ETAS ES4441.1 User Manual
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ETAS ES4441.1 User Manual

Compact error simulation module with breakout frontpanel
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ES4441.1 Compact Error Simulation Module with
Breakout Frontpanel
User's Guide

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  • Page 1 ES4441.1 Compact Error Simulation Module with Breakout Frontpanel 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

    General Instructions on Operating the ES4441.1 ..... 23 Table of possible Errors the ES4441.1 ......24...
  • Page 4 Master/Slave Operation of Several ES4441.1 Systems ....50 External Triggering of the ES4441.1 ......50 IP Addresses .
  • Page 5 9 ETAS Contact Addresses ........
  • Page 6 Contents ETAS ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 7: General Information

    Please read the documentation accompanying the product ("ES4441 Safety Advice" and this User’s Guide) carefully before using the product. ETAS GmbH cannot be made liable for damage which is caused by incorrect use and handling and not adhering to the safety instructions.

  • Page 8: Connecting/Removing Devices

    Please take the following precautionary measures to avoid any injuries and damage to hardware: • Do not apply any voltages to the ports of the ES4441.1 which do not correspond to the specifications of the relevant port. Refer to the corres- ponding boards’...

  • Page 9: Intended Use

    General Information 1.1.6 Intended Use The ES4441.1 Compact Error Simulation Module is a 19” housing with a height of 9 HU which can be assembled in a rack using the corresponding mounts. WARNING! The ES4441.1 must always be integrated in the ETAS LABCAR system and must not be used as a "standalone"...
  • Page 10 • Leave the casing open at the back. When the ES4441.1 is being operated in a 19" rack, make sure you observe the following points: • The air vents must be at least 15 cm away from walls and objects in the environment.

  • Page 11: Identifications On The Product

    Declaration of Conformity for the product is available upon request. RoHS Conformity 1.4.1 European Union The EU Directive 2011/65/EU limits the use of certain dangerous materials for electrical and electronic devices (RoHS conformity). ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 12: China

    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 Content markings and newly introduced logical and arithmetic is not pos- terms are shown in italics sible. Important notes for the user are shown as follows: Note Important note for the user. ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 14 General Information ETAS ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 15: Introduction

    ETAS Introduction Introduction This User’s Guide contains a description of the ES4441.1 Compact Error Simula- tion Module with Breakout Frontpanel. It consists of the following chapters: • Introduction • "Hardware Features" on page 43 This chapter contains a detailed description of the features of the ES4441.1 Compact Error Simulation Module.

  • Page 16: Applications

    The ES4441.1 Compact Error Simulation Module must not be operated over 2000m! The ES4441.1 Compact Error Simulation Module is a 19” housing with a height of 9 HU which can be assembled in a rack using the corresponding mounts. The Breakout Frontpanel of the ES4441.1 Compact Error Simulation Module is used to divide the signals between the control unit and the ETAS LABCAR all- owing the user to simulate a cable break simply by pulling a jumper.

  • Page 17: Functions And Features

    "Hardware Features" on page 43. 2.2.1 Error Simulation The ES4441.1 Compact Error Simulation Module makes it possible to simulate errors in real time for 255 ECU channels (per ES4441.1). Error Channels The 255 failure simulation channels are for voltages up to 30 V and currents up to 40 A.

  • Page 18: Connectors, Displays And Fuses

    Connectors, Displays and Fuses Connectors on the Front Panel and Rear The ES4441.1 Compact Error Simulation Module has several connectors on the front and rear for connecting the ECU and loads, addressing the ES4441.1 and for master/slave operation. CAUTION! All external I/O-lines must be less than 3m.
  • Page 19 • Connector for current measurement (two yellow screw pads) • Connector for optional LC-Bridge (DSUB) • Connector for external Synchronisation and Trigger (DSUB) • Ethernet interface (RJ45) • Powerline connector ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 20: Application Environment

    Back View of the ES4441.1 Compact Error Simulation Module Status Displays via LEDs on the Front Panel There are several LEDs on the front panel of the ES4441.1 Compact Error Simu- lation Module which provide information on operating states of the ES4441.1 and the communication interfaces.
  • Page 21 ETAS Introduction Communication Interfaces The ES4441.1 Compact Error Simulation Module has an interface for communi- cation via the Ethernet protocol. In addition, it is also possible to realize complex hardware configurations in a HiL system with a real-time PC as simulation target.

