: Full Bridge, Lowside or HighSide Drive)
• 15Amp Peak (100ms) 8Amp Continuous Drive
• Current Monitoring on each pin

Inputs

• 4 Analogue or switch inputs (0-5V)
• 4 MagnetoResistive Wheel Speed Sensor Inputs

Interfaces

• USB For Updates and Config
• 2 x CAN 2.0B interface for communication with other controllers or logging systems
• 1 x Kline Interface

Power Supply

• 6 to 26V input voltage range
• Ignition Switch Logic with high current supply

Physical

• Waterproof Sealed in Automotive Spec -40c to 125c
• 34 way Superseal 1.0
• 85mm x 70mm

Wiring

Syvecs Description| iO4 Pinout| Function| Notes
---|---|---|---
PWRGND| A1| Ground|
PWRGND| A2| Ground|
H-Bridge1| A3| H Bridge with Current Sense|
H-Bridge2| A4| H Bridge with Current Sense|
H-Bridge3| A5| H Bridge with Current Sense|
H-Bridge4| A6| H Bridge with Current Sense|
12V HC| A7| 12v Supply – High Current|
Kline/LinBus| A8| Kline/LinBus|
MagnetoResistive 1| A9| Connects to ABS +Wire| Other side of Sensor Gnd
MagnetoResistive 2| A10| Connects to ABS +Wire| Other side of Sensor Gnd
MagnetoResistive 3| A11| Connects to ABS +Wire| Other side of Sensor Gnd
MagnetoResistive 4| A12| Connects to ABS +Wire| Other side of Sensor Gnd
12V HC| A13| 12v Supply – High Current|
Can0 H (1.33mb)| A14| Slave CanBus| 1.33MB
Can0 L (1.33mb)| A15| Slave CanBus| 1.33MB
12v IGSW| A16| 12v – Ignition Switch| Wakes up Unit
Can1 H (500kb)| A17| XCan H| XCan Protocol
Can1 L (500kb)| A18| XCan L| XCan Protocol
12V HC| A19| 12v Supply – High Current|
5v Out| A20| 5v Output Supply|
AN1| A21| 0-5v Analog Input|
AN2| A22| 0-5v Analog Input|
AN3| A23| 0-5v Analog Input|
AN4| A24| 0-5v Analog Input|
PWRGND| A25| Ground|
PWRGND| A26| Ground|

Mating Connector – TE 2-1437285-3

Power Connection

The X4 has four power connection points, three of these are high current and can be connected to a fused battery power or switched power source. One of them is Logic Switch / Ignition Switch power and used to switch the power gate so that current is able to flow from the 3x High current 12v pins into the Device.

The three high current pins are linked internally, as are the power ground pins. If driving motors or solenoids which pull a lot of current then ensure the correct amount of pins are connected. Each pin on the X4 is able to sink around 14 amps of current continuously, so if driving multiple solenoids that pull 20+ amps total, ensure at least two high current 12v pins and two power ground pins are used.

Example Schematic

CanBus Connections

Syvecs ECU Slave Link 1.33mb

• S7
  • S7-I & S7Plus connect X4 Can0L (Pin15) to S7 Can2L (PinB2)
  • S7-I & S7Plus connect X4 Can0H (Pin14) to S7 Can2H (PinB3)
• S8/GDi4
  • S8 connect X4 Can0L (Pin15) to S8 Can2L (Pin79)
  • S8 connect X4 Can0H (Pin14) to S8 Can2H (Pin80)
• S8/GDi4
  • S8 connect X4 Can0L (Pin15) to S8 Can2L (Pin18)
  • S8 connect X4 Can0H (Pin14) to S8 Can2H (Pin76)

ECU Pin Assignments – Syvecs ECU

The Syvecs range of ecus from S7 onwards can use the spare canbus available for communicating with the X4 expander over a slave protocol which runs at 1.33mb

To bring the Slave connection online you only need to assign a pin to the Slave of choice, do not need to setup anything in the DataStream section. If this is a S7 which has a slave1 already in use then use Slave2 Inputs and Output assignments. With the S8 and S12 you can use Slave 1.

After assigning and doing a Device – Program , The message system at the bottom right hand corner of Scal should state Master : Slave2 Online : SNXXX… If not check the canbus connections and ensure the canbus is terminated correctly.

