Page 2
The contents of this document may not be reproduced in any form or communicated to any third party without the prior written consent of AVL. While every effort is made to ensure its correctness, AVL assumes no responsibility neither for errors and omissions which may occur in this document nor for damage caused by them.
The product may only be used and operated by qualified personnel capable of observing the necessary safety precautions. All accessories and equipment used with the product must be supplied or approved by AVL. The operating prin- ciple of this product is such that the accuracy of the measurement results depends not only on the correct operation and functioning of the product, but also on a variety of peripheral conditions beyond the control of the manufacturer.
Make sure that the device is supplied with the correct supply voltage and safe power isolation of the supply voltage is guaranteed. NOTICE Always place the device in a position that allows air to circulate freely through the device’s venting aperture. F-FEM-CON — User’s Guide...
System Environment ......................16 Data Transfer between Test Bed and PUMA Open System ..........17 Cascade ..........................18 Visualization ........................... 18 F-FEM-CON Block Diagram ....................19 3 Installation ........................21 Scope of Supply ........................21 Mechanical Installation ......................22 3.2.1 External Dimensions, Space Requirement ...............
Page 8
4.7.1 Block Diagram ........................69 4.7.2 Description of Modes ......................70 4.7.2.1 Signal type: PWM, PWM inverted ..............70 4.7.2.2 Signal type: Simulate ABZ ................71 4.7.2.3 Signal type: Signal Splitter (SiSp) ..............72 4.7.3 Accuracy of the Frequency Synthesis ................74 F-FEM-CON — User’s Guide...
Product specific information The F-FEM-CON (Fast-Front End Modul Controller) is part of a family of Front End Modules that operate together in a network. Data communication takes place via an IEEE1394-compatible bus. Thus, within a PUMA system real time data communication is ensured.
PUMA Open channels (normnames) and use them in PUMA Open. Information This documentation does not and cannot replace adequate training. The F-FEM-CON manual supports you in planning and installation as well as in your daily work at the test bed. It assumes that you are familiar with:...
What you should know This manual documents the I/O component when using the F-FEM-CON in a Contents & Scope test bed system and describes the hardware used: Connector pin out Power supply Grounding and shielding Sensor types ...
We want to hear from you Your comments and suggestions help us to improve the quality and practical relevance of our manuals. If you have any suggestions for improvements, please send them to: docu@avl.com We look forward to hearing from you! F-FEM-CON — User’s Guide...
Furthermore, the installation effort for the F-FEM-CON is rela- tively low compared to other data acquisition systems. The main application of the F-FