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ES4440.2 Compact Failure Simulation Module

User’s Guide

Summary of Contents for ES4440.2

Page 1: ...ES4440 2 Compact Failure Simulation Module User s Guide...

Page 2: ...t or single license Using and copying is only allowed in concurrence with the specifications stipulated in the contract Under no circumstances may any part of this document be copied reproduced transm...

Page 3: ...k 10 1 3 3 RoHS Conformity 10 1 4 Taking the Product Back and Recycling 12 1 5 Materials Subject to Declaration 12 1 6 Applications 13 1 7 Functions and Features 14 1 7 1 Failure Simulation 14 1 7 2 C...

Page 4: ...e Rails Relays 27 2 7 3 Automatic Monitoring of the Fuses 27 2 7 4 Changing Fuses 28 2 7 5 Changing the Mains Fuses 29 3 Pin Assignment 31 3 1 SYNC Connector 31 3 2 CAN Connector 32 3 3 Ethernet Conne...

Page 5: ...Basic Safety Instructions Please adhere to the safety instructions in this manuals to avoid injury to yourself and others as well as damage to the device 1 1 1 Identification of Safety Information The...

Page 6: ...tion Module is a standalone unit which electrically simulates faults in automotive ECUs in real time The unit can also be installed as part of a hardware in the loop test system The ES4440 2 Compact F...

Page 7: ...2 Requirements for Operation The following requirements are made to ensure safe operation Only use the product according to the specifications in the corresponding user manual If the product is used i...

Page 8: ...r battery or a suitable lab power supply Only use lab power supplies with dual protection for the supply network with double reinforced insulation DI RI This requirement is met by lab power supplies w...

Page 9: ...on openings must have a distance of at least 15 cm to walls or objects in the environment Keep a distance of at least 1 RU to the next module at the top and bottom Cleaning Clean the device only with...

Page 10: ...ts packaging ETAS confirms that the product has been registered in accordance with the product specific KCC guidelines of the Republic of Korea 1 3 3 RoHS Conformity European Union The EU Directive 20...

Page 11: ...ETAS confirms that the product meets the product specific applicable guidelines of the China RoHS Management Methods for Controlling Pollution Caused by Electronic Information Products Regulation appl...

Page 12: ...t be disposed of as residual garbage The user is obliged to collect the old devices separately and return them to the WEEE take back system for recycling The WEEE directive concerns all ETAS devices b...

Page 13: ...or CAN interface The LABCAR PINCONTROL software provided offers simple and user friendly interfaces for operating and configuring the ES4440 2 via Ethernet The individual functions are described in d...

Page 14: ...ed load Pull down resistance to UBatt_A or UBatt_B with or without connected load High Voltage Channels A further 16 channels are for voltages up to 80 V RMS and currents up to 10 A the following fail...

Page 15: ...1 7 2 Connectors Displays and Fuses Connectors on the Front Panel and Rear The ES4440 2 Compact Failure Simulation Module has several connectors on the front and rear for connecting the ECU and loads...

Page 16: ...nnected slave systems This takes place by connecting the failure rails and the synchronization lines of the ES4440 2s involved and assigning corresponding IP addresses in the operat ing software LABCA...

Page 17: ...OL controller 1 7 4 Block Diagram Fig 1 3 Block Diagram of the ES4440 2 Compact Failure Simulation Module The core of the ES4440 2 Compact Failure Simulation Module is a micro controller C with an int...

Page 18: ...ES4440 2 Compact Failure Simulation Module User s Guide 18 Introduction ETAS...

Page 19: ...Several ES4440 2 Systems on page 25 Safety Concept on page 27 2 1 Failure Simulation for 80 Channels The ES4440 2 Compact Failure Simulation Module has 64 channels which are equipped for a continuous...

Page 20: ...ure shows the failures which can be realized on the 16 high voltage channels whether several failures can be activated simultaneously the settable duration of the failure state and whether this failur...

Page 21: ...e resistance for the contact between the lines or not the second whether the load is connected during fail ure simulation or not The fourth column tells you whether a loose contact can be simulated or...

Page 22: ...required duration of the failure state is set in the LABCAR PINCONTROL user interface The selectable duration is between 20 ms and 60 s for relays and between 1 ms and 60 s for MOSFETs it can be set...

Page 23: ...owing via the rails can be measured For this purpose a current measuring device is con nected to the Current connector on the front panel and measuring is activated with the command CurrentMeasurement...

