Vector VC-VCCU Technical Reference

Document Information

History

Reference Documents

Safety Instructions

Caution

To avoid personal injuries and damage to property you have to read and understand the following safety instructions and hazard warnings prior to installation and use of this ECU. Keep this documentation always near the ECU.

Proper Use and Intended Purpose

Caution

The ECU may only be operated according to the instructions and descriptions of this manual. The ECU is exclusively designed for use by skilled personnel as its operation may result in serious personal injuries and damage to property. Therefore only those persons may operate the ECU who have understood the possible effects of the actions which may be caused by the ECU. Users have to be specifically trained in the handling (e.g. calibration) with the ECU, the applied embedded software and the system intended to be influenced. Users must have sufficient experience in using the ECU safely.

Hazard Warnings

Caution

The ECU may control and/or otherwise influence the behavior of control systems and electronic control units. Serious hazards for life, body and property may arise, in particular without limitation, by interventions in safety relevant systems (e.g. by deactivation or otherwise manipulating the engine management, steering, airbag and/or braking system) and/or if the ECU is operated in public areas (public traffic). Therefore you must always ensure that the ECU is used in a safe manner. This includes inter alia the ability to put the system in which the ECU is used into a safe state at any time (e.g. by "emergency shutdown”), in particular without limitation in the event of errors or hazards. Furthermore all technical safety and public law directives which are relevant for the system in which the ECU is used must apply. Provided that serious hazards for life, body and property may occur and before the use in public areas the system in which the ECU is used must be tested according to recognized rules of engineering in a non-public area.

Contents

1. General ......................................................................................................................................... 7
2. System Architecture ...................................................................................................................... 8
• 2.1 Supported Peripherals .......................................................................................................... 9
3. ECU ............................................................................................................................................. 10
• 3.1 ECU Overview ..................................................................................................................... 10
• 3.2 Key ECU Characteristics ..................................................................................................... 11
4. Functional Overview ..................................................................................................................... 12
• 4.1 Power Line Communication ................................................................................................. 12
• 4.1.1 Low Level communication with EVSE ........................................................................... 12
• 4.1.2 AC Charging with Low Level Communication ................................................................. 12
• 4.1.3 DC Charging with High Level Communication ............................................................... 13
• 4.2 Stop Button .......................................................................................................................... 13
• 4.3 StopCharge CAN Signal ..................................................................................................... 14
• 4.4 Generic switch input ............................................................................................................ 14
• 4.5 Terminal 15 signal input ...................................................................................................... 14
• 4.6 Status LEDs ......................................................................................................................... 14
• 4.7 High Side Outputs ................................................................................................................ 14
• 4.8 Reprogramming of the ECU Software .................................................................................. 15
• 4.9 Self-diagnostics and fault memory ..................................................................................... 15
• 4.10 ECU state handling ............................................................................................................ 15
• 4.11 Coupler present detection ................................................................................................... 16
• 4.12 Locking / unlocking the Combo2 and Combo1 coupler ................................................... 16
• 4.13 Temperature monitoring ..................................................................................................... 16
• 4.14 Configuration of Software ................................................................................................. 16
• 4.15 Value Added Services (VAS) .............................................................................................. 17
• 4.16 Charging Arbitration ........................................................................................................... 17
5. Qualification ................................................................................................................................ 18
• 5.1 Configuration ...................................................................................................................... 18
• 5.2 Electrical Tests ..................................................................................................................... 18
• 5.3 EMC Test ............................................................................................................................. 19
• 5.4 Climatic Tests ...................................................................................................................... 19
• 5.5 Mechanical Tests ................................................................................................................. 20
• 5.6 Life Tests ............................................................................................................................. 20
• 5.7 Chemical Tests ..................................................................................................................... 20
6. Industrialization .......................................................................................................................... 22
7. Delivery Content .......................................................................................................................... 23
• 7.1 ECU ..................................................................................................................................... 23
• 7.2 Packaging ........................................................................................................................... 23
• 7.3 Software ............................................................................................................................. 24
• 7.4 Technical Documents ............................................................................................................ 24
• 7.5 Quality Documents ............................................................................................................... 24
8. Glossary and Abbreviations ........................................................................................................ 26
• 8.1 Glossary and Abbreviations ................................................................................................ 26
9. 9 Contact ..................................................................................................................................... 27

Illustrations

• Figure 1-1 VC-VCCU ...................................................................................................................... 7
• Figure 2-1 System Overview ........................................................................................................... 8
• Figure 3-1 VC-VCCU Interfaces ..................................................................................................... 10
• Figure 7-1 VC-VCCU packed in cardboard package ...................................................................... 23