Outputs

H Bridge outputs 1 -4 are assigned under SlaveOut 1-4. If wanting to control a Motor in Full bridge then it must be wired in equal pairs 1-2 / 3-4 / 5-6 etc then assign the first number of the pair. Example Motor connected to Hbridge 1 and 2, assign the strategy function to Slave Out1 as below. Each H-Bridge output can handle 15amps peak and 8amp continuous.

Low side and High side drive can just be assigned to the corresponding pin as required in pin assignments

Calibrators need to set the Output type in the strategy they are planning to use. Example: user has assigned Slave out1 to Basic PWM strategy and requires the pin to be run in Full bridge for Motor control where 50% is zero drive and 0% or 100% is maximum drive.

The Output type can be set in the strategy they are planning to use:

• Low-Side = Output drives to Ground
• Half Bridge = Output Drives to 12v
• Full bridge = Motor Drive

Example: Using basic PWM1 for Fully bridge Motor Control.. Output Functions – Basic PWM 1 – Output Type

Set Output Type as Full Bridge
The Minimum Frequency a H-Bridge output can be driven is 20hz

Current Sense Monitoring

H Bridge outputs 1 -4 have a current sensor fitted on each device. These can be monitored under Slave*AN 9-12 assignments in Scal. 2.5v is the rest voltage for 0mA

• HBridge1 = Slave* AN9
• HBridge2 = Slave* AN10
• HBridge3 = Slave* AN11
• HBridge4 = Slave* AN12

Scale is -18.3333A at 0V and 18.3333A at 5V

ADC Inputs

Four Analog Inputs are available on the X4. These are just 0-5v Analog inputs and cannot support frequency waveforms.
They are designed for sensors like pressure transducers or position sensors.

AN Inputs 1 -4 are assigned under Slave*AN 1-4.

The Input Type for the sensor it is assigned to, must be set to 5v otherwise the message system in the bottom right of Scal will bring up a Slave error and the engine won’t be allowed to start

MagnetoResistive Inputs

The X4 expander supports four magneto-resistive wheels speed sensors which most new factory cars use. These can be connected directly to the Syvecs AWD controller via Pins 9 to 12.

This means users can remove the OEM ABS Computer from the car if wanted and read the sensors direct .

MagnetoResitive Inputs 1 -4 are assigned under Slave*AN 5-8.

• MagnetoRes1 = Slave* AN5
• MagnetoRes2 = Slave* AN6
• MagnetoRes3 = Slave* AN7
• MagnetoRes4 = Slave* AN8

Under Sensors – Vehicle Speed …Calibrators will then need to set the Measurement area up as below

• Input Configuration – 5v
• Input Filters – Off
• Low Threshold Voltage – 1.25
• High Threshold Voltage – 3.75
• Tooth Timeout – 0.25
• Number of teeth – Number of teeth on the ABS ring

XCan – Custom Projects / Other Engine Management Systems

The XCan protocol which is available on Can1 of the X4 is designed for other engine management systems or older Syvecs ecus
which don’t have a spare canbus.

The DBC for this Can Protocol can be found at the below link to help speed up development www.syvecs.com/downloads/XCan_DBC.dbc

The X-CAN Protocol runs default at 500kb, Custom builds can be done to change this speed.

XCan Protocol – Outputs

H-Bridge Output Setup
Frame 0x770 is used to configure the output setup (Output Type & Output Frequency)
Output Setup frames can be sent to expander just once at boot up or continuously but the protocol only grabs the setup once when it recieves a frame. If can messages disappear (0x770 and 0x778) for longer than 1000ms then a reset is applied to the Output setup. This can be used for programming different types and frequencies.

Each Output channel is configured by 2 bytes in MSB data format

The top 2 bits set the Output type – 1100:0000 | 0000:0000
The 14 other bits set the Output Frequency as a raw decimal in HZ – 0011:1111 | 1111:1111

Output Type is set as below –

• OFF(Output Off) – 0x00 = 0000:0000 | 0000:0000
• LS (Low Side Drive) – 0x40 = 0100:0000 | 0000:0000
• HB (High Side Drive) – 0x80 = 1000:0000 | 0000:0000
• FB (Motor Control) – 0xC0 = 1100:0000 | 0000:0000

Example – 0x85DC = 1000:0101 | 1101:1100 = High Side Output at 1500hz
When controlling in FB Mode the opposite output channel needs to be set to OFF and 0 Frequency

Example – Byte0 | 0xC5DC and B1 | 0x0000 = Full Bridge Control on HBR1 and 2 at 1500hz

Ganged Mode Control – Allows 2 outputs to be driven off same duty. Useful for when needing to control very high current devices as a single pin on the superseal connector can only handle 15 amps.