Page 24: ...issible current depends on the voltage drop over the cascade it is 3 A with a voltage drop of 14 V and 1 A with a voltage drop of 30 V As an failure state is normally only ever active for a very short...

Page 25: ...1 2 HV UBatt ECU HV LOAD HV ECU CH0 CH42 ECU CH43 CH63 LOAD CH0 CH42 LOAD CH43 CH63 A D C B G F N E K J P H M L S R T A K L M G H N J D E T F B C R S P A H B I G C J F D E D E C B A G J K F H L N R S...

Page 26: ...ROL in individual systems via relays Note In master slave operation either the reference voltages or the battery voltages must be connected to master and slave Otherwise not all failure modes will be...

Page 27: ...place as follows 1 Checking the state of the fuses 2 Applying an failure 3 Resetting the failure 4 Checking the state of the fuses Note When in operation the temperature of the ES4440 2 Compact Failu...

Page 28: ...re opening the housing 1 Switch off the device 2 Remove all connected lines To remove the right hand front panel 3 Remove the four screws shown in the figure from the right hand front panel with a Phi...

Page 29: ...older The mounting position of the fuse holders is shown in the following figure To replace the right hand front panel 7 Place the front panel cover in the position intended 8 Now tighten the screws y...

Page 30: ...Module User s Guide 30 Hardware Features ETAS 2 Push down the tab with a screwdriver and pull out the fuse holder 3 Change the defective fuse s 4 Slide the fuse holder back in until it clicks into po...

Page 31: ...CU HV Connector on page 33 LOAD HV Connector on page 35 ECU CH0 CH42 ECU CH43 CH63 Connector on page 36 LOAD CH0 CH42 LOAD CH43 CH63 Connector on page 40 3 1 SYNC Connector The synchronization signals...

Page 32: ...3 Ethernet Connector The Ethernet connector is used for the Ethernet connection to the host system or an Ethernet switch Type RJ45 Fig 3 3 Ethernet Pin Assignments View from Front of Housing Tab 3 3 E...

Page 33: ...1S B 01 female Counterpart ITT Cannon CA06COM E18 1P B 01 male Fig 3 4 Rail 1 2 Pin Assignments Tab 3 4 Rail 1 2 Pin Assignment 3 6 ECU HV Connector The 16 high voltage channels of the ECU are connect...

Page 34: ...wisted pairs Pin Signal Internally Connected to Connector LOAD HV Pin A ECU0 LOAD0 B ECU1 LOAD1 C ECU2 LOAD2 D ECU3 LOAD3 E ECU4 LOAD4 F ECU5 LOAD5 G ECU6 LOAD6 H ECU7 LOAD7 J ECU8 LOAD8 K ECU9 LOAD9...

Page 35: ...the individual pins of the ECU HV and LOAD HV connections Therefore you should only open the housing when the device has been discon nected from the mains power and all other connections have been re...

Page 36: ...CU CH43 CH63 Pin Assignments N LOAD12 ECU12 P LOAD13 ECU13 R LOAD14 ECU14 S LOAD15 ECU15 T The pins T of LOAD HV and ECU HV are directly connected with each other Pin Signal Internally Connected to Co...

Page 37: ...LOAD17 V ECU18 LOAD18 W ECU19 LOAD19 Y ECU20 LOAD20 Z ECU21 LOAD21 a ECU22 LOAD22 b ECU23 LOAD23 c ECU24 LOAD24 d ECU25 LOAD25 e ECU26 LOAD26 f ECU27 LOAD27 g ECU28 LOAD28 h ECU29 LOAD29 j ECU30 LOAD...

Page 38: ...49 LOAD49 H ECU50 LOAD50 J ECU51 LOAD51 K ECU52 LOAD52 L ECU53 LOAD53 M ECU54 LOAD54 N ECU55 LOAD55 P ECU56 LOAD56 R ECU57 LOAD57 S ECU58 LOAD58 T ECU59 LOAD59 U ECU60 LOAD60 V ECU61 LOAD61 W ECU62 LO...

Page 39: ...n c u n c n c v n c n c w n c n c y n c n c The lines of the signals ECU60 ECU61 pins U V and ECU62 ECU63 pins W Y are routed to LOAD CH43 CH63 as twisted pairs Together with the two Shield lines pin...

