INSTALLATION MANUAL

2696_06 S1 DECORATION LIGHTING LEDS

INDEX

1 FEATURES .......................................................................................................... 2

1.1 OPERATION .............................................................................................................. 2

1.2 SYSTEM ELEMENTS. .................................................................................................. 2
2 TECHNICAL SPECIFICATIONS ................................................................................ 4

2.1 LIGHTING SYSTEM SPECIFICATIONS: .......................................................................... 4

2.2 TECHNICAL SPECIFICATIONS OF THE CONTROL BOARD: .............................................. 4
2.3 TECHNICAL SPECIFICATIONS OF THE COOL WHITE LIGHT CEILING LEDS: ....................... 5
3 CONNECTOR LAYOUT........................................................................................... 6

3.1 CAR LIGHTING CONTROL BOARD (CIC) ........................................................................ 6

3.1.1 CONNECTOR ALLOCATION .................................................................................... 6
3.1.2 CONNECTOR DETAILS .......................................................................................... 7
3.2 CAR CEILING LIGHT ................................................................................................... 7
3.2.1 CONNECTOR ALLOCATION .................................................................................... 8
3.2.2 CONNECTOR DETAILS. ......................................................................................... 8
4 PARAMETERIZATION ............................................................................................ 8

4.1 MAXIMUM LIGHTING ADJUSTMENT (PUSH BUTTON P2) ................................................ 8

4.2 JUMPER SETTINGS.................................................................................................... 8
5 BOARD REPLACEMENT ......................................................................................... 9

6 REVISION LOG .................................................................................................... 10

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1 FEATURES

The lighting system has two functions; it provides the light statutorily required in normal operation
and serves as an emergency lighting system in case of failure of the normal lighting.
The lighting system S1 comprises 2 subsystems:
i) the car lighting control system and
ii) the car ceiling lighting, the light source itself.
The first subsystem is generic and can be used, within its range of use for any car lighting.
The second subsystem is more specific to car decoration S1 and can be replaced by the
corresponding design for other needs always within the range of use of the lighting control
system.

1.1 Operation

The control subset has two main functions:

i) Controlling the car lighting depending on the system status:
a. Normal operation. While the mains input voltage is present (normal lighting) and is
not acting on the control signals, it functions as normal lighting.
b. Emergency operation. The mains power failure (normal lighting) is automatically
detected, allowing the system to be powered from the battery, until then disabled;
lighting is reduced to the emergency mode lighting. Emergency mode operation lasts
over 5 hours and ends when the battery voltage falls below the proper level to
prevent its deep discharge or when the mains is restored.
c. Energy Saving. Only effective during normal operation. Through the control signal
(X5.3 or X6.3) lighting turns off to reduce power consumption. The behaviour of the
load / battery maintenance is not affected by the energy savings. For appropriate
behaviour, the J2 jumper must be set as indicated in section ¡Error! No se
encuentra el origen de la referencia depending on the control.
d. Maximum illumination setting (for more information, please see section 4.1).
ii) Control the load and the level of the battery that supplies power in emergency operation.

1.2 System elements.

To perform its functions, it is equipped with:

i) Light box (not installed in CMC4+)
ii) An electronic board for Car Lighting Control (C.I.C) which has:
a. A microcontroller-based control system,

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b. a power supply that is capable of modifying the current injected into the ceiling light
so that the lighting varies according to the status,
c. a power source for battery charging, which monitors battery loading and prevents
deep discharge;

iii) A switching power supply with universal input (110-220Vac), 15V dc 35w output
responsible for feeding the system in normal operation (it supplies power to the control
system, the ceiling light and the battery charging system)
iv) A 12V1200mAh battery to supply the power needed in emergency mode such that the car
is adequately lighted for the time indicated in the regulation.
v) An optocoupler adapter board 220Vac (2665.69). Not needed for CMC4 +.
vi) The ceiling lighting system is the subset consisting of the mechanical support for
attachment within the car and the light source according to the regulations both in normal
and emergency operation.
The light source comprises two same PCBs (2665.58) that support the LEDs. Drawing
2320.92 specifies how to assemble the two PCBs using extra plates 2320.91.01.
Assembling the LED PCBs with the rest of the lighting system is shown in drawing
2320.18.01.

Connector X3 is delivered disconnected from the factory (disconnected battery)

and must be connected on site.

Figure 1.1: Photograph of car lighting control set except CMC4+.

Figure 1.2: Photograph of the car ceiling lighting set.

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2 TECHNICAL SPECIFICATIONS

2.1 Lighting system specifications:

GENERAL CHARACTERISTICS
Parameter Minimum Typical Maximum
Supply voltage Vin 88Vac 230Vac 264Vac
Power Pin 28W 30W 32W
Frequency F 47Hz 50Hz 63Hz
Brightness lm 2330lm
Normal lighting level (car
S11000kg in black)
E 108lux1

Emergency lighting level

E 10lux
(car S11000kg in black)
Light temperature 5000K
Battery voltage Vbat 12.2Vdc
Battery capacity 1200mAh
Emergency time Temer 5h

2.2 Technical specifications of the control board:

POWER SUPPLY [X1 PINS 1,2]

Parameter Minimum Typical Maximum
Voltage Vcc 14.8Vdc 15Vdc 15.5Vdc
Maximum current Icc 1.75A 2.1A
Maximum power Pcc 26.25W 32W

LED OUTPUT [X2]

Parameter Minimum Typical Maximum
Normal output voltage Vled 21Vdc 26Vdc 28Vdc
Standby output voltage Vled|stb 0Vdc
Emergency output
Vled|emer 16Vdc 18Vdc 21Vdc
voltage
Normal output current Iled 0.79A 1.055A 1.2A
1
Measurement obtained at ground level in the most unfavourable part of the car of 1000kg with model S1 in black

