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ETAS ES5392.1 User Manual

High current switch board 6-ch
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ES5392.1 High Current Switch Board (6-CH)
User's Guide

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Summary of Contents for ETAS ES5392.1

  • Page 1 ES5392.1 High Current Switch Board (6-CH) 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

    Design of ES5392.1 ........
  • Page 4 7 ETAS Contact Addresses ........

  • Page 5: Introduction

    A total of 6 high current channels for connecting ECUs or loads are available. The ES5392.1 features a current measurement for each channel. Each of the six channels of the ES5392.1 can be configured as battery node sim- ulation or as independent high current switch.
  • Page 6 • Configurable status outputs via RTIO • Feeding the battery voltage to the measurement outputs -VBat and +VBat and controlling the LED of the ES5300.1-A Housing Block Diagram Fig. 1-1 shows a block diagram of the ES5392.1 High Current Switch Board (6-CH) -VBAT Battery...
  • Page 7 Battery Node 1 Battery Node x ECUx ES4408.1 Load Chassis Realtime PC ES5300.1-A HiL Systemhousing PSU Control CBAV325.1-3 CBAV305.1-3 Output Voltage Current Limit CBAV305.1-3 Automotive Battery Simulation (e.g. TDK-Lambda Genesys50-30) Hardware In the Loop Simulator Fig. 1-2 ES5392.1 in an HiL system...

  • Page 8: Basic Safety Notices

    The User's Guide and the Product Safety Advice must be read carefully prior to the startup of the product! ETAS GmbH does not assume any liability for damages resulting from improper handling, unintended use or non-observance of the safety precautions.

  • Page 9: Intended Use

    1.2.4 Intended Use The ES5392.1 is an add-on card for the ES5300.1-A Housing and the ES5300.1-B Housing for mapping battery nodes (KL15, KL30,…), for mapping high current switches and for remote control of power supplies. The ES5392.1 add-on card has the following components: •...
  • Page 10 Switch off the ES5300.1-A Housing or the ES5300.1-B Housing and external power supplies, and unplug the power plug and other connectors attached to the plug-in board. Wait at least three minutes before removing the plug-in board. ES5392.1 High Current Switch Board (6-CH) - User’s Guide...
  • Page 11 IEC 60332-1-2, IEC 60332-2-2, UL 2556/UL1581VW-1! For connecting lab power supplies and connecting an ES4408.1, use only cables that are approved by ETAS. Appropriate cables are specified in this User’s Guide in the chapter "Accessories" on page 29. When ordering a power supply from ETAS (e.g. SM52-AR-60 from Delta Elek- tronika), the matching cable is included in the scope of supply.

  • Page 12: Connecting/Disconnecting Devices

    To avoid injuries and hardware damages, please observe the following precau- tionary measures: • Do not apply any voltages to the connections of the ES5392.1 that do not correspond to the specifications of the respective connection. The exact specification of the I/O hardware is located in the manuals of the corre- sponding boards.

  • Page 13: Identifications On The Product

    47. 1.3.1 CE Mark With the CE mark attached to the product or its packaging, ETAS confirms that the product corresponds to the product-specific, applicable European Directives. The CE Declaration of Conformity for the product is available upon request.

  • Page 14: Rohs Conformity

    The user is obligated to separately collect old devices and provide them to the WEEE return system for recycling. The WEEE Directive applies to all ETAS devices, but not to external cables or bat- teries. Additional information about the recycling program of ETAS GmbH is available from the ETAS sales and service locations (see "ETAS Contact Addresses"...

