Output Module

The system Output Module connects to the genisys modular system providing a safe, internally fused, high power output switching system. Safety is assured by means of onboard current monitoring and feedback to the System ECU allowing the outputs to be disconnected should a user defined fault condition occur. Beyond this, each output channel is internally fused preventing excessive current or heat build up in case of a short circuit.

Outputs are controlled by semi conductor switches rather than mechanical relays. These provide longer operating life, faster switching, and require very little drive current. Each output includes a dedicated resettable fuse allowing them to disconnect safely without the need for system interaction. Semi conductor switches, however, have slight electrical losses causing heat to be generated. This typically limits the power handling capability of electronic switching modules. At Carnation, this has always been a concern, but with efficient thermal management and state of the art switching technologies, the genisys output modules can deliver up to 150A per module, with a maximum of 30A available on 2 dedicated high output channels.

150A Total output current per module
2x30A Rated outputs
14x15A Rated outputs
Short Circuit and Overload detection
100ms Update rate

The output module is available in a number of driver variations. The primary module consists of 16 high-side drivers rated at 2x30A and 14x15A outputs. A high/low side option is available giving 2x30A, 12x15A high-side and 2x15A low-side drivers. For the low side option, an Anderson style ground connector, is used to sink the load current through the module. A lower cost unit is available giving 8 high-side outputs, 1x30A and 7x15A.
The enclosure houses power and status LEDs and an array of output status indicators. Module labels are generated by the PC configuration tool showing the type of output connected to each channel, allowing rapid trouble shooting of wiring faults. Each output can be in one of four states as indicated on the label:

1) Output Off – No fault (Indicator OFF)
2) Output On – No fault (Indicator GREEN)
3) Output On – Current nearing user defined threshold (Indicator ORANGE)
4) Short circuit detected (Current > Upper Theshold + 5A), output has been disconnected (Indicator RED)

Each output channel can have two current levels associated with it, a minimum and maximum current that is expected during normal operation. If the current draw reaches this maximum level than an indicator light for that output channel turns orange to signify this. If the current exceeds the maximum level by over 5A for more than a short period of time, for example in the event of a short circuit in the wiring or a stalled motor, the output is turned off and the indicator light turns red. This corresponds to software “fuse rating”. If this condition occurs, the System ECU can notify the operator by means of a text display on an 18 Way keypad or touch-screen interface along with an audible alert – both programmable by the user.

The minimum current level can be set to alert the user of open-circuit conditions such as a blown bulb or heater filament since the current draw will drop below this level. Again, text and audible alerts can be used to warn the operator. In such a manner, genisys can provide fast, reliable switching of high current loads whilst maintaining an unsurpassed level of safety and flexibility.

Electrical/Mechanical Specifications