Tables

• Table 1-1 Delivery Content ............................................................................................................ 7
• Table 3-1 VC-VCCU Key Characteristics ....................................................................................... 11
• Table 4-1 Low Level Communication – Duty Cycle of CP PWM ................................................... 12
• Table 5-1 Qualification configuration ........................................................................................... 18
• Table 8-1 Glossary and Abbreviations .......................................................................................... 26

1 General

The Vector Controller - Vehicle Charge Control Unit (VC-VCCU) is a generic ECU for 24V environments. It realizes electrical charging according to DIN SPEC 70121 see [1] and ISO 15118 see [5] for power line communication (PLC) with the infrastructure.

The Hardware basis is the VC36PLC-24 with an integrated flash bootloader. The VC-VCCU also includes an AUTOSAR 4 stack with a charging application flashed on the hardware.

A textual description of the VC-VCCU hardware is provided below:

The device is a rectangular metal casing with a black connector on one side. It has various labels on its surface, including "VECTOR", "VC-VCCU", "SW-Rev", "HW-Rev: 3.0.0", "FBL-Rev: 2.0.0", "-Rev: 2.0.0", "PROTOTYPE", and "IP67".

Delivery Content

2 System Architecture

The VC-VCCU is designed to be integrated into the vehicle with the following system architecture.

A textual description of the system overview diagram is provided below:

The diagram shows the VC-VCCU connected to various components within an electric vehicle (EV) and the Electric Vehicle Supply Equipment (EVSE). The EVSE is connected to a Conductive Charge Spot. The VC-VCCU receives power and signals from the EVSE via the CCS inlet on the EV. It communicates with other vehicle systems like the Battery Management System (BMS), Vehicle Control Unit (VCU), and Rechargeable Energy Storage System (RESS) via different communication buses, including a J1939 Vehicle CAN bus. The VC-VCCU also manages the charging process, including inlet locking and temperature monitoring.

2.1 Supported Peripherals

The supported peripherals depend on the VC-VCCU variant:

VC-VCCU CCS-1 (Combo 1 Inlet):

• Phoenix CCS Type 1 Inlet EV-T1GBIE12-1AC series (inlet w. lock)

VC-VCCU CCS-2 (Combo 2 Inlet):

• Amphenol HVCO-CF6-ATR8-SF series (inlet) & C-NEVDC12V_ELOCK (lock)
• Phoenix CCS Type 2 Inlet EV-T2GBIE12-1AC series (inlet w. lock)
• Phoenix CCS Type 2 Inlet EV-T2GBIE12-3AC series (inlet w. lock)
• REMA REV-2C series (inlet) & REMA CCS Actuator (lock)

Caution

The VC-VCCU CCS-1 variant has restriction due to hardware modifications:

• No over voltage protection on PP (pin 2K) in 24V systems (short-circuit)
• No open load detection on PP (pin 2K)
• PP detection (HV charging connector plugged/unplugged) is unreliable

Once other inlets are used than mentioned above, please contact the Vector support in order to check the compatibility with the VC-VCCU.

3 ECU

This chapter contains an overview about the VC-VCCU. A detailed description of the electronics and housing can be found in the User Manual of the VC-VCCU [4].

3.1 ECU Overview

The following diagram and tables give an abstract overview of the interfaces of the hardware.

Note

There are many different configuration options for the hardware of the VC-VCCU. The following figure shows the configuration of the VC-VCCU. The VC-VCCU is based on the hardware platform VC36PLC-24.

A textual description of the VC-VCCU Interfaces diagram is provided below:

The diagram illustrates the various interfaces of the VC-VCCU. It includes inputs for Clamp 30, 31, Sensor Supply (5V, 70mA), Analog Inputs for Temperature Sensors, Analog Input for Plug Present, Analog Input for Inlet latch motor position, Digital Inputs for Charging stop switch and Generic switch, and a Wake Input for Terminal 15. It also shows outputs for 3x LED Output, 1x High Side Output (VBAT, 5A), 2x High Side Output (VBAT, 200mA), and 1x H-Bridge 12V 5A Latch motor drive. Communication interfaces include 2x CAN HS and 1x PLC (CP, PE). The central unit is the VC-VCCU, which has Voltage Supply (VBAT 10...32V) and Power Management (incl. Window-Watchdog) capabilities. Diagnostics are indicated for several interfaces.