  • Page 15: About This Manual

    This section provides a description of the different connections, connec- tors and pin assignments of the ES5392.1. • "Technical Data and Standards" on page 47 This chapter contains the technical data of the ES5392.1. It also contains the norms and standards met. • "Ordering Data" on page 50 1.6.1...
  • Page 16 Content-based highlights and newly intro- and arithmetic data types is not duced terms are placed in italics. possible. Important notes for the user are presented as follows: Note Important note for the user. ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 17: Design, Installation And Fuses

    ETAS Design, Installation and Fuses Design, Installation and Fuses This chapter contains information about the design and installation of ES5392.1, as well as information about the fuses. • "Design of ES5392.1" on page 18 • "Connectors CO200, X1 PwrCtrl, X2 SwCtrl, X3 Battery Input and X4 Power I/O"...

  • Page 18: Design Of Es5392.1

    Design, Installation and Fuses ETAS Design of ES5392.1 Fig. 2-1 and Fig. 2-2 show the ES5392.1 High Current Switch Board (6-CH) and its components. Battery Input X4 Power I/O SwCtrl PwrCtrl CO 200 Fig. 2-1 Front plate and plug side of the ES5392.1...

  • Page 19: Connectors Co200, X1 Pwrctrl, X2 Swctrl, X3 Battery Input And X4 Power I/O

    Connectors CO200, X1 PwrCtrl, X2 SwCtrl, X3 Battery Input and X4 Power I/O The connectors of the ES5392.1 are shown in Fig. 2-1 on page 18. The pin assignment of the plugs are listed in the chapter "Connections and Con- nectors"...

  • Page 20: Fuses

    Design, Installation and Fuses ETAS Fuses The high current paths of the ES5392.1 are protected with fuses (60 V / 15 A). Additional fuses are used for protecting voltages of the backplane, the MRC sig- nal and VBat. In case of a fuse defect, we recommend to send the board to ETAS for further testing.

  • Page 21: Installation In The Es5300.1-A/B Housing

    Fig. 2-2 on page 19). The heat sinks must not be disassembled. Defective fuses can be recognized, e.g. as software feedback in the RTIO. In case of a fuse defect, please send the ES5392.1 to ETAS (see "ETAS Contact Addresses" on page 51), since a professional replace- ment and reassembly must be ensured.
  • Page 22 3. Wait a few minutes for the components (capacitors, etc.) to be discharged. 4. Place the ES5392.1 in the upper and lower rail of the slot and push it in a little bit. The backplane con- nector CO200 must be located at the lower rail so that it is possible to insert it in the backplane.

  • Page 23: Configuration

    Design, Installation and Fuses Configuration With the help of screws, the ES5392.1 can be configured as battery node simu- lation with voltage supply from an external power supply or as high current switch. The digital inputs and outputs of the ES5392.1 can be adjusted to an external power supply with the help of jumpers.

  • Page 24: Configuration Of Digital Inputs/Outputs Of X1 Pwrctrl

    2.5.2 Configuration of Digital Inputs/Outputs of X1 PwrCtrl There are five connection strips on the ES5392.1 for jumpers that are used for configuring the digital inputs/outputs of X1 (PwrCtrl) to an external power sup- ply. Fig. 2-5 shows the position of the jumpers.
  • Page 25 The block diagram for the digital outputs is located in Fig. 3-3 on page 34. Note Ensure that Pin 1 and Pin 2 of neighboring connection strips are not connected by a jumper. ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 26: Internal Connections To Es5300 Chassis Connections +/-Vbat And Led

    On the front plate of the ES5300.1-A Housing at the bottom right are two sock- ets, -VBAT and +VBAT. Next to the sockets is an LED (Fig. 2-6 on page 26). If the ES5392.1 is connected with the contacts of -VBAT, +VBAT and the LED on the inside, then they have the following functions: •...
  • Page 27 Connecting -VBAT, +VBAT and LED with X4 Power I/O of the ES5392.1 Fig. 2-7 shows the connection of -VBAT and +VBAT to X4 Power I/O of the ES5392.1. The connection is done via channel 5 of the ES5392.1. This channel is equipped with a 5-A fuse.
  • Page 28 • Matching the cross section of the cable (0,34 mm • Operating temperature: max. 60 °C • RoHS conformity Cable type for the cable between ES5392.1 and +/- VBAT: • Flexible single core line with fine copper strands (e.g. H05V-K) • Cross section: 0,34 mm •...

