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ETAS ES4408.1 User Manual

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ES4408.1 Load Chassis
User's Guide

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Summary of Contents for ETAS ES4408.1

  • Page 1 ES4408.1 Load Chassis User’s Guide...
  • Page 2 The data in this document may not be altered or amended without special noti- fication from ETAS GmbH. ETAS GmbH undertakes no further obligation in rela- tion to this document. The software described in it can only be used if the customer is in possession of a general license agreement or single license.

  • Page 3: Table Of Contents

    2 Getting Started ........... 15 General Safety Instructions for Operating ES4408.1 Load Chassis ..15 2.1.1...
  • Page 4 3 Hardware ............19 The Boards for the ES4408.1 Load Chassis ......20 3.1.1...

  • Page 5: Introduction

    ETAS Introduction Introduction This User’s Guide describes the ES4408.1 Load Chassis. It consists of the follow- ing chapters: • "Introduction" on page 5 This chapter. Here you will find general information on the ES4408.1 Load Chassis and other system components.

  • Page 6: Features

    Introduction ETAS Features The ES4408.1 Load Chassis is a 19”/4 U housing for creating a system to simu- late electric loads. Using various boards makes it possible to simulate various loads to test the behavior of ECUs in an HIL system. These particularly include pull-up/pull-down loads with currents up to 150 mA and the simulation of electromagnetic injec- tors up to 20 A.

  • Page 7: Control Unit

    ETAS Introduction 1.1.3 Control Unit The ES4408.1 Load Chassis has one further slot on the rear for the optional ES4408CON.1 Communication Interface for the following functions: • Master controller for all boards in the ES4408.1 Load Chassis • Ethernet interface –...

  • Page 8: Connectors

    Introduction ETAS 1.1.5 Connectors The ES4408.1 Load Chassis has various connectors on the back (see Fig. 1-1 on page 9) for the following purposes: • for connecting the various loads • for the measure signals of the high current loads •...
  • Page 9 ETAS Introduction The following figure shows the front and rear of the ES4408.1 Load Chassis. SwCtrl SwCtrl Fig. 1-1 Front (Right) and Rear (Left) of the ES4408.1 Load Chassis ES4408.1 Load Chassis - User’s Guide...

  • Page 10: 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. ETAS GmbH cannot be made liable for damage which is caused by incorrect use and not adhering to the safety instructions.

  • Page 11: Labeling Of Safety Instructions

    1.2.3 Demands made regarding the Technical State of the Product To ensure safe operation of the ES4408.1 Load Chassis, read and adhere to the information in the chapter "Getting Started" on page 15. ES4408.1 Load Chassis - User’s Guide...

  • Page 12: Identifications On The Product

    1.5.1 European Union The EU Directive 2002/95/EU limits the use of certain dangerous materials for electrical and electronic devices (RoHS conformity). ETAS confirms that the product corresponds to this directive which is applicable in the European Union. 1.5.2 China ETAS confirms that the product meets the product-specific applicable guidelines...

  • Page 13: Taking The Product Back And Recycling

    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 but not external cables or batteries. For more information on the ETAS GmbH Recycling Program, contact the ETAS sales and service locations (see "ETAS Contact Addresses"...
  • Page 14 Introduction ETAS ES4408.1 Load Chassis - User’s Guide...

  • Page 15: Getting Started

    When choosing a place to set-up the ES4408.1 Load Chassis, please take the following into consideration: • Only operate the ES4408.1 Load Chassis if it has been integrated in a 19" rack or in the ETAS casing specially designed for this purpose (ES4015.2 Housing 9U, F-00K-107-884).

  • Page 16: Connecting/Removing Devices

    To avoid injury and damage to the hardware, please observe the following pre- cautionary measures: • Do not apply any voltages to the connectors of the ES4408.1 Load Chassis which do not correspond to the specification of the relevant connector.

  • Page 17: Power Supply

    ETAS Getting Started Power Supply The ES4408.1 Load Chassis can be operated between 100 V and 230 V at 50 Hz - 60 Hz; the maximum current consumption is 3,15 A. DANGER! Before you open the device, disconnect it from the power supply by unplugging it.