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Standby output current Iled|stb 0A

Emergency output
Iled|emer 35mA 50mA 100mA
current

BATTERY [X3]
Parameter Minimum Typical Maximum
Battery Voltage Vbat 10.5V 12.5Vdc 13.8Vdc
Battery charging current Ibat 15mA - 60mA
Battery maintenance
Ibat|stby 4mA 6mA 8mA
current
Battery emergency
Ibat|emer -70mA -80mA -90mA
current

CONTROL SIGNALS [X5, X6]

Parameter Minimum Typical Maximum
Input voltage (High level) VinH 5Vdc 24Vdc 35Vdc
Input voltage (Low level) VinL 0 0 0.5Vdc
Input resistance Rin 4.2K 4.7K 5.1K

HARDWARE
Internal supply 5V linear source
Battery short circuit protection Current monitoring.
Battery deep discharge protection Voltage monitoring.

2.3 Technical Specifications of the cool white light ceiling LEDs:

POWER SUPPLY [X1 PINS 1,2]

Parameter Minimum Typical Maximum
Voltage Vcc 19Vdc 26Vdc 28Vdc
Current Icc 1.055A 1.200A
Power Pcc 27.4W

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3 CONNECTOR LAYOUT

3.1 Car lighting control board (CIC)

Figure 1.4: Car lighting control board connector layout.

3.1.1 CONNECTOR ALLOCATION

AMP2.54mm Straight Male Connector

Pins
Connector Functionality
P1 P2 P3 P4 P5
X1 Power supply 15V AGND X X X
X3 Battery Vbat A-GND X X X
X5 Control signals 24V GNDes L1 L2 EL
X6 Control signals Vc GND L1 GNDes X

MOLEX 2.5mm Straight Male Connector

Pins
Connector Functionality
P1 P2
X2 LED output Iled AGND

Output pin Input pin

Bidirectional pin Empty or unspecified Pin
Neutral Pins 220V AC Pins 220V AC
GND 24VP
AGND Other power supply
Potential-free pin Earth (PE)
Pin without internal connection Programming Pin

Connector signal colour key.

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3.1.2 CONNECTOR DETAILS

X1 - Power supply
AMP 2-pin P=2.54mm Straight Male Connector.
Control board 15V Power supply.

X2 – LED output
MOLEX 2-pin P=2.50mm Straight Male Connector.
Controlled current output for ceiling LEDs.

X3 - Battery
AMP 2-pin p2.54mm Straight Male Connector.
Connector for battery charging and for power supply from the battery in an emergency situation.

X4– Programming
AMPMicroMatch 6-pin SMD Straight Female Connector.
For RENESAS or USB-CMC4 E8/E8a programmer connection. Used for firmware programming
and upgrading.

X5 – Control signals
AMP 4-pin p2.54mm Straight Male Connector.
Used with CMC4.
L1 energy saving input control signal.

X6 – Control signals
AMP5-pin p2.54mm Straight Male Connector.
Used as of CMC4+ New Generation.
L1 energy saving input control signal.
L2 control signal without functions assigned.
Control output without functions assigned.
3.2 Car ceiling light

Figure 1.5: Connector layout on the car ceiling lighting board.

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3.2.1 CONNECTOR ALLOCATION

CONNECTORS
Pins
Connector Functionality
P1 P2
X1 LED Input/ output Iled AGND
X2 LED Input/ output Iled AGND

3.2.2 CONNECTOR DETAILS.

X1 –LED Input
MOLEX 2-pin p2.50mm Straight Male Connector.
Input, if the first PCB, or output, if the second PCB, of ceiling LED controlled current.

X2 – LED output
MOLEX 2-pin p2.50mm Straight Male Connector.
Output, if the first PCB, or input, if the second PCB, of ceiling LED controlled current.

4 PARAMETERIZATION

4.1 Maximum lighting adjustment (Push button P2)

The light level in normal operation can be adjusted with the P2 button.
Each time it is pressed, the light is reduced by about 2%, until it reaches the emergency lighting
level, then returning to the maximum level allowed.
In any situation, if the push button is kept pressed down, it returns to the maximum lighting
position.

4.2 Jumper settings

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Jumpers
Pins
Jumper Functionality
P1 P2 P3
Without functions
JP1 Com 0V
assigned
JP2 CMC4/CMC4+ CMC4 Com CMC4+
JP3 I Limit
ledmax
1.3A Com 1.6A

Control type selection

CMC4 CMC4+

Control type configuration table.

Selection of Iledmax limit depending on the ceiling light

Limit Iledmax1.3A Limit Iledmax1.6A

Maximum Iledmax table.

For the J3 configuration, the maximum LED output current limit is selected. In the case of ceiling
lights 2320.18, the case at hand, a jumper is placed between 1 and 2.

5 BOARD REPLACEMENT

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Board replacement is subject to compliance with the following instructions:

1. If UPS (G20) is available, press the OFF button.
2. Disconnect breaker (F20) and control differential switch (F21).
3. Disconnect power breaker (Q00) and if available, also S00 switch.
4. Disconnect breakers (F11, F12) and differential lighting switch (F10). If any, also disconnect
breakers F13 and F14 or differential switches F15 and F16.
5. Replace the desired board with a new one and check the jumper layout.

6 REVISION LOG

Changed Revised Approved

Ed. Changes
by by by
Aabellanas AAbellanas MVega
1 Initial edition.
16/01/12 25/04/12 25/04/12
VGomez F.Castillo M.Vega
2 Document and technical characteristic updates
15/04/13 21/05/13 21/05/13
3
4

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