  • Page 29: Accessories

    Cable Imprint Signal +VBAT -VBAT When ordering a power supply from ETAS (e.g. SM52-AR-60) from Delta Elek- tronika, the matching cable is included in the scope of supply. 2.6.2 External Power Supplies A list of the power supplies supported by the software is located in the RTC User's Guide in the section of the ES5392 description.
  • Page 30 Design, Installation and Fuses ETAS ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 31: Signals

    When it is used as high current switch, install the screw on the left. Then the signals HS_UBAT15A_0,...HS_UBAT15A_5 are active. For every channel, the current is measured and is available as physical value in the RTIO and, as such, for the model. ES5392.1 High Current Switch Board (6-CH) - User’s Guide...
  • Page 32 HC_OUT_x OUT15A_x ES5392.1 Fig. 3-1 Block diagram of the high current unit of the ES5392.1 Right screw: battery node simulation Left screw: high current switch The pin assignment of X4 Power I/O is located in Tab. 4-4 on page 46.

  • Page 33: Control Of An External Power Supply Via X1 Pwrctrl

    ETAS Signals Control of an External Power Supply via X1 PwrCtrl The ES5392.1 can control an external power supply via the connector X1 PwrCtrl (pin assignment on page 41). The inputs and outputs of X1 PwrCtrl have the following functions: •...

  • Page 34: Digital Outputs At X1 Pwrctrl

    The configuration for the digital outputs via jumper is described in "Configura- tion of Digital Inputs/Outputs of X1 PwrCtrl" on page 24. The pin assignment of X1 PwrCtrl is located in Tab. 4-1 on page 41. ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 35: Analog Inputs At X1 Pwrctrl

    ±60 V 3.3.4 Analog Outputs at X1 PwrCtrl To adjust the target voltage and target current at the external power supply, two analog outputs ANA_OUT_0 and ANA_OUT_1 are available at X1 PwrCtrl. ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 36: Generic Ttl Signals At X2 Swctrl And X4 Power I/O Outputs

    The connector X2 SwCtrl is intended for connecting an ES4408.1 Load Chassis and does not offer overload protection.Connecting the Switch Control outputs to non-intended devices may lead to the destruction of the outputs or to an undefined behavior . ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 37: Main Relay Control Mrc (X4 Power I/O)

    • Minimum voltage of 6 V must be present to generate a usable MRC signal • Setting range of current source/drain possible from 0 mA to 150 mA in increments of 1 mA ES5392.1 High Current Switch Board (6-CH) - User’s Guide...
  • Page 38 Input voltage 0 V to 60 V Input current 0 mA -150 mA Accuracy 3 mA Galvanic isolation Overvoltage protection up to +/- 60 V Tab. 3-2 Technical data of MRC input ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 39: Connections And Connectors

    Fig. 4-1 Connector to backplane (top view) • The assignment of the pins is as follows (the maximum possible pin assign- ment for the ES5300.1-A Housing and the ES5300.1-B Housing is given): ES5392.1 High Current Switch Board (6-CH) - User’s Guide...
  • Page 40 GBLI_TX_n_0 GBLI_TX_p_0 GBLI_RX_n_0 GBLI_RX_p_0 M_LVDS_n_7 M_LVDS_p_7 BN_5 BN_4 12-shield GBLI_TX_n_1 GBLI_TX_p_1 GBLI_RX_n_1 GBLI_RX_p_1 M_LVDS_n_6 M_LVDS_p_6 SPI_CS_B_n SPI_CS_A_n 11-shield GBLI_TX_n_2 GBLI_TX_p_2 GBLI_RX_n_2 GBLI_RX_p_2 M_LVDS_n_5 M_LVDS_p_5 SPI_MOSI SPI_CLK 10-shield GBLI_TX_n_3 GBLI_TX_p_3 GBLI_RX_n_3 GBLI_RX_p_3 M_LVDS_n_4 M_LVDS_p_4 PCIE_WAKEn SPI_MISO 9-shield GBLI_PRESENT_n GEO_ADDR_4 PCIE_REFCLK_n PCIE_REFCLK_p M_LVDS_n_3 M_LVDS_p_3 n.c.

