MSEL Master Relay User manual

Master Relay

User’s Manual

www.msel.com | [email protected] | +64 9 525 2991

 
Contents 
Description..............................................................................................................................1 
 Safety Precautions...........................................................................................................1 
Installation...............................................................................................................................3 
Mounting ............................................................................................................................................. 3 
Electrical Connection .......................................................................................................................... 3 
Switch Connection .............................................................................................................................. 4 
PDM / ECU Connection ...................................................................................................................... 5 
CAN Bus Connection.......................................................................................................................... 5 
Master Relay States ...............................................................................................................6 
LED Indicator States........................................................................................................................... 6 
Battery Connected .............................................................................................................................. 6 
Battery Isolated................................................................................................................................... 7 
Resetting the Device...............................................................................................................8 
Load Dump Protection ............................................................................................................ 8 
Shutdown Delay......................................................................................................................8 
Temperature Monitoring .........................................................................................................9 
Load Current Monitoring.........................................................................................................9 
Power Saving Mode................................................................................................................9 
CAN Communications ..........................................................................................................10 
Message Format............................................................................................................................... 10 
CAN Shutdown ................................................................................................................................. 12 
Device Configuration ............................................................................................................13 
Changing the base CAN Identifier .................................................................................................... 13 
Changing the CAN Baud Rate & Shutdown Delay ........................................................................... 14 
Changing the PDM Output Drive Configuration................................................................................ 15 
Setting up CAN Shutdown ................................................................................................................ 16 
Specifications........................................................................................................................18 
Drawing.................................................................................................................................19 
Revision History....................................................................................................................20 

Master Relay - User’s Manual 1

Description

The Master Relay is a battery isolator that goes much further than just safety in mind. It has

been designed with the sole purpose of a motorsport environment. Utilising solid state

switching components, the Master Relay has excellent temperature resistance, as well as an

aluminium enclosure that is lightweight and robust in even the harshest motorsport

environment.

The Master Relay not only has built in engine shutdown functionality in accordance to FIA

regulations, it also incorporates alternator load dump protection unavailable on most rival

devices. This helps to avoid nasty voltage spikes often seen when disconnecting the battery

source whilst the alternator is still charging.

The device can safely shut down the vehicle under a number of different events including:

external kill switch press, over current / short circuit, over temperature, and can even be shut

down via a remote CAN message. For example, in the event of a severe impact or an

overturned.

When connected to a data logger on a CAN bus, the Master Relay provides valuable

information about the current, voltage and internal temperature, as well as diagnostic

information that makes finding problems a lot easier. As well as transmission to a data logger

the Master Relay has a multi-coloured LED that shows a unique colour combination for each

of the 10 different states. The driver switch can also be connected with an LED to show when

the battery is isolated.

Safety Precautions

These instructions provide vital information to the safe and desired installation of the Master

Relay. Please ensure you are familiar with the entire process before installing this device into

your car. Failure to comply with these instructions could damage the Master Relay or other

components in the vehicle.

The Master Relay must be completely disconnected before any welding is conducted on the

installed vehicle.

The Master Relay should always have the PDM output connected and correctly shutting the

engine down. Failure to do so could damage not only the Master Relay but also other

computers connected in the vehicle such as ECUs, displays, control units etc.

While all efforts are made to ensure the accuracy of the information in this manual, no

responsibility will be taken for the consequences of any omissions in this manual.

Figure 1: Connection Diagram

Master Relay - User’s Manual 3

Installation

Mounting

The MSEL Master Relay has two tags designed for mounting the device to a flat surface. The

spacing between the mounting holes is 84mm (see Drawing for details). The location of the

Master Relay, as well as the total current load, can have significant effect on the internal

temperature of the Master Relay. Where possible try to mount the Master Relay away from

significant heat sources.

Electrical Connection

The Master Relay is connected between the positive terminal of the battery and the rest of

the vehicles positive power supply. The device should be positioned as close to the battery

as possible, keeping the positive lead as short as you can. See the Connection Diagram for

a typical installation.

ENSURE THAT THE GROUND CONNECTION IS MADE BEFORE CONNECTING THE

BATTERY AND VEHICLE TERMINALS.

Power Studs

The battery and output terminals are copper plated M6 studs. Care should be taken to

ensure that cables are insulated from the housing and neighbouring studs. It is

recommended to use the supplied nut caps with insulated lugs, or for maximum

protection, rubber insulating boots can be used on each stud.