Page 40: ...A51P B 01 male Fig 3 8 LOAD CH0 CH42 and LOAD CH43 CH63 Pin Assignments Pin Signal Internally Connected to Connector ECU CH0 CH42 Pin A LOAD0 ECU0 B LOAD1 ECU1 C LOAD2 ECU2 D LOAD3 ECU3 E LOAD4 ECU4 F...

Page 41: ...ECU30 k LOAD31 ECU31 l LOAD32 ECU32 m LOAD33 ECU33 n LOAD34 ECU34 p LOAD35 ECU35 r LOAD36 ECU36 s LOAD37 ECU37 t LOAD38 ECU38 u LOAD39 ECU39 v LOAD40 ECU40 w LOAD41 ECU41 y LOAD42 ECU42 Pin Signal Int...

Page 42: ...D59 ECU59 U LOAD60 ECU60 V LOAD61 ECU61 W LOAD62 ECU62 Y LOAD63 ECU63 Z Shield 1 shielding for LOAD60 LOAD61 Shield 1 a Shield 2 shielding for LOAD62 LOAD63 Shield 2 b n c n c c n c n c d n c n c e n...

Page 43: ...ls LOAD60 LOAD61 pins U V and LOAD62 LOAD63 pins W Y are routed to ECU CH43 CH63 as twisted pairs Together with the two Shield lines pins Z and a these are thus suitable to be used as CAN lines but ca...

Page 44: ...ES4440 2 Compact Failure Simulation Module User s Guide 44 Pin Assignment ETAS...

Page 45: ...VAC 15 A China AC supply cable China for various ETAS devices with PRC 3 and IEC 60320 C13 plug Rated for 250 VAC 10 A 2 50 m length F 04A 109 512 Europe Korea AC supply cable for Europe and Korea for...

Page 46: ...owing is an overview of the most important features of the ES600 Net work Module Ethernet switch with 10 100 MBit s data rate Six Ethernet ports 1 x front 5 x rear One host port Cascadable to eight le...

Page 47: ...or the power supply of an ES600 Network Module Fig 4 3 CBE120 2 Cable Note Only ETAS cables can be used at the ES600 interfaces The maximum permissi ble cable lengths must be adhered to Side A Side B...

Page 48: ...ES4440 2 Compact Failure Simulation Module User s Guide 48 Accessories ETAS...

Page 49: ...age 30 V Maximum permissible current 20 A Total resistance between in and outputs after clean up of the relays 25 m Number 16 Maximum permissible voltage 80 V RMS 250 V Peak Maximum permissible curren...

Page 50: ...A Contact resistance Approx 1 5 m Approx 3 m Max permissible voltage 30 VDC Max permissible current 70 A Resistance Approx 14 m Relay MOSFET Duration from receipt of switch command at the ES4440 2 to...

Page 51: ...ies Mains circuit breaker 2 x 1 6 AH slow blow 250 V glass fuse 5x20 IEC60127 2 3 For information on the position of the fuses see To change fuses on page 29 see Changing the Mains Fuses on page 29 E1...

Page 52: ...ions Environment Use only inside enclosed and dry rooms Max contamination level 2 Permissible ambient temperature during operation 5 C to 35 C 41 F to 95 F Permissible storage temperature 20 C to 85 C...

Page 53: ...53 ETAS Ordering Data 6 Ordering Data The ordering data for the ES4440 2 are as follows Ordering name Short name Ordering num ber ES4440 2 Compact Failure Simulation Module ES4440 2 F 00K 107 497 Scop...

Page 54: ...ES4440 2 Compact Failure Simulation Module User s Guide 54 Ordering Data ETAS...

Page 55: ...hnical Support For details of your local sales office as well as your local technical support team and product hotlines take a look at the ETAS website Borsigstra e 24 Phone 49 711 3423 0 70469 Stuttg...

Page 56: ...ES4440 2 Compact Failure Simulation Module User s Guide 56 ETAS Contact Addresses ETAS...

Page 57: ...U HV 33 Ethernet 32 LOAD CH0 CH42 40 LOAD CH43 CH63 40 LOAD HV 35 Rail 1 2 33 SYNC 31 Connectors 15 Correct use 6 D Documentation 6 E Electrical data 51 Environmental conditions 52 Error state duratio...

Page 58: ...ure system reset 27 P Pins assignment 31 Product Back 12 Product non liability 6 Protective contact 8 R Rear view of the ES4440 1 13 Recycling 12 Relay specifications 22 Resistor cascade 15 24 RoHS co...

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ETAS ES4440.2, User Manual, Page: 1 / 58

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