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ETAS ES4440.2 User Manual

Compact failure simulation module
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ES4440.2 Compact Failure Simulation Module
User's Guide

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Summary of Contents for ETAS ES4440.2

  • Page 1 ES4440.2 Compact Failure Simulation Module 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

    Intended Use ......... . 6 General Instructions on Operating the ES4440.2 ..... . 8 Identifications on the Product .
  • Page 4 7 ETAS Contact Addresses ........

  • Page 5: Introduction

    ETAS Introduction Introduction This User’s Guide contains a description of the ES4440.2 Compact Failure Simu- lation Module. It consists of the following chapters: • Introduction This chapter • "Hardware Features" on page 19 This chapter contains a detailed description of the features of the ES4440.2 Compact Failure Simulation Module.

  • Page 6: General Safety Information

    Introduction ETAS 1.1.2 General Safety Information Please read the product safety advice ("ETAS Safety Advice") as well as the fol- lowing safety instructions to avoid injury to yourself and others as well as dam- age to the device. Note Please read the documentation accompanying the product ("ETAS Safety Advice Housing"...
  • Page 7 ETAS Introduction The intended purpose of the ES4440.2 Compact Failure Simulation Module is for it to be used: • To electrically simulate faults in ECUs. • In industrial lab facilities or workplaces. • For tests on engine test benches. • For tests on chassis dynamometers.

  • Page 8: General Instructions On Operating The Es4440.2

    IEC60332-1-2, IEC60332-2-2, UL2556/UL1581VW-1. Grounding/Grounding Contact The ES4440.2 is grounded by the protective conductor of the power supply cord. Avoid the danger of electric shock when touching housing components by ensuring that the power connection used has properly connected grounding contacts.
  • Page 9 The module must not be operated when the fuse box lid is open. To avoid injuries and damage, only fuses specified in the user manual may be used. The corre- sponding requirements and the ETAS order numbers can be found in the section "Safety Concept" on page 27.

  • Page 10: Identifications On The Product

    Declaration of Conformity for the product is available upon request. 1.3.2 KC Mark With the KC mark attached to the product and its packaging, ETAS confirms that the product has been registered in accordance with the product-specific KCC guidelines of the Republic of Korea.
  • Page 11 ETAS Introduction China 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) applicable in China with the China RoHS marking affixed to the product or its packaging.

  • Page 12: 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 13: Applications

    The ES4440.2 Compact Failure Simulation Module is not intended for operation in a traveling vehicle! The ES4440.2 Compact Failure Simulation Module is a 19” housing with 3 U which can be assembled in a rack using the corresponding mounts. Fig. 1-2 shows the front panel (with mounts for rack assembly) and the rear of the ES4440.2.

  • Page 14: Functions And Features

    "Hardware Features" on page 19. 1.7.1 Failure Simulation The ES4440.2 Compact Failure Simulation Module makes it possible to simulate failures in real time for 80 ECU channels (per ES4440.2). High-Current Channels 64 of these channels are for voltages up to 30 V and currents up to 20 A – the following failures can be simulated for these 64 channels: •...

  • Page 15: 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, addressing the ES4440.2 and for master/slave operation. The following connectors are on the front panel: •...

  • Page 16: Application Environment

    ETAS Status Displays via LEDs on the Front Panel There are several LEDs on the front panel of the ES4440.2 Compact Failure Sim- ulation Module which provide information on operating states of the ES4440.2 and the communication interfaces. For more details on the LEDs, refer to the section "Status Displays via LEDs on the Front Panel"...

  • Page 17: 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 (μC) with an integrated Ethernet controller – the μC is connected directly to Ethernet-PHY. A CAN transceiver acts as a second interface to control the ES4440.2.
  • Page 18 Introduction ETAS ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 19: Hardware Features

    ETAS Hardware Features Hardware Features This chapter contains detailed information on the features of the ES4440.2 Com- pact Failure Simulation Module. These are: • "Failure Simulation for 80 Channels" on page 19 • "Failure modes" on page 20 • "Time Response" on page 23 •...

  • Page 20: Failure Modes

    (single) (single) (single) Error) 20 ms - 60 s 20 ms - 60 s 20 ms - 60 s Duration    (fixed or PWM) Fig. 2-1 Failures for High-Voltage Channels ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 21: Failures For High-Current Channels

    In a non-protected case, make sure that the maximum per- missible current of 20 A is not exceeded, e.g. by a current limitation in the power supply or by protecting the output stages accordingly. ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 22: Relay Or Mosfet

    (see Fig. 2-1 on page 20 and Fig. 2-2 on page 21). Relay Specifications The relays and the conductors of the ES4440.2 are designed to simulate failures with ECUs – usually, the corresponding output stages are disabled only a few μs after an failure has occurred.

  • Page 23: Decoupling The Load Before Failure Activation

    2.2.7 Decoupling the Load before Failure Activation Normally the ES4440.2 is switched between the ECU and the LABCAR or between the ECU and the real vehicle. The following takes place to ensure that no channels of the LABCAR or components of the real vehicle are destroyed by shorts: if an failure is switched without a load, the connection to the load is interrupted before the failure is activated.

  • Page 24: Resistor Cascade

    Overtemperature" on page 27). Status Displays via LEDs on the Front Panel There are several LEDs on the front panel of the ES4440.2 Compact Failure Sim- ulation Module, the meaning of which is described in this section. +24 V...

  • Page 25: Master/Slave Operation Of Several Es4440.2 Systems

    ETAS Hardware Features Master/Slave Operation of Several ES4440.2 Systems An ES4440.2 Compact Failure Simulation Module has 80 channels – this number is sufficient if, for example, failures are to be simulated for the outputs of an engine ECU. If, however, inputs and outputs of an ECU are to be tested simultaneously, a second ES4440.2 Compact Failure Simulation Module is required.

  • Page 26: Ip Addresses And Can Identifiers

    Otherwise pins can be short-circuited through the rail already during con- figuration. Note In master/slave operation the resistor cascade of the ES4440.2 is used, in which the failure occurred. In case of multiple failures the resistor cascade of the first failure pin is used.

  • Page 27: Safety Concept

    2.7.2 Protecting the Rails/Relays To protect the relays and the entire circuit, the ES4440.2 Compact Failure Simu- lation Module has five fuses. These are standard blade fuses used commonly in the automotive environment.

  • Page 28: Changing Fuses

    3. Remove the four screws shown in the figure from the right-hand front panel with a Phillips screw- driver. 4. Remove the front panel cover. The five fuses of the failure rails can now be easily accessed (see the following figure). ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 29: Changing The Mains Fuses

    Changing the Mains Fuses The mains fuses (for the specification see "Fuses" on page 51) are on the back of the device in the IEC appliance inlet C14. 1. Remove the power cord. ES4440.2 Compact Failure Simulation Module - User’s Guide...
  • Page 30 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 posi- tion. 5. Reconnect the power cord. ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 31: Pin Assignment

    • "”ECU CH0-CH42” / ”ECU CH43-CH63” Connector" on page 36 • "”LOAD CH0-CH42” / ”LOAD CH43-CH63” Connector" on page 40 ”SYNC” Connector The synchronization signals for the master/slave operation of several ES4440.2 Compact Failure Simulation Modules are pending at the ”SYNC” connector. Type: DSub 9-pin (male) Counterpart: DSub 9-pin (female) Fig.

  • Page 32: Can" Connector

    ”Ethernet” Pin Assignments (View from Front of Housing) Signal Meaning send data, plus TX-. send data, minus receive data, plus n.c. reserved n.c. reserved receive data, minus n.c. reserved n.c. reserved Tab. 3-3 ”Ethernet” Pin Assignment ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 33: Current" Connector

    The 16 high-voltage channels of the ECU are connected via these two connec- tors. Type: ITT Cannon CA02COM-E20-29P-B (male) ES4440.2 Compact Failure Simulation Module - User’s Guide...
  • Page 34 ECU11 LOAD11 ECU12 LOAD12 ECU13 LOAD13 ECU14 LOAD14 ECU15 LOAD15 * The pins T of „ECU HV“ and „LOAD HV“ are directly connected with each other Tab. 3-5 ”ECU HV” Pin Assignment ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 35: Load Hv" Connector

    ”ECU HV” - Pin: LOAD0 ECU0 LOAD1 ECU1 LOAD2 ECU2 LOAD3 ECU3 LOAD4 ECU4 LOAD5 ECU5 LOAD6 ECU6 LOAD7 ECU7 LOAD8 ECU8 LOAD9 ECU9 LOAD10 ECU10 LOAD11 ECU11 Tab. 3-6 ”LOAD HV” Pin Assignment ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 36: Ecu Ch0-Ch42" / "Ecu Ch43-Ch63" Connector

    ”ECU CH0-CH42” and ”ECU CH43-CH63” Pin Assignments Signal Internally Connected to Connector ”LOAD CH0-CH42” - Pin: ECU0 LOAD0 ECU1 LOAD1 ECU2 LOAD2 ECU3 LOAD3 ECU4 LOAD4 ECU5 LOAD5 Tab. 3-7 ”ECU CH0-CH42” Pin Assignment ES4440.2 Compact Failure Simulation Module - User’s Guide...
  • Page 37 LOAD27 ECU28 LOAD28 ECU29 LOAD29 ECU30 LOAD30 ECU31 LOAD31 ECU32 LOAD32 ECU33 LOAD33 ECU34 LOAD34 ECU35 LOAD35 ECU36 LOAD36 ECU37 LOAD37 ECU38 LOAD38 ECU39 LOAD39 Tab. 3-7 ”ECU CH0-CH42” Pin Assignment (Forts.) ES4440.2 Compact Failure Simulation Module - User’s Guide...
  • Page 38 ECU62 * LOAD62 ECU63 * LOAD63 Shield 1 Shield 1 (shielding for ECU60/ECU61) Shield 2 Shield 2 (shielding for ECU62/ECU63) n.c. n.c. n.c. n.c. n.c. n.c. Tab. 3-8 ”ECU CH43-CH63” Pin Assignment ES4440.2 Compact Failure Simulation Module - User’s Guide...
  • Page 39 Together with the two ”Shield” lines (pins Z and a), these are thus suitable to be used as CAN lines, but can also be used as normal channels. Tab. 3-8 ”ECU CH43-CH63” Pin Assignment (Forts.) ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 40: Load Ch0-Ch42" / "Load Ch43-Ch63" Connector

    LOAD4 ECU4 LOAD5 ECU5 LOAD6 ECU6 LOAD7 ECU7 LOAD8 ECU8 LOAD9 ECU9 LOAD10 ECU10 LOAD11 ECU11 LOAD12 ECU12 LOAD13 ECU13 LOAD14 ECU14 LOAD15 ECU15 LOAD16 ECU16 Tab. 3-9 ”LOAD CH0-CH42” Pin Assignment ES4440.2 Compact Failure Simulation Module - User’s Guide...
  • Page 41 ”LOAD CH0-CH42” Pin Assignment (Forts.) Signal Internally Connected to Connector ”ECU CH43-CH63” - Pin: LOAD43 ECU43 LOAD44 ECU44 LOAD45 ECU45 LOAD46 ECU46 LOAD47 ECU47 LOAD48 ECU48 Tab. 3-10 ”LOAD CH43-CH63” Pin Assignment ES4440.2 Compact Failure Simulation Module - User’s Guide...
  • Page 42 Tab. 3-10 ”LOAD CH43-CH63” Pin Assignment (Forts.) ES4440.2 Compact Failure Simulation Module - User’s Guide...
  • Page 43 Together with the two ”Shield” lines (pins Z and a), these are thus suitable to be used as CAN lines, but can also be used as normal channels. Tab. 3-10 ”LOAD CH43-CH63” Pin Assignment (Forts.) ES4440.2 Compact Failure Simulation Module - User’s Guide...
  • Page 44 Pin Assignment ETAS ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 45: Accessories