Interface Connector

All low current connections are made through a single 6-way Souriau mil-spec connector;

keeping things tidy, protected and allowing for quick removal / installation.

The mating connector (Souriau 8STA6-04-06SN) can be purchased individually for

custom installs or a breakout harness with DTM connectors is available for generic

installs.

Table 1: Interface connector pinout

Function

Colour

Ground

Black

Driver Switch

Blue

External Switch

Orange

PDM / ECU Output

Brown

CAN L

Green

CAN H

Yellow

Table 1 shows the pinout along with the standard wiring colours supplied with the breakout

harness. For those making a custom harness the Souriau connector has #26 terminals

and accept 30AWG through to 24AWG wire.

Switch Connection

The Master Relay is controlled by two types of switch, the driver kill switch and the external

kill switch.

Driver Kill Switch

The driver kill switch is generally operated from within the vehicle and is the main control

for the battery isolation. Generally, just a single driver kill switch is used, however multiple

switches can be wired as shown in Multiple Switches, the extra switch could be hidden

and used as an additional security measure.

Wiring of the driver kill switch is carried out as shown in the Connection Diagram. The

switch used should be of a latching type (either toggle or push button). When the switch

is in the off position there should be an open circuit between the two terminals. One side

of the switch connected to pin 2 of the Master Relay connector, and the other side is

connected to ground.

An LED can be added to the circuit as shown in Figure 2. This LED will be on solid when

the device is in the normal state, flash when the battery is isolated, and be turned off when

the driver switch is off.

Figure 2: LED indicator wiring

External Kill Switch

The external kill switch allows remote triggering of the Master Relay. It is often mounted

on the exterior of the vehicle and indicated by a red lightning bolt on a blue triangle.

Multiple external switches can be wired as shown in Multiple Switches. If an external

switch is not required, pin 3 of the Master Relay connector should be permanently

connected to ground.

Wiring of the external kill switch is carried out as shown in the Connection Diagram. The

switch used should be of a momentary non-latching type with a normally closed (NC)

configuration. When the switch is pressed there should be an open circuit between the

two terminals. One side of the switch is connected to pin 3 of the Master Relay connector,

and the other side connected to ground.

Multiple Switches

Multiple external kill switches can be connected in series provided that when all switches

are in the ‘ON’ position there is continuity between the input to the Master Relay and

ground. When any switch is in the ‘OFF’ position the connection to ground should be open

circuit. See Figure 3 for examples of multiple switch configurations.

Master Relay - User’s Manual 5

Figure 3: Example multiple external switch configuration

PDM / ECU Connection

Pin 4 of the Master Relay connector provides a logical output for a PDM / ECU allowing engine

shutdown functionality in accordance with FIA rules. The drive of this output can be configured

in the combinations shown in Table 2 below. The device ships standard with configuration 0

(active high, half bridge). In this configuration when the Master Relay is in an ‘On’ or ‘Normal’

state the output is connected to the battery supply, and when ‘Off’ the output is connected to

ground.

Table 2: PDM output drive configurations

Active State

Output Drive

Config.

Output 'On'

Output 'Off'

High

Half Bridge

Vbattery

GND

Low Side

GND

High Side

Vbattery

Low

Half Bridge

GND

Vbattery

Low Side

GND

High Side

Vbattery

In order to change the output drive to one of the other configurations please refer to Changing

the PDM Output Drive Configuration, or specify your requirements when purchasing.

The PDM / ECU output is short circuit protected and current limited to 200mA. To drive larger

loads an external relay is recommended.

CAN Bus Connection

To receive status and channel information from the Master Relay it must be connected to a

compatible device on the same CAN bus. Examples of these include a data logger, dash

display, or ECU. The Master Relay transmits two messages on a configurable address and is

compatible with most CAN capable data loggers on the market. For further information on the

format and transmission refer to the CAN Communications section.

The Master Relay does not have any internal termination resistors and therefore requires

100R termination resistors at each end of the CAN bus.

Master Relay States

LED Indicator States

The table below shows the corresponding states for each of the possible colour codes

displayed on the status LED.

Table 3: LED indicator states

Status

LED Colour

Normal



Green

(CAN Error)

/

Green Flashing

Over Temperature Warning

/

Blue Flashing

Over Current Kill



Yellow

Low Voltage Warning

/

Green/Blue Flashing

High Voltage Warning

/

Green/Red Flashing

Over Temperature Kill

/

Blue/Red Flashing

Driver Switch Kill



Red

External Switch Kill

/

Red Flashing

CAN Trigger Kill



Blue

Power On Reset



Purple

Battery Connected

Normal Operation

The battery is connected to the output and the device is operating normally.