  • Page 22: Block Diagram

    • Configuration of the Ethernet interface • Configuration for master/slave operation Block Diagram The following figure shows a principle overview of the jumpers, the error swit- ches and the connectors of the ES4441.1 Compact Error Simulation Module +UBATT1 Rail1 - UBATT1...

  • Page 23: Control Unit

    ETAS Introduction Control Unit The core of the ES4441.1 Compact Error Simulation Module is a microcontroller (μC) with an integrated Ethernet controller – the μC is connected directly to Ethernet-PHY. A serial, non-volatile EEPROM saves a range of specific parameters such as MAC address and IP address.

  • Page 24: Table Of Possible Errors The Es4441.1

    Introduction ETAS Table of possible Errors the ES4441.1 The following table shows the errors that can be simulated with the ES4441.1 Compact Error Simulation Module. Comm. Type of Error Switch Multi. Comment Error Open load Relay Possi- Possible error num-...
  • Page 25 26 0xB Pull down resistor to MOS- For this kind of error –UBATT1 for ECU both rails will be nee- pin, load pin discon- nected ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 26 To activate the error M7 will open. At reset, over temp. or over current vice versa. This error can be set as multiple error with every other error type. ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 27 50 0x10 Reset all errors All errors will be reset to default Tab. 2-1 Errors that can be simulated with the ES4441 ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 28 Introduction ETAS ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 29: Commands

    ETAS Commands Commands The following tables are describing the structure of the ES4441.1 Compact Error Simulation Module. Tab. 3-1 ES4441.1 Compact Error Simulation Module ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 30 Commands ETAS Tab. 3-2 ES4441.1 Compact Error Simulation Module ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 31 ETAS Commands Tab. 3-3 ES4441.1 Compact Error Simulation Module ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 32 Commands ETAS Tab. 3-4 ES4441.1 Compact Error Simulation Module ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 33 ETAS Commands Tab. 3-5 ES4441.1 Compact Error Simulation Module ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 34 Commands ETAS Tab. 3-6 ES4441.1 Compact Error Simulation Module ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 35 ETAS Commands Tab. 3-7 ES4441.1 Compact Error Simulation Module ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 36 Commands ETAS Tab. 3-8 ES4441.1 Compact Error Simulation Module ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 37 ETAS Commands Tab. 3-9 ES4441.1 Compact Error Simulation Module ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 38 Commands ETAS Tab. 3-10 ES4441.1 Compact Error Simulation Module ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 39 ETAS Commands Tab. 3-11 ES4441.1 Compact Error Simulation Module ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 40 Commands ETAS Tab. 3-12 ES4441.1 Compact Error Simulation Module ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 41 ETAS Commands Tab. 3-13 ES4441.1 Compact Error Simulation Module ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 42 Commands ETAS The following table is showing the Control Commands that are available for the ES4441.1. Tab. 3-14 ES4441.1 Control Commands ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 43: Hardware Features

    ETAS Hardware Features Hardware Features This chapter contains detailed information on the features of the ES4441.1 Com- pact Error Simulation Module. These are: • "Error Simulation for 255 channels" on page 43 • "Error Types" on page 44 • "Time Response" on page 47 •...

  • Page 44: Error Types

    (single) • the settable duration of the error state • whether an error can also be realized in PWM control as a loose contact. Abb. 4-1 Error Channels ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 45: Pin-To-Pin Resistance

    The period of time for which an error is active can be of interest for measuring latencies of the diagnostic system. For example, the ES4441.1 can simulate a specific error for 20 ms, but the ECU software requires at least 30 ms to generate an error memory entry.

  • Page 46: Number Of Possible Active Error States

    If you are using PINCONTROL for error simulation, errors which cannot be selec- ted are excluded from the selection in the user interface. If, however, you address the ES4441.1 automatically by Ethernet, you should ensure that the selected types of error are also possible simultaneously as other- wise an error message will be issued.