3.2 Key ECU Characteristics

4 Functional Overview

4.1 Power Line Communication

4.1.1 Low Level communication with EVSE

According to [2] and [3] a low-level communication via PWM on the CP pin is supported. The following PWM duty cycles are valid:

4.1.2 AC Charging with Low Level Communication

With the low-level communication, AC charging can be performed in the following sequence:

• Lock coupler after plugged into inlet
• Establish communication to EVSE via CP
• Get charging clearance from vehicle
• Start charging
• Continuous monitoring of charging progress
• Vehicle state monitoring; Stop button monitoring; Temperature monitoring; EVSE communication; Self-diagnostic of actuators/sensors
• Stop charging
• Release coupler after a pressed stop button or a CAN signal

Note

For detailed information, please refer to the AC Charging diagram.

4.1.3 DC Charging with High Level Communication

According to [1] and [5], high level communication for DC charging is supported. The supported charging profile is EIM (External Identification Means).

Caution

Plug and Charge is not supported by the VC-VCCU.

The DC charging is done in the following sequence:

• Lock coupler after plugged into inlet
• Get charging clearance from vehicle
• Session setup with EVSE
• Parameter exchange with EVSE (charging mechanism, schedule tables...)
• Isolation measurement with EVSE
• Start pre-charge
• Start charging
• Continuously monitoring of charging progress
• Vehicle state monitoring; Stop button monitoring; Temperature monitoring; EVSE communication; Self-diagnostic of actuators/sensors
• Stop charging
• Release coupler after a pressed stop button or a CAN-signal

Note

For detailed information, please refer to the DC Charging diagram. The first schedule table from EVSE will always be accepted on the protocol layer but ignored in the application (charging will start immediately, independent from the received schedule table).

4.2 Stop Button

The button is monitored continuously when the VC-VCCU is active. If the button is pressed, the charging is stopped, the coupler will be unlocked.

4.3 StopCharge CAN Signal

The StopCharge CAN Signal is monitored continuously when the VC-VCCU is active and the feature is activated. If the StopCharge CAN Signal is set to pressed, the charging is stopped, the coupler will be unlocked. See also warning above.

Caution

The voltage levels at the inlet power supply pins are not checked by the VC-VCCU prior to unlocking the coupler. This must be done by the other system components and controlled by the CAN signal which sets the signal VCVCCU_Vehicle_PlugUnlockPermission. Please refer to the UserManual_VC-VCCU, chapter 4.5.3. for details.

4.4 Generic switch input

An additional digital input to connect an additional button. Besides, the generic input is used for the charging arbitration.

4.5 Terminal 15 signal input

If there is the need for a discrete wakeup of the ECU instead of a CAN network wakeup, the Terminal 15 signal input may be used to wake the ECU and keep it awake.

4.6 Status LEDs

The charging status can be displayed via three LED which can be controlled via CAN messages by an external ECU. For more details, please refer to the User Manual of the VCVCCU [4].

4.7 High Side Outputs

Caution

If the VC-VCCU suffers from an unintentional GND contact loss, the freewheeling diode inside HSOUT4 may lead to an unexpected flow of current from HSOUT4 via its external load to GND. As this may lead to undefined behavior of the external load (e.g. a BMS relay), the usage of HSOUT4 must be considered with care. If in doubt, please contact the Vector support.

Three High Side Outputs are available for general purposes which can be controlled via CAN signals by an external ECU. For more details, please refer to the User Manual of the VC-VCCU [4].

4.8 Reprogramming of the ECU Software

Reprogramming will be done via diagnostic CAN (CAN0). Therefore, the UDS protocol will be used. The following reprogramming features are supported:

• Download of one logic block of application and basic software
• Download of one logic block of Ethernet transceiver firmware
• Pipelined programming
• Pipelined verification
• Security via CRC (no signature)

Updater for the flash bootloader itself is not supported

4.9 Self-diagnostics and fault memory

The VC-VCCU continuously monitors all relevant inputs and outputs. The information is available in the self-diagnostic messages of the outputs. In addition to that, the self-diagnostic also includes faults during charging or in case of internal faults. Furthermore, the VC-VCCU includes a fault memory which is able to store several DTCs.

4.10 ECU state handling

An ECU wakeup is performed due to following reasons:

• Terminal 15 signal
• CAN wakeup
• Stop button pressed
• Vehicle coupler connected
• Control Pilot Pin active
• Wake up from real time clock

If the ECU is active there are the following awake reasons possible to stay active:

• Terminal 15 signal
• Control Pilot activity
• CAN active
• Active Diagnostic Session

In all other cases, the VC-VCCU will go to sleep.

4.11 Coupler present detection

For the coupler present detection, the proximity pin (PP) or the PWM signal of the control pilot line (CP) is used.