  • Page 41: Connector X1 Pwrctrl

    GND_ANA_OUT_0** ANA_OUT_1 Analog output 1 GND_ANA_OUT_1** Housing GND_EARTH * Reference of digital inputs and outputs, internally connected ** Reference of analog inputs and outputs, internally connected Tab. 4-1 Connector X1 PwrCtrl ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 42: Connector X2 Swctrl

    DIG_OUT_3 Digital output 3 GND_DIG_OUT_1* DIG_OUT_4 Digital output 4 1, 2 GND_DIG_OUT_0* DIG_OUT_5 Digital output 5 GND_DIG_OUT_1* Housing GND_EARTH * Reference of digital outputs, internally connected Tab. 4-2 Connector X2 SwCtrl ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 43: Connector X3 Battery Input

    The sum of absolute current values must not exceed 40 A and must be limited by the upstream element (power supply). In case on non-observance, overheating can lead to damages to the ES5392.1, the ES5300 housing and personal injuries. ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 44: Connector X4 Power I/O

    (see "Ordering Data" on page 50). Type: PCIM30W15F8000, female Manufacturer: Positronic Order number: PCIM30W15F8000/AA Crimp Contacts (15 parts for each type): Type: FC422N8 Manufacturer: Positronic Order number: FC422N8/AA-1565.0 Type: FC114N2 Manufacturer: Positronic Order number: FC114N2/AA ES5392.1 High Current Switch Board (6-CH) - User’s Guide...
  • Page 45 ETAS Connections and Connectors Fig. 4-2 X4 Power I/O connector ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 46: Connecting Cable

    The cables used must be suitable particularly for occurring currents, voltages and temperatures and flame-retardant in accordance with one of the following standards IEC60332-1-2, IEC60332-2-2, UL2556/UL1581VW-1! Note The signal lines may not exceed a maximum length of 3 m! ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 47: Technical Data And Standards

    ETAS Technical Data and Standards Technical Data and Standards This chapter contains the technical data of the ES5392.1. It also contains the norms and standards met. • "Technical Data" on page 47 • "Norms and Standards Met" on page 49 •...
  • Page 48 0 V to 60 V Input current 0 mA -150 mA Accuracy 3 mA Galvanic isolation Current Consumption from Backplane Current consumption 0.1 A @ +3.3 V DC 1.65 A @ +12 V DC ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 49: Norms And Standards Met

    Should that be the case, the operator may be requested to institute reasonable measures. Note The signal lines may not exceed a maximum length of 3 m! ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 50: Ordering Data

    * The cable pair of the wire with ring terminals is imprinted with numbers. The numbers’ meaning is as follows: Cable Imprint Signal +VBAT -VBAT Note The crimp tool for the crimp contacts of the AS_Positronic_ES5392 must be ordered separately. ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 51: 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 52 ETAS Contact Addresses ETAS ES5392.1 High Current Switch Board (6-CH) - User’s Guide...

  • Page 53: Index

    Safety notices, identification of 8 Safety precautions 8 Signals 31 Electrical safety 10 Analog Inputs 35 ETAS Contact Addresses 51 Analog inputs 35 Analog Outputs 35 Battery node and high current Fuses 17 ES5392.1 High Current Switch Board (6-CH) - User’ Guide...
  • Page 54 Generic TTL Signals 36 Main Relay Control MRC 37 Voltage supply 31 Signals Analog outputs 35 Standards and norms 49 Technical Data 47 Waste Electrical and Electronic Equip- ment 14 WEEE return system 14 ES5392.1 High Current Switch Board (6-CH) - User’ Guide...

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