  • Page 47: Time Response

    For errors which are switched by MOSFETs, this kind of measuring is not neces- sary due to fast activation. ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 48: General Resistor Cascade

    Excess Temperature" on page 50). Ground Shift Resistor Cascade To simulate a ground shift on the ground channel (340), the ES4441.1 Compact Error Simulation Module has a parallel resistor cascade with a minimum resistor 0,5 Ω and a maximum resistor of 4,0 Ω.

  • Page 49: Status Displays Via Leds On The Front Panel

    Current Limit of the ground shift resistor cascade Status Displays via LEDs on the Front Panel There are several LEDs on the front panel of the ES4441.1 Compact Error Simu- lation Module, the meaning of which is described in this section.

  • Page 50: Master/Slave Operation Of Several Es4441.1 Systems

    “Trigger“ connector (see chapter 6.6 on page 63). External Triggering of the ES4441.1 It is possible to activate an error of the ES4441.1 Compact Error Simulation Module via external triggering. The Trigger input is TTL compliant and has a gal- vanic separation.

  • Page 51: Power Cord

    Power cord Due to regional differences in the power supply, no power cords are provided for the ES4441.1 Housing. The respective requirements and the ETAS order number are located in the following table. Use only power cords that are specified there.
  • Page 52 ETAS CAUTION! To avoid injury and damage, observe the following: Connect the ES4441 to a protective contact socket using only power cords that are specified in the table above. ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 53: Mechanical Construction

    The connectors to the control unit ("ECU") are mounted on the right-hand side (see Figure "Front View of the ES4441.1 Compact Error Simulation Module" on page 53). The connec- tors to the ES4500 Component Rack (“LOAD”) or signal box are located on the left.

  • Page 54: Connectors Load (1) And Ecu (1)

    (wrong side, etc.). The user has to take care to insert the connectors on the correct sides. It is not allowed to connect an ECU to the LOAD connector or to connect a load/signal box to the ECU connector. ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 55: Connectors Load (2) And Ecu (2)

    7,5 A while the 4 mm system is used for signals exceeding 7,5 A. In both systems, the jumpers include center tabs that enable the user to short- circuit signals via cable jumpers or to connect external measuring systems. ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 56: Signal Channel Labels

    5.4.1 Signal Channel Labels As the breakout frontpanel of the ES4441.1 Compact Error Simulation Module is designed for use in combination with the ETAS ES4500 Component Rack, the standard labels of the individual signal channels are based on the layout of the ES4500 backplane.

  • Page 57: Layout Of The Lab Jacks

    (ECU) while the lower lab jack connects the component rack (LOAD) / signal box (see Figure "Layout of the Lab Jacks" on page 57). Abb. 5-4 Layout of the Lab Jacks ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 58: Safety Measures

    Mechanical Construction ETAS Safety Measures The over current protection of the 15A, 20A and 40A channels of the ES4441.1 Compact Error Simulation Module is realised by fuses. These are standard blade fuses used commonly in the automotive environment. 5.5.1 Overview Fuses:...

  • Page 59: Changing Fuses

    1. Remove the two screws shown in the figure from the fuse compartment cover. 2. Remove the fuse compartment cover. The eight fuses of the error channels can now be easily accessed. ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 60 2. Now tighten the screws you removed before. Note Be sure to use 15 A and 20 A rated fuses only. Using fuses with hig- her ratings will void the warranty. ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 61: Signal Routing

    Mechanical Construction Signal Routing In general, all connections between the LOAD(1),(2) and ECU(1),(2) connectors of the ES4441.1 Compact Error Simulation Module are point-to-point links that can be opened with the use of jumpers and relays. Note It is not possible to use error channels 327, 329, 331 and 333, because this channels are combined with other channels (see "Table...

