Version20141021 P a g e |1Infinitybox,LLC|www.infinitybox.com|(847)232‐1991
J1939POWERCELLSetupandConfigurationGuideHMISystems482CRMSwitches
TableofContentsOverview .......................................................................................................................................... 2
Warnings.......................................................................................................................................... 3
J1939 POWERCELL Technical Details ............................................................................................... 4
POWERCELL Installation Steps ........................................................................................................ 5
Mounting the POWERCELL .......................................................................................................... 5
Supplying 12‐volt Power .............................................................................................................. 5
Wiring the Output Harnesses ...................................................................................................... 6
Installing Fuses ............................................................................................................................ 8
Connecting J1939 CAN Network .................................................................................................. 8
Configuring J1939 Commands from HMI Systems 482CRM ........................................................... 9
Load CANconnect Software ......................................................................................................... 9
Install Software for CAN to J1939 Adaptor ................................................................................. 9
Setting the J1939 POWERCELL Address .................................................................................... 10
CAN Parameter Setup ................................................................................................................ 11
POWERCELL Personality Glossary .............................................................................................. 14
Track...................................................................................................................................................14 Toggle.................................................................................................................................................14 PulseWidthModulation(PWM).............................................................................................14 Post‐Time..........................................................................................................................................14 ToggleTime.....................................................................................................................................15 Track:Pattern.................................................................................................................................15
Powering the System ..................................................................................................................... 16
Warranty Information ................................................................................................................... 17
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Overview
TheInfinityboxJ1939POWERCELLbringsflexiblemultiplexedpowerdistributiontoanyvehiclebuilder.UsingstandardJ1939PGNstructuresandcommands,youcancontroltheoutputsonthePOWERCELLwithpracticallyanyJ1939inputdevice.
TheJ1939POWERCELLcomeswithastandardconfigurationthatallowstheend‐userbroadflexibilityincreatingtheirownlayoutstosuittheiruniqueapplications.UsingsimplesoftwaretoolsfromtheirJ1939inputmanufacturer,theycanquicklyconfigurethesysteminthefield.Incaseswherecustomconfigurationsarerequiredforaspecificvehicle,thesystemcanbemodifiedeasily.Contacttechnicalsupportformoredetails.
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WarningsTHEINFINITYBOXJ1939POWERCELLISAFUSEDPOWERDISTRIBUTIONMODULEFORVEHICLES.PROPERCAREMUSTBETAKENTOFUSETHEINPUTFEEDSTOTHECELLAND THE OUTPUT FEEDS FROM THE CELL. IMPROPER FUSE SELECTION CAN CAUSEDAMAGETOTHEVEHICLEELECTRICALSYSTEMRESULTINGINFIRE.PROPERCAREMUSTBETAKENTOENSURETHATPOWER IS CORRECTLYAPPLIED TOTHEPOWERCELL.REVERSINGPOLARITYTOTHEPOWERANDGROUNDFEEDSWILLCAUSEIRREPARABLEDAMAGETOTHECELLANDWILLVOIDTHEWARRANTY.ADDINGANYELECTRONICSMODULESTOAVEHICLEWILLINCREASETHEDEMANDONTHEBATTERY.CAREMUSTBETAKENTOMAINTAINACHARGEONTHEBATTERYWHENTHEVEHICLESITSIDLEFORPERIODSOFTIME.THISISESPECIALLYIMPORTANTWITHGEL‐CELL AND AGM BATTERIES. WE STRONGLY RECOMMEND INSTALLING A
DISCONNECTSWITCHTHATSEPARATESTHEELECTRICALLOADSINTHEVEHICLEFROM
THEBATTERYWHENNOTINUSE.
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J1939POWERCELLTechnicalDetailsSystemOperatingVoltage:7.0to15.8VDCNumberofOutputs:10OutputType:High‐SideSwitchedviaMOSFETsMaximumCurrentRatingperOutput:25‐ampsMaximumCurrentRatingperPOWERCELL:125‐ampsInternalFusing:StandardMini™FuseMaximumOperatingTemperature:125°CMinimumOperatingTemperature:‐20°C
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POWERCELLInstallationSteps
MountingthePOWERCELLMountthePOWERCELLonasuitableflatsurfaceinthevehicle.Usethe4mountingpointsinthecornersofthecelland1/4–inchhardware.TherecommendedmethodtomountthePOWERCELListouse¼‐inchX5/8‐inchshoulderscrews.Ifnotusingshoulderscrews,takecareastonotcrushthemountingpointsbyovertighteningthescrews.Inapplicationswherethesteady‐statecurrentdrawoutofthePOWERCELLexceeds90‐amps,mountthePOWERCELLinanareawithadequateventilationandwiththefinsoftheheatsinkrunningvertically.