4.12 Locking / unlocking the Combo2 and Combo1 coupler

The locking / unlocking of the Combo2 and Combo1 coupler is done with a motor, controlled by an H-Bridge.

The coupler will be locked when:

• A vehicle coupler is detected and
• A CAN lock signal is received
• If the coupler was unlocked but not removed after a certain time

The locking is performed after a specified time the coupler was detected.

The coupler will be unlocked when:

• An unlock message is received on CAN and
• The charging stop button is pressed or
• [in case of Combo1] the S3Switch is pressed or
• The StopCharge CAN Signal is pressed

4.13 Temperature monitoring

The supported Combo2 and Combo1 vehicle inlet has 2 temperature sensors:

• One sensor is used for AC charging
• One sensor is used for DC charging

The VC-VCCU has a third temperature sensor Input which might be used for individual purposes. The read temperature is not used for the control of the charging.

4.14 Configuration of Software

The VC-VCCU allows configurations of the firmware on the diagnostic channel:

• Baudrate adjustment between 250 kBaud, 500 kBaud and 1 MBaud on the J1939 CAN
• Automatic switch of high side output to wakeup other ECUs
• Configurable message cycle times of several messages
• Transport Layer Security (TLS) for V2G communication and VAS
• Configurable Security Key Constant

4.15 Value Added Services (VAS)

Value added service are additional service which are not part of the V2G communication and not mandatory for charging. The VC-VCCU supports VAS according to ISO 15118-2 [5] and VDV 261 [6].

4.16 Charging Arbitration

The charging arbitration enables the operation of two VC-VCCUs on the same CAN channel. It targets use cases which require two charging inlets (two VC-VCCUs) per vehicle but only one charging inlet is used for charging at a time.

For charging arbitration, the VC-VCCU provides the following configurations on the diagnostic channel:

• Configuration of Primary Source Address
• Configuration of Secondary Source Address
• Activation/Deactivation of Charging Arbitration

For more details, please refer to the User Manual of the VC-VCCU [4].

5 Qualification

This section describes the qualification of the VC-VCCU. The qualification of Vector ECUs is executed by accredited test labs, according to international standards. Documents with detailed test specification and test results are not provided. Further details on the performed tests could be available on individual request.

5.1 Configuration

The qualification of the VC-VCCU design has been performed in the following configuration of the hardware.

5.2 Electrical Tests

The following electrical tests have been performed:

• E-01 Overvoltage
• E-05 Load dump
• E-06 Superimposed alternating voltage
• E-07 Slow decrease and increase of supply voltage
• E-08 Slow decrease, quick increase of the supply voltage
• E-08 Reset behavior at voltage drop
• E-10 Short interruptions
• E-11 Starting profile
• E-12 Voltage curve with interactive generator regulation
• E-13 Single line interruption
• E-14 Multiple line interruption
• E-15 Reversed voltage
• E-16 Ground reference and supply offset
• E-17 Short circuit protection
• E-19 Quiescent current
• E-22 Overcurrent
• E-23 Direct current supply voltage
• E-24 Voltage transient to engine rpm steps
• E-25 Momentary drop in supply voltage

5.3 EMC Test

The following tests have been performed:

• EMC1 - RF-emissions - Measurements at the artificial network (AN-Test, CISPR 25:2008-03)
• EMC2 - RF-emissions – Measurements with antennas (RE-Test, CISPR 25: 2008-03)
• EMC7 - Transient emissions on supply cables (CTE-Test, ISO 7637-2: 2011-03)
• EMC9 - RF-immunity to Interference – Bulk current injection (BCI-Test, ISO/DIS 114524: 2010-01)
• EMC10 - RF-immunity to interference – Using antennas (ALSE-Test, ISO 11452-2: 2004-11)
• EMC14 - Transients on supply lines (TSUP-Test, ISO 11452-2: 2004-11)
• EMC15 - Transients on lines except supply lines (TOL-Test, ISO 7637-3: 2007-07)
• EMC16 - Electrostatic discharge – Handling Test (ESDH, ISO 10605: 2008-07)
• EMC17 - Electrostatic discharge – Direct discharge (ESDD, ISO 10605: 2008-07)
• EMC18 - Electrostatic discharge – Indirect discharge (ESDI, ISO 10605: 2008-07)

5.4 Climatic Tests

The following climatic tests have been performed:

• K-01 High / Low temperature storage test
• K-02 Temperature step test
• K-03 High / Low temperature operation test
• K-05 Rapid change of temperature with specified transition duration
• K-06 Salt spray tests - Leakage and function test
• K-07 Salt spray tests - Corrosion test
• K-09 Humid heat, cyclic test - Composite temperature/humidity cyclic test
• K-10 Protection against water
• K-11 Steam jet test
• K-12 Ice water shock test - Splash water test
• K-13 Ice water shock test - Submersion test
• K-14 Damp heat, steady-state test
• K-15 Humid heat, cyclic test - Dewing test
• K-19 Temperature cycle with specified change rate

5.5 Mechanical Tests

The following mechanical tests have been performed:

• M-01 Free fall
• M-03 Dust test
• M-04 Vibration test (Profile D)
• M-06 Mechanical shock (Severity II, Drivers door)

5.6 Life Tests

The following life tests have been performed:

• L-02 High temperature endurance test
• L-03 Alternating temperature endurance test

Assumed Life time: 50000h / 15 Years

5.7 Chemical Tests

The following chemical tests have been performed:

• AA - Diesel fuel
• BA - Engine oil
• BE - Greases
• BF - Silicone oil
• CC - Antifreeze fluid
• CD - Urea
• CG - Protective lacquer remover
• CA - Battery fluid
• CE - Cavity protection
• CF - Protective lacquer
• DF - Cold cleaning agent
• DJ - Ammonium containing cleaner
• EB - Transpiration
• ED - Refreshment containing caffeine and sugar
• EF - Cream, coffee whitener
• DB - Vehicle washing chemicals
• DC - Interior cleaner
• DD - Glass cleaner
• DE - Wheel cleaner
• EE - Runway de-icer
• AE - Methanol
• DG - Acetone
• DH - Cleaning solvent
• DK - Denatured alcohol

6 Industrialization

This section describes the elements of the VC-VCCU industrialization, which are installed and released by Vector:

• Production engineering
• Production requirements
• Quality requirements
• Control plan
• P-FMEA
• D-FMEA
• Production installation
• Series Production line for electronic parts
• Automated Optical Inspection (AOI)
• In Circuit Test (ICT)
• Production line for mechanical assembly
• Leakage test
• Generic End of Line Test (EOL)
• Production Specification

The common part of production is described in the Production Specification and is released by Vector.

Note

The documents listed in this chapter are for internal documentation of processes only. They are not released for external use or delivery to Customer.

7 Delivery Content

The VC-VCCU hardware is packed in a single packaging and shipped as off-the-shelf product from Vector warehouse. The standard delivery for software and documents takes place via download link as ZIP file from the Vector homepage.

7.1 ECU

Based on the offer and order, the customer will receive an off-the-shelf product:

• VC-VCCU CCS-2 Series (No.: 120248)
• VC-VCCU CCS-2 Evaluation (No.: 120209)
• VC-VCCU CCS-1 Evaluation (No.: 120265)

The ECUs are stored inside the cardboard package. The goods will be extracted from the stock as per ordered quantity and packed individually within our logistics department in Stuttgart.

7.2 Packaging

The VC-VCCU is packed in a single box (non ESD) with the following description:

• Approximate sizing of a single package: 250 mm x 191 mm x 64 mm (L x W x H, approximately)
• Approximate weight: 0,74 kg (approximately, Cardboard 0,18 kg + ECU 0,56 kg)

A textual description of the VC-VCCU packed in cardboard package image is provided below:

The image shows the VC-VCCU unit inside its cardboard packaging. The unit is a silver-colored metal box with a prominent black connector. The packaging appears to be a standard cardboard box designed to protect the unit during shipping.

Several ECUs in one shipment are packed in overpacks, e.g.:

• 5 ECUs: Approximately 450 x 320 x 320 mm, 5 kg
• 10 ECUs: Approximately 560 x 360 x 310 mm, 10 kg
• 25 ECUs: 800 x 600 x 400 mm, 25 kg

7.3 Software

• VC-VCCU for vFlash package (.vflashpack)
• CANoe project (.cfg)
• CAN J1939 communication matrix (.dbc)
• Diagnosis CAN communication matrix (.dbc)
• Diagnosis description file for CANdela Studio (.cdd)

7.4 Technical Documents

• Release Notes VC-VCCU (.pdf)
• Technical Reference VC-VCCU (.pdf)
• User Manual VC-VCCU (.pdf)
• Charging Sequence Description AC/DC (.pdf)
• Envelope model 3D (STEP)
• VC-VCCU technical drawing (2D)
• VV-Report VC36PLC-24 (.pdf)*

7.5 Quality Documents

The following quality documents can be made accessible to a customer representative remotely:

• PFMEA (Top 10)
• Control Plan

*will be provided if required

8 Glossary and Abbreviations

8.1 Glossary and Abbreviations

9 Contact

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