  • Page 62: Channel 339 (+Ubatt)

    It is possible to simulate ground shift for channel 340 by setting the value of a resistor cascade. Note The error channels 334 and 335 do not exist (see "Table of the High Current Signals" on page 73) ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 63: Pin Assignment Back Side

    • "”TRIGGER” Connector" on page 63 • "”Ethernet” Connector" on page 64 ”RAIL 1 & RAIL 2” Connectors The Rail1 and Rail2 connector are used to cascade two or more ES4441.1 Com- pact Error Simulation Modules. Type: Green Banana Jack (female) ”+UBATT 1 &...

  • Page 64: Ethernet" Connector

    The ”Ethernet” connector is used for the Ethernet connection to the host system or an Ethernet switch. An Ethernet crossover cable has to be used for this con- nection. Type: RJ45 FEMALE CONNECTOR Abb. 6-2 ”Ethernet” Connector ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 65: Pin Assignment Front Side

    The following Chapter describes the pin allocations of the connectors to the ES4500 Component Rack (“LOADBOX”) or signal box, and the connectors to the control unit ("ECU"). Connector Pin Allocations Fig. 7-1 260-pin ITT Cannon DLM5-260 Connector ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 66 The following table shows the allocation of the signal channels to the corre- sponding connector pins: Channel Max. Current [A] ITT Cannon DLM5-260 Tab. 7-1 Table of Low Current Signals ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 67 ETAS Pin Assignment Front Side Channel Max. Current [A] ITT Cannon DLM5-260 Tab. 7-1 Table of Low Current Signals ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 68 Pin Assignment Front Side ETAS Channel Max. Current [A] ITT Cannon DLM5-260 Tab. 7-1 Table of Low Current Signals ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 69 ETAS Pin Assignment Front Side Channel Max. Current [A] ITT Cannon DLM5-260 Tab. 7-1 Table of Low Current Signals ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 70 Pin Assignment Front Side ETAS Channel Max. Current [A] ITT Cannon DLM5-260 Tab. 7-1 Table of Low Current Signals ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 71 ETAS Pin Assignment Front Side Channel Max. Current [A] ITT Cannon DLM5-260 Tab. 7-1 Table of Low Current Signals ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 72 Pin Assignment Front Side ETAS Channel Max. Current [A] ITT Cannon DLM5-260 Tab. 7-1 Table of Low Current Signals ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 73 ETAS Pin Assignment Front Side Chan- Max. current [A] ITT Cannon ITT Cannon DLM5-260 KPTC22-55 Tab. 7-2 Table of the High Current Signals ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 74 ; v ; g G ; d ; H J ; e ; f ; K ; L ; M Tab. 7-2 Table of the High Current Signals ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 75: Technical Data

    ETAS Technical Data Technical Data This chapter contains the technical data of the ES4441.1 Compact Error Simula- tion Module. General Technical Data Error Channels Number Maximum permissible volt- 30 V Maximum permissible cur- rent 1 A (Channel: 67 – 281) 3.0 A (Channel: 282 –...
  • Page 76 Low current in rails ±3% of actual value ±20 mA High current in rails ±3% of actual value ±400 mA Current in channel 340 ±3% of actual value ±800 mA ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 77 The device must not be operated with fuse cover open! Electrical Data Input voltage 100 - 240 VAC (mains frequency) (50 / 60 Hz) Power input 250 W Overvoltage category II Pollution degree ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 78: Fuses

    • Plug-in bridge 4 mm • Fuse 20 A • Fuse 15 A • Customized front panel • English Manual: ES4441.1 Compact Error Simulation Module User’s Guide The accessories are available on request. ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 79: Etas Contact Addresses

    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 ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 80 ETAS Contact Addresses ETAS ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

  • Page 81: Index

    Documentation 7 LABCAR-PINCONTROL 22 Electrical data 77 LEDs 20 Electrical safety 9 Loose contacts Environmental conditions 78 simulation 45 Error state duration 45 Master/slave operation 50 Errors IP addresses 50 ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...
  • Page 82 Safety concept 50 Safety instructions 7 Safety instructions, labeling 7 Technical data 75 Time response 17 Use, intended 9 Waste Electrical and Electronic Equipment 12 WEEE take-back system 12 ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide...

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