Supplying12‐voltPowerThePOWERCELLgetsits12‐voltpowerfromthe3circularMaxi‐styleconnectorsontheedgeofthecell.Eachoftheseconnectorscanacceptupto60‐amps.Thefollowingtablesummarizesallofthecomponentsfortheseconnectors.ThePOWERCELLinputconnectorsusereadilyavailableconnectorcomponentsfromDelphi.SeetheinstructionsfromDelphiforproperassemblyandterminationoftheseconnectorcomponents.BasedonthetotalcurrentoutputofthePOWERCELLrequired,install1or2powerfeedsintotheroundMaxi‐styleconnectors.SealthethirdremainingconnectorwithanPOWERCELLsealingplug.Table1:POWERCELLInputConnectorComponents.
DelphiPartNumber
POWERCELL
Input
Connector
Connector 12129380Seal 12129382TPA 12129384WireSeal 12129381Terminal 12129414
EachofthepowerfeedwirestothePOWERCELLshouldbeprotectedwithafuselocatedascloselytothebatterysourceaspossible.SizethefusebasedonthegaugeofwirefeedingthePOWERCELL.TheTable2summarizestheproperfusesizesfordifferentwires.
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Table2:MaximumFuseRatingsforDifferentWireGauges.
AWGSize MaximumFuseRating(Amps)12 4010 508 60
WiringtheOutputHarnessesThePOWERCELLoutputconnectorsusereadilyavailableconnectorcomponentsfromDelphi.SeetheinstructionsfromDelphiforproperassemblyandterminationoftheseconnectorcomponents.Table3summarizesalloftheconnectorandterminalcomponentsrequiredtobuildcustomwiringharnessesforyourJ1939POWERCELL.Table3:POWERCELLOutputConnectorComponents.
DelphiPartNumber
POWERCELL
Output
Connector
Connector/Seal 12110295
TPA 12059195
WireSeal 12015323
Terminal 12129493
Eachoutputharnesshasonegroundwireand5outputwires.Thegroundwiresshouldbe14‐AWGandshouldbeconnectedtothevehicleground.ItisimportantthatthePOWERCELLisgroundedtothechassisthroughametal‐to‐metalconnection.Makesuretoremoveallpaint,powdercoating,dirtandgreasefromthecontactarea.Theindividualoutputwiresshouldbeproperlysizedtocarrytheoutputload.ThemaximumoutputcurrentforasinglePOWERCELLoutputis25‐amps.ThetotalPOWERCELLcancarryupto125‐amps.Exceedingthesevalueswilldamagethecellandvoidthewarranty.
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Table4summarizesthedetailsoftheoutputharnessesbyconnectorandcavityidentification.Table4:POWERCELLOutputHarnessConnectorDetails.CavityID ConnectorA ConnectorBA GROUND GROUNDB Output10 Output1C Output9 Output2D Output8 Output3E Output7 Output4F Output6 Output5Figure1identifiesalloftheconnectorsontheJ1939POWERCELL.
Figure1:SocketIdentificationforJ1939POWERCELL.
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InstallingFusesThePOWERCELLhasinternalfuseholderstoprotecttheoutputwiresfromshortcircuitsandlow‐overloads.TheholdersaredesignedforastandardMini™automotivefuse.Selecttheratingoffusetoprotectthesmallestgaugeofwireintheharnessforeachoutput.Neveruseafuseratedathigherthan25‐ampstoprotectaPOWERCELLoutput.Table5givesrecommendationsonfuseratingsfordifferentwiregauges.Table5:MaximumFuseRatingsforDifferentWireGauges.
AWGSize MaximumFuseRating(Amps)20 1018 1516 2014 25
UseonlyOEMapprovedMini™fusestoprotectthePOWERCELLoutputs.Therearenumerousgrey‐marketmanufacturersoffusesthatareunsafeandunreliable.RecommendedmanufacturersforthesefusesareLittelfuse,Inc,BussmannandPacificEngineering.
ConnectingJ1939CANNetworkTheCANsocketsontheJ1939POWERCELLsconnecttheJ1939inputdevicetothecells.Thesesocketsprovide12‐voltpowerfortheJ1939inputdeviceandtheCANHI&LOWconnectionfortheJ1939network.TherearetwoCANsocketsonthePOWERCELLsothatmultipleJ1939POWERCELLsandJ1939inMOTIONCellscanbeconnectedonthesamenetwork.AnCANterminatorplugwitha120‐ohmresistorshouldbeinsertedintothelastopenCANsocketontheJ1939network.ThetwoCANsocketsonaPOWERCELLareelectricallyidenticalsoyoucanplugtheCANconnectorintoeithersocket.Table6showsthefunction,cavityidentificationandwirecolorsfortheCANconnector.ConnectthecorrespondingwiresfromtheJ1939inputdevicetothesecavitiesintheconnector.
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Table6:CANConnectorWiringDetails.
CavityID Function StandardWireColor5 Ground Black6 CANLOW Green7 CANHIGH Yellow8 +12VoltPower Red
WhenbuildingtheJ1939networkbetweenthecells,the+12VoltPowerwiresandtheGroundwiresshouldonlygobetweenthefirstPOWERCELLandtheJ1939inputdevice.ThereshouldnotbepowerandgroundwiresbetweenthedifferentJ1939cellsinthenetwork.TheJ1939POWERCELLcansupplyatotalof0.6‐ampsoutonthe+12VoltPowerwireintheconnectorsocket.IfthetotalcurrentdrawfortheJ1939inputdevicesexceedsthislimit,theymustbeconnectedto+12voltsfromadifferentsource.
ConfiguringJ1939CommandsfromHMISystems482CRM
LoadCANconnectSoftwareFollowtheinstructionssuppliedwiththeHMISystemsCANconnectSoftwareforproperinstallation.Moreinformationcanbefoundatwww.hmisystems.net.
InstallSoftwareforCANtoJ1939AdaptorFollowtheinstallationinstructionssuppliedwithyourJ1939toUSBadaptor.
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SettingtheJ1939POWERCELLAddressEachJ1939POWERCELLorJ1939inMOTIONCellmusthaveitsownuniqueaddressforthenetworktoworkcorrectly.TheaddressissetbyarrangingjumpersinabinarypatternunderthecoverofthePOWERCELL.Figure2showsthelocationoftheaddressheadersonthePOWERCELL.
Figure2:LocationoftheAddressHeadersontheJ1939POWERCELL.
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Figure3showshowtoproperlyorientthejumpersontheheaderstosetthecelladdress.
Figure3:CorrectOrientationoftheAddressHeaders.
CANParameterSetupForPGN’sintherangeofFF00throughFF0F,thefirst60ofthe64bitsintheavailable8bytescorrespondtooutputsonthecellsattachedtotheJ1939network.A(1)inanyofthesebitswillcauseitscorrespondingcelloutputtoreactbasedonitsconfigurationtable.OnoneJ1939network,therecanbetwodifferentgroupsofJ1939inputdevicesassignedtoPGN’sFF00throughFF0F.J1939inputdevicesinGroup1canbeassignedPGN’sFF00throughFF07andcancontrolPOWERCELLorinMOTIONcellsaddressedatA1,A2orA3..J1939inputdevicesinGroup2canbeassignedPGN’sFF08throughFF0FandcancontrolPOWERCELLorinMOTIONcellsaddressedatA4,A5orA6.SwitchesassignedtoGroup1cannotcontrolcellsassignedinGroup2.SwitchesinGroup2cannotcontrolcellsassignedinGroup1.SeeFigure4formoredetails.
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Figure4:Groups,PGN’sandCellAddressesforJ1939Network.Table7summarizesthecontrolbits,theassignedpersonalitiesandthedetailsforeachoutputintheGroup1cells.Table7:ControlBitDetailsforGroup1Outputs.
7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Cell Address 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 1 1
Cell Output 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2
Connector B B B B B A A A A A B B B B B A A A A A B B B B B A A A A A B B
Cavity ID B C D E F F E D C B B C D E F F E D C B B C D E F F E D C B B C
Personality
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Toggle
Toggle
7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Cell Address 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 2 2 X X X X
Cell Output 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 6 7 8 9 10 9 10 X X X X
Connector B B B A A A A A B B B B B A A A A A B B B A A A A A A A X X X X
Cavity ID D E F F E D C B B C D E F F E D C B B C D E F F E D C B X X X X
Personality
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Track: PWM 50%
Track: PWM 50%
Track: PWM 50%
Post Time: 30 Sec.
Post Time: 60 Sec.
Toggle Time: 30 Sec.
Track: Pattern
Track: Pattern
Track: Pattern
Track: Pattern
X X X X
Byte 5 Byte 6 Byte 7 Byte 8
Byte 1 Byte 2 Byte 3 Byte 4
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Table8summarizesthecontrolbits,theassignedpersonalitiesandthedetailsforeachoutputintheGroup2cells.Table8:ControlBitDetailsforGroup2Outputs.
7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Cell Address 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 4 4
Cell Output 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2
Connector B B B B B A A A A A B B B B B A A A A A B B B B B A A A A A B B
Cavity ID B C D E F F E D C B B C D E F F E D C B B C D E F F E D C B B C
Personality
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Track
Toggle
Toggle
7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Cell Address 4 4 4 4 4 4 4 4 5 5 5 5 5 5 5 5 5 5 4 4 4 4 4 4 4 4 5 5 X X X X
Cell Output 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 1 2 3 6 7 8 9 10 9 10 X X X X
Connector B B B A A A A A B B B B B A A A A A B B B A A A A A A A X X X X
Cavity ID D E F F E D C B B C D E F F E D C B B C D E F F E D C B X X X X
Personality
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Toggle
Track: PWM 50%
Track: PWM 50%
Track: PWM 50%
Post Time: 30 Sec.
Post Time: 60 Sec.
Toggle Time: 30 Sec.
Track: Pattern
Track: Pattern
Track: Pattern
Track: Pattern
X X X X
Byte 5 Byte 6 Byte 7 Byte 8
Byte 1 Byte 2 Byte 3 Byte 4
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POWERCELLPersonalityGlossaryTheJ1939POWERCELLhasapre‐configuredlibraryofpersonalitiesthatdefinehowtheoutputreactswhenitreceivesaJ1939command.Thefollowinglistdescribesthesedifferentpersonalitiesandtheirbehaviors.
TrackTrackisthemostbasicpersonality.Theoutputtracksthestateoftheinput.WhentheJ1939switchispressedorlatchedintoanONposition,itisbroadcastinganONcommandtothePOWERCELLoutput.ThatoutputwillremainONaslongastheJ1939inputdeviceisbroadcastingtheONcommand.WhentheJ1939inputdevicebroadcastsanOFFcommand,thePOWERCELLoutputturnsOFF.
ToggleThetogglepersonalitylatchesthestateofthePOWERCELLoutputineitheranONorOFFstatebasedonreceivingacommandfromtheJ1939inputdevice.TheJ1939inputdevicebroadcastsacommandindicatingthatthestateoftheswitchhaschangedfromOFFtoONandbacktoOFFagain.ThisactioncausesthePOWERCELLtochangethestateoftheoutputfromOFFtoONorONtoOFF.ThisistobeusedwithJ1939inputsdevicesthathaveamomentarymechanicalactionandbroadcastachangeinswitchstateinthepressedpositionoftheswitch.
PulseWidthModulation(PWM)ThePoweroutputsarecontrolledbysolid‐stateMOSFETs.ThisallowsthePOWERCELLtovarytheamountofpowercomingoutofanoutputbypulsingtheoutputrapidly.Thisallowsforeasycontroloflightdimming,heatercontrolandmotorspeed.ThedefaultPWMdutycycleforaJ1939POWERCELLoutputis50%.ThebasefrequencyofthePWMpulseis200Hz.Customdutycyclesandbasefrequenciesareavailable.Contacttechnicalsupportformoreinformation.NOTE:PulseWidthModulationofinductiveloadswillrequireaquenchingdiodetosuppressanyback‐EMF.Consultthemanufacturerofyourloadformoreinformation.FailuretoinstallquenchingdiodeswillresultindamagetothePOWERCELLoutputandvoidthewarrantyofthecell.
Post‐Time
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APostTimeoutputisaTrackoutputwithdelaybuiltintoit.TheoutputturnsONwiththeJ1939input.WhentheJ1939inputturnsOFF,thePOWERCELLoutputremainsONforapresetperiodoftime.Thestandardconfigurationhasoptionsfor30and60seconds.Customtimingisavailable.Contacttechnicalsupportformoreinformation.
ToggleTimeToggleTimesetsatimeronthePOWERCELLoutputbasedonamomentaryinputfromtheJ1939inputdevice.AmomentarypressoftheinputswitchwillcausethePOWERCELLoutputtoturnONforapresetperiodoftime.ThePOWERCELLoutputwillturnOFFafterthispresetperiodoftimeregardlessforhowlongtheJ1939inputswitchispressed.Thestandardtimervalueis30secondsfromthepressoftheJ1939inputswitch.Customtimingisavailable.Contacttechnicalsupportformoreinformation.
Track:PatternTrackPatternisatrackingpersonalitythatgeneratesapatternapproximatingavehicleturn‐signal.ThePOWERCELLoutputwillturnONandOFFatarateofapproximatelyonecycleper2seconds.Theduty‐cycleofthepatternisapproximately50%.Custompatternsareavailable.Contacttechnicalsupportformoreinformation.
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PoweringtheSystemOncetheJ1939inputdevicesareproperlysetupandconfigured,connectthenetworkto+12voltsthroughtheinputharnessestothecells.After3seconds,thesystemwillbecommunicatingwiththeJ1939inputdevices.ThereisablueLEDlocatedtowardsthecenterofthePOWERCELLundertheclearcover.Thislightindicatesthestatusofthecommunicationonthenetwork.Whenthesystemisproperlyconnectedandcommunicating,thelightshouldblinkattherateestablishedontheHMIswitchpanel.ThelightwillalsoflashwhenitreceivesaswitchcommandfromoneoftheJ1939inputdevicesonthenetwork.IftheblueLEDturnsonandstaysonafterpowerisappliedtothesystem,checktheconnectorsintheJ1939networkorchecktomakesurethatthe120‐Ohmterminatorresistorisproperlyinstalledinthenetwork.AsteadybluelightindicatesthatthePOWERCELLprocessorisoperatingbutthereisnocommunicationontheJ1939network.IftheblueLEDdoesnotilluminateatall,checktomakesurethatyouaregettingpowertothePOWERCELL.
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WarrantyInformationInfinitybox,LLC(“Infinitybox”)warrantsagainstanydefectsinmaterialsandworkmanshiptotheProduct’smodules,wiringharnessesandaccessorymodulesforaperiodofone(1)yearfromthefirstdateofpurchase.Subjecttothetermsofthiswarrantydescribedbelow,InfinityboxwillreplaceanysuchdefectiveProductthatisreturnedtoInfinityboxwithintheone(1)yearperiodfrominitialpurchase.ReplacementofanydefectivepartorProductwillnotextendtheapplicablewarrantyperiod.Thewarrantydoesnotapplyto:(i)anyProductthatisnotinstalledincompliancewiththeapplicableProductdocumentation;(ii)anydefectin,orfailureof,theProductresultingfromanaccident,shock,negligence,waterimmersionormisuse;(iii)anyProductthathasbeenmodified,adjusted,repaired,ordisassembledbyanypartyotherthanInfinitybox;or(iv)anydefectotherthaninmaterialsandworkmanship.ThiswarrantycoversonlytheoriginalpurchaserofProductpurchasedfromanInfinityboxauthorizeddealerintheUnitedStates.Inordertoreceivewarrantyservice,purchasermustprovideInfinityboxwithacopyofthereceiptstatingthedealername,productpurchasedanddateofpurchase.Productsfoundtobedefectiveduringthewarrantyperiodwillbereplaced(withaproductdeemedtobeequivalentorbetter)atthediscretionofInfinitybox.Infinitybox’ssoleliabilityforanydefectiveProductislimitedsolelytothereplacementofProductpursuanttothiswarranty.Infinityboxreservestherighttoreplaceanyrepairablepartswithneworrefurbishedparts.INFINITYBOXDISCLAIMSALLOTHERWARRANTIES,WHETHEREXPRESS,IMPLIEDORSTATUTORY,SUCHASWARRANTIESOFMERCHANTABILITYANDFITNESSFORPURPOSE.INNOEVENTSHALLINFINITYBOXBELIABLEFORANYPUNITIVE,INDIRECT,INCIDENTALORCONSEQUENTIALDAMAGES,INCLUDINGWITHOUTLIMITATION,LIABILITYFORLOSSOFUSE,LOSSOFPROFITS,LOSSOFPRODUCTORBUSINESSINTERRUPTIONHOWEVERTHESAMEMAYBECAUSED,INCLUDINGNEGLIGENCE.