  • Page 18: Environmental Conditions

    Getting Started ETAS Environmental Conditions Only operate the ES4408.1 Load Chassis under the following environmental conditions: Environment Only use indoors Operating temperature 5 °C to 35 °C (41 °F to 95 °F) Relative humidity 0 to 95% (non-condensing) Power supply 100 - 240 V/50 - 60 Hz, 3 A ES4408.1 Load Chassis - User’s Guide...

  • Page 19: Hardware

    ETAS Hardware Hardware This chapter contains an overview of boards available for the ES4408.1 Load Chassis and further information on the housing. These are: • "The Boards for the ES4408.1 Load Chassis" on page 20 This section contains an overview of the boards which can be used in the ES4408.1 Load Chassis for controlling and load simulation.

  • Page 20: The Boards For The Es4408.1 Load Chassis

    Power Supply Controller Board) and led through again (to the ES1392.2 High Current Switch Board) at the ES4408CON.1 Communication Interface. These sig- nals are routed to the backplane of the ES4408.1 Load Chassis and used there for the ES4434.1 Configurable Load Board to switch battery nodes or on the ES4435.1 Current Source Load Board to activate current sources.

  • Page 21: Es4435.1 Current Source Load Board

    (two each in the form of a piggyback) can be obtained separately. Place of Installation and Connections The injector loads are installed in slot 0...slot 2 of the ES4408.1 Load Chassis (see "The Slots of the ES4408.1 Load Chassis (View from the Front)" on page 22).

  • Page 22: Connecting The Battery Voltage

    – 1 x 6 HP (slot 3) and 1 x 4 HP (slot 4) for loads with position feedback (throttle valve, EGAS. etc) • Seven 4 HP slots (3 U) for low current loads (slot 5...slot 11). Fig. 3-1 shows the arrangement of the above-mentioned slots in the ES4408.1 Load Chassis. Fig. 3-1 The Slots of the ES4408.1 Load Chassis (View from the Front)

  • Page 23: The Power Supply Of The Es4408.1 Load Chassis

    "Pin Assignment and Display Elements" on page 25). The Power Supply of the ES4408.1 Load Chassis Power is supplied to the ES4408.1 Load Chassis with a wide-range power supply unit with input voltages between 100 V and 240 V with mains frequencies between 50 Hz and 60 Hz;...

  • Page 24: Ventilation Of The Es4408.1 Load Chassis

    ETAS Ventilation of the ES4408.1 Load Chassis For cooling the loads, the ES4408.1 Load Chassis has a total of six cooling vents on the bottom of the device. The filter mat in the ventilation unit has to be cleaned or replaced from time to time.

  • Page 25: Pin Assignment And Display Elements

    The battery voltage from the power supply unit is supplied at the “Bat- tery_IN” connector. • "LEDs" on page 35 There are five LEDs on the front panel of the ES4408.1 Load Chassis which indicate the state of the five supply voltages. ES4408.1 Load Chassis - User’s Guide...

  • Page 26: Load 9

    Slot n:a18 Slot n:Load 23 Slot n:b18 Slot n:Load 24 Slot n:c18 GND board Slot n:c10 Housing ES4408 protective earth Tab. 4-1 Pin Assignment of “Load 9”... “Load 15“ (n = 11...5) and Backplane Connectors ES4408.1 Load Chassis - User’s Guide...

  • Page 27: Load 1

    “Load1” ... “Load6”). See "“CBAV340.1-1” Cable" on page 39. Current Rating of the Connectors Please note the maximum admissible current of 7.5 A (90 V) for pins A1 and A2 , and 1 A (90 V) for pins 1...5. ES4408.1 Load Chassis - User’s Guide...
  • Page 28 Load 3:3 Measure signal 3-3 Slot 3:d18 Load 3:4 Measure signal 3-4 Slot 3:z20 Load 3:5 Measure signal 3-5 Slot 3:b20 Housing ES4408 protective earth Tab. 4-3 Pin Assignment: “Load 1” ... “Load 3” ES4408.1 Load Chassis - User’s Guide...
  • Page 29 Load 6:3 Measure signal 6-3 Slot 4:d18 Load 6:4 Measure signal 6-4 Slot 4:z20 Load 6:5 Measure signal 6-5 Slot 4:b20 Housing ES4408 protective earth Tab. 4-4 Pin Assignment: “Load 4” ... “Load 6” ES4408.1 Load Chassis - User’s Guide...

  • Page 30: Load 7" Connector

    Which signals of the relevant load are connected to which signals of the PT-LAB- CAR is also described in the description of the cable. Current Rating of the Backplane Pins Please note the maximum admissible current of 7.5 A (90 V) per backplane pin. ES4408.1 Load Chassis - User’s Guide...

  • Page 31: Load 8-1" And "Load 8-2" Connectors

    Slot 1:b28 Slot 1:d28 Slot 1:Load 4+ Slot 1:z30 Slot 1:b30 Slot 1:d30 Slot 1:Load 4– Slot 1:z32 Slot 1:b32 Slot 1:d32 Housing ES4408 protective earth Tab. 4-6 Pin Assignment: “Load 8-1” (Slot 1) ES4408.1 Load Chassis - User’s Guide...
  • Page 32 Which signals of the relevant load are connected to which signals of the PT-LAB- CAR is also described in the description of the cable. Current Rating of the Backplane Pins Please note the maximum admissible current of 7.5 A (90 V) per backplane pin. ES4408.1 Load Chassis - User’s Guide...

  • Page 33: Connector "Meas 7

    Which signals of the relevant load are connected to which signals of the PT-LAB- CAR is also described in the description of the cable. Current Rating of the Connectors Please note the maximum admissible current of 1 A (60 V) per pin/backplane channel. ES4408.1 Load Chassis - User’s Guide...

  • Page 34: Meas 8-1" And "Meas 8-2" Connectors

    “Meas 7”, “Meas 8-1” and “Meas 8-2” to the “Measure” connector of the PT- LABCAR (see "“CBAV343.1-1” Cable" on page 44). Which signals of the relevant load are connected to which signals of the PT-LAB- CAR is also described in the description of the cable. ES4408.1 Load Chassis - User’s Guide...

  • Page 35: Battery In" Connector

    Please note the maximum admissible total current rating of 20 A (90 V) per pin. LEDs There are five LEDs on the front panel of the ES4408.1 Load Chassis which indi- cate the state of the five supply voltages. Fig. 4-8 LEDs Showing the State of the Supply Voltages An LED which is on indicates that the relevant supply voltage is okay –...
  • Page 36 Pin Assignment and Display Elements ETAS ES4408.1 Load Chassis - User’s Guide...

  • Page 37: Accessories

    This chapter contains a description and order data of ETAS accessories for the ES4408.1 Load Chassis. Cables A number of cables are available from ETAS for integrating the ES4408.1 Load Chassis into the LABCAR environment. These cables are described below, and listed with their ordering information: •...

  • Page 38: Cbav300.1-2" Cable

    The signals between the two connectors are assigned as follows: Signal Ring Terminal Signal +UBatt A, C -UBatt Black – Tab. 5-1 Pin Assignment of the “CBAV300.1-2” Cable For information on ordering this cable, refer to the section "Order Data" on page 46. ES4408.1 Load Chassis - User’s Guide...

  • Page 39: Cbav340.1-1" Cable

    ES4408.1 side: Hybrid DSUB 7W2 (female) PT-LABCAR side: Hybrid DSUB 7W2 (male) The assignment of the corresponding connectors on the ES4408.1 is described in the section "“Load 1” ... “Load 6” Connectors" on page 27; for that of the con- nectors of the PT-LABCAR, refer to the PT-LABCAR User’s Guide.

  • Page 40: Cbav341.1-1" Cable

    ES4408.1 side: 2 x Hybrid-DSUB 8W8 (female) PT-LABCAR side: ITT Cannon CA06COM-E20-29P-B (male) The assignment of the corresponding connectors on the ES4408.1 is described in the section "“Load 8-1” and “Load 8-2” Connectors" on page 31; for that of the connectors of the PT-LABCAR, refer to the PT-LABCAR User’s Guide.
  • Page 41 Inj 7 Slot 1:b22 Slot 1:d22 Slot 1:z24 Slot 1:Load 2– Load 8-1:A4 Inj_Ch11 Inj 7 Slot 1:b24 Slot 1:d24 Slot 1:z32 Slot 1:Load 4– Load 8-1:A8 Inj_Ch13 Inj 8 Slot 1:b32 Slot 1:d32 ES4408.1 Load Chassis - User’s Guide...
  • Page 42 * see "“Load 8-1” and “Load 8-2” Connectors" on page 31 ** see documentation on PT-LABCAR Tab. 5-2 Pin Assignment of the “CBAV341.1-1” Cable (in gray) and the Fur- ther Environment of the Signals ES4408.1 Load Chassis - User’s Guide...

  • Page 43: Cbav342.1-1" Cable

    ES4408.1 side: Hybrid DSUB 8W8 (female) PT-LABCAR side: Hybrid DSUB 8W8 (male) The assignment of the corresponding connectors on the ES4408.1 is described in the section "“Load 7” Connector" on page 30; for that of the connectors of the PT-LABCAR, refer to the PT-LABCAR User’s Guide.

  • Page 44: Cbav343.1-1" Cable

    ES4408.1 side: 3 x DSUB9 (male) PT-LABCAR side: DSUB25 (female) The assignment of the corresponding connectors on the ES4408.1 is described in the sections "Connector “Meas 7”" on page 33 and "“Meas 8-1” and “Meas 8-2” Connectors" on page 34; for that of the connectors of the PT-LAB- CAR, refer to the PT-LABCAR User’s Guide.
  • Page 45 * Make sure you allocate the DSUB9 connector correctly to the connectors of the ES4408.1 Load Chassis. Tab. 5-3 Pin Assignment of the “CBAV343.1-1” Cable (in gray) and the Fur- ther Environment of the Signals ES4408.1 Load Chassis - User’s Guide...

  • Page 46: Order Data

    8W8 - 8W8 - Round Connector (8mc- 8mc+17mc), 1m High Current Connection Cable CBAV342.1-1 F-00K-106-181 (ES4640), 8W8 - 8W8, 1m Connection Cable (ES4640), DSUB - CBAV343.1-1 F-00K-106-322 3xDSUB, 1m Tab. 5-4 Order Data for Cables ES4408.1 Load Chassis - User’s Guide...

  • Page 47: Technical Data

    ETAS Technical Data Technical Data This chapter contains the technical data of the ES4408.1 Load Chassis. Labeling of the product The nameplate is on the rear of the device. It contains the following information: • ETAS logo • Product name •...
  • Page 48 Connector IEC 60320 C14 chassis plug Dimensions Height Width 482 mm Depth 475 mm Environmental Conditions Operating temperature 5 °C to 35 °C (41 °F to 95 °F) Relative humidity 0 to 95% (non-condensing) ES4408.1 Load Chassis - User’s Guide...

  • Page 49: Etas Contact Addresses

    Germany WWW: www.etas.com ETAS Subsidiaries and Technical 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: ETAS subsidiaries WWW: www.etas.com/en/contact.php ETAS technical support WWW: www.etas.com/en/hotlines.php...
  • Page 50 ETAS Contact Addresses ETAS ES4408.1 Load Chassis - User’s Guide...

  • Page 51: Index

    “Load1” ... “Load6” 27 Positioning 15 “Meas8-1” and “Meas8-2” 34 Power cord cables 17 Power supply 17 Product Back 13 Environmental conditions 18 Protective contact 15 ES4408.1 Load Chassis backplane 22 front 9 Recycling 13 ES4408.1 Load Chassis - User’s Guide...
  • Page 52 Index ETAS Safety instructions, basic 10 Safety instructions, labeling 11 Technical data 47 Use, correct 10 Ventilation 15 Waste Electrical and Electronic Equip- ment 13 WEEE take-back system 13 ES4408.1 Load Chassis - User’s Guide...

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