    Compact Failure Simulation Module. Power Supply Cord Due to regional differences in the power supply, ETAS does not supply power cords with the ES4440.2 Compact Failure Simulation Module. The following table contains details of the relevant requirements and the ETAS order numbers.

  • Page 46: Es600 Network Module

    Stable and functional metal housing Ordering Information Order Name Short Name Order Number ES600 Module, Cable CBP120-2, ES600 F 00K 102 712 4 T-Brackets for ES600 Housing, User’s Guide (German and English) ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 47: Cables

    ETAS Accessories Cables Note Only ETAS cables can be used at the ES600 interfaces. The maximum permissi- ble cable lengths must be adhered to. 4.3.1 Ethernet Cable (RJ-45 Connector – Lemo Connector) This cable is used to connect an ES600 Network Module to the host.
  • Page 48 Accessories ETAS ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 49: Technical Data

    ETAS Technical Data Technical Data This chapter contains the technical data of the ES4440.2 Compact Failure Simu- lation Module. High-Current Channels "LOAD CH0-CH42"/"LOAD CH43-CH63" connectors and "ECU CH0-CH42"/ "ECU CH43-CH63" connectors Number Maximum permissible voltage 30 V Maximum permissible current...
  • Page 50 1% - 99% at 3 Hz to 100 Hz 50% at 2 Hz Accuracy of duty cycle ±0,1% Communication Interfaces Ethernet 10 MBaud High Speed CAN (CAN2.0B) to 1 MBaud Transceiver: MCP2515 ES4440.2 Compact Failure Simulation Module - User’s Guide...
  • Page 51 100 - 240 VAC (50 Hz /60 Hz) Power input 70 W Overvoltage category Pollution degree Mechanical Data Height of the front panel Width of the front panel 19” Depth (incl. connectors) 455 mm Weight 14 kg/31 lbs ES4440.2 Compact Failure Simulation Module - User’s Guide...
  • Page 52 5 °C to 35 °C (41 °F to 95 °F) during operation Permissible storage temperature -20 °C to +85 °C (-4 °F to 185 °F) Relative humidity 0 to 95% (non-condensing) Operating altitude Max. 2000 m / 6500 ft ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 53: Ordering Data

    ETAS Ordering Data Ordering Data The ordering data for the ES4440.2 are as follows: Ordering name Short name Ordering num- ES4440.2 Compact Failure Simulation ES4440.2 F-00K-107-497 Module Scope of delivery ES4440.2 Compact Failure Simulation Module ES4440.2 Compact Failure Simulation Module - User’s Guide...
  • Page 54 Ordering Data ETAS ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 55: 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 56 ETAS Contact Addresses ETAS ES4440.2 Compact Failure Simulation Module - User’s Guide...

  • Page 57: Index

    ”LOAD CH0-CH42” 40 monitoring 27 ”LOAD CH43-CH63” 40 ”LOAD HV” 35 ”Rail 1/2” 33 High-current channels 14 ”SYNC” 31 High-voltage channels 14 Connectors 15 Correct use 6 Identifications on the product 10 Introduction 5 ES4440.2 Compact Failure Simulation Module - User’s Guide...
  • Page 58 China 11 European Union 10 Safety concept 27 Safety instructions 6 basic 5 Marking of 5 Technical data 49 Time response 14 Transport 8 Use, correct 6 Waste Electrical and Electronic Equip- ES4440.2 Compact Failure Simulation Module - User’s Guide...

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