Normal Operation (CAN Error)

The device is operating normally; however, the CAN bus has been unresponsive for more

than 2 transmission cycles. CAN communications have been disabled until the CAN bus

is back online (this is checked every 5 seconds).

Over Temperature Warning

The device temperature has exceeded the warning temperature (90°C). The device will

continue to function normally; however, the temperature is getting close to the device

limits. This should be remedied to avoid undesired performance and/or potential damage.

Once the fault is remedied the device will automatically return to normal operation.

Low Voltage Warning

The device voltage has dropped below the lower warning limit (7V). The device will try to

continue to function normally, however the voltage is getting close to the device limits.

This should be remedied to avoid undesired performance and/or potential damage.

Once the fault is remedied the device will automatically return to normal operation.

Master Relay - User’s Manual 7

High Voltage Warning

The device voltage has exceeded the upper warning limit (28V). The device will try to

continue to function normally, however the voltage is getting close to the device limits.

This should be remedied to avoid undesired performance and/or potential damage.

Once the fault is remedied the device will automatically return to normal operation.

Battery Isolated

Driver Kill

The driver kill switch has been turned off or the connection has broken. The battery is

disconnected and the indicator will be solid red.

The device will remain in this state for 30 seconds before entering a low power state. To

return to normal operation a reset is required (see Resetting the Device).

External Kill

The external kill switch has been triggered or the connection has broken. The battery is

disconnected and the indicator will be flashing red.

To return to normal operation a reset is required (see Resetting the Device).

CAN Kill

A CAN message has triggered a shutdown. The battery is disconnected and the indicator

will be solid blue. See CAN Shutdown for further details on the CAN kill function.

To return to normal operation a reset is required (see Resetting the Device).

Over Temperature Kill

The device temperature has exceeded the maximum allowed temperature (110°C). The

battery is disconnected and the indicator will be flashing red and blue.

Once the fault is remedied the device will automatically return to normal operation.

Power On Reset

The device has been powered on with the driver & external switches on. The battery

remains disconnected and the indicator will be solid purple.

To return to normal operation a reset is required (see Resetting the Device).

Over Current Kill

The device temperature has exceeded the maximum allowed current. The battery is

disconnected and the indicator will be solid yellow.

Check for any short circuits between the output terminal and the chassis ground. To return

to normal operation once the fault is remedied, a reset is required (see Resetting the

Device).

Resetting the Device

Once the device has been triggered by one of the 5 faults (external kill, driver kill, CAN kill,

over-current kill or over-temperature kill) the device will remain in the off state until reset. The

LED indicator will show the current fault as outlined in LED Indicator States.

Once the fault has been remedied the device can be reset by cycling the driver kill switch off

and then back on.

Load Dump Protection

The Master Relay has on board circuitry that will help protect sensitive electronic devices in

the event of a shutdown during engine operation. The PDM output will be turned off

immediately therefore stopping the engine. However, the battery is not disconnected until the

alternator is no longer charging. This avoids the situation where the alternator may still be

generating as the battery is disconnected, resulting in voltage spikes as large as 120V that

can damage sensitive electronic components.

The Master Relay has a 5 second timeout where by even if for some reason the battery is still

being charged it will be disconnected regardless (this can be extended by specifying a longer

shutdown delay, see Shutdown Delay).

Shutdown Delay

The Master Relay can be programmed to delay switching the battery power off to allow for

diagnostic data logging. The shutdown delay is in addition to the load dump protection delay

described in Load Dump Protection. Therefore, the battery is guaranteed to be connected for

the duration of the shutdown delay, except for an over current event where the battery is

disconnected immediately to prevent potential damage.

The recommended procedure for this is to use a PDM or ECU to shut down the engine and

disable everything except the data logging systems. This allows these devices to receive the

shutdown event information and store it before shutting down.

The table below indicates the recommended delay times for different data logging systems:

Table 4: Recommended shutdown delay times

Data Logging Device

Shutdown Delay

All MoTeC products

1.0 seconds

All devices are shipped with no additional shutdown delay, in order to activate this feature

please request it at the time of purchase, or program the desired delay as described in

Changing the CAN Baud Rate & Shutdown Delay.

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