• If Out1 = FB, Out2 = OFF == BOTH Out1 and Out2 will be control in Full bridge motor and driven from the Duty on Out 1 frame
• If Out1 = FB, Out2 = LS == BOTH Out1 and Out2 will be LS Ganged and driven from the Duty on Out 1 frame
• If Out1 = FB, Out2 = HS == BOTH Out1 and Out2 will be HS Ganged and driven from the Duty on Out 1 frame

H Bridge Outputs (HBR1-4) – Support OFF, LS, HS and FB, During FB Mode HBR1 and HBR2 would be linked to drive a Motor forward and back

Frame 0x770 – HBR1-4

Output Duty Setup

Frame 0x778 is used to configure the output duty cycle set on each output, these needs to be transmitted at 50ms per frame rate or faster
This again is done via 2 Bytes and the duty is calculated as a multiple of 81.92

If you wanted to drive the output at 22% Duty then would take 81.92 * 22 = 1802 (Decimal) convert to Hex 0x070A. Byte 0 =

• 0x07 Byte 1 = 0x0A
• 0x0000 = 0% Duty
• 0x2000 = 100% Duty

H Bridge Outputs(HBR1-4) – Duty Setup

Frame 0x778 – HBR1-4

XCan Protocol – Inputs

Frame 0x760 is used to configure the input setup (Input Type & Thresholds)
Input Setup frames can be sent to Expander just once at boot or continuously but the code only grabs the setup once when it recieves a frame. If can messages disappear for longer than 1000ms then a reset is applied to the Input setup. This can be used for programming different input setups and thresholds for frequency inputs.

The MagnetoResistive Inputs and Current Measurement Inputs don’t need to be setup, they will be transmitted when the X4 has received a 0x760 Frame.
The X4 expander has 4 x AV Inputs (AN01-4) , 4 x Freq (MagnetoResistive) Inputs and 4 x Current measurement values – AV Input which mean they can only read a ADC Voltage 0-5v – DO NOT SUPPORT FREQ or Pull-Up

Each Input channel is configured by 2 bytes in MSB data format

• Bit15 – (0x8000) – 1000:0000 | 0000:0000 = Sets the Input Pull-Up Option to be enabled . This enables a 5v 3k pull up on the input
• Bit14 – (0x4000) – 0100:0000 | 0000:0000 = Sets the Input Type – If this bit is set then the input is setup for Frequency detection,if its NOT set then the input is setup for ADC monitoring
• Bit13 – (0x2000) – 0010:0000 | 0000:0000 = Sets the bipolar flag but only if the Input is not in Frequency Mode.. If in Frequency
• Mode Bit5 is part of the High Thresold setup
• Bit13 to Bit7 – (0x3F80) – 0011:1111 | 1000:0000 = These 7 bits set the High threshold for the Inputs when in Frequency mode |
• Engineering Value 0.078125 to V
• Bit6 to Bit0 – (0x007F) – 0000:0000 | 0111:1111 = These 7 bits set the Low threshold for the Inputs when in Frequency mode |
• Engineering Value 0.078125 to V
• Example – (0x578F) – 0101:0111 | 1000:1111 = Frequency Mode Enabled with Low Threshold at 1.2v and High Threshold at 3.7v

Frame 0x760 – AN1-4

AN1-4 Input Values
0x780 Frame transmits the readings on the Analog inputs.
Each Input reading is represented by 2 bytes in MSB data format. The 2 bytes represent the ADC Reading on the Input.

The Engineering value is 0.000076 to V. Example Hex 0x4E80 = 1.527v

Frame 0x780 – AN1-4

HBR1-4 Current Values
0x200 Frame transmits the current readings on HBR1 -4
Each Input reading is represented by 2 bytes in MSB data format. The 2 bytes represent the ADC Reading on the Input.
The Engineering value is 0.001 to A.

Frame 0x200 – HBR1-4 Current

References

• syvecs.com/downloads/XCan_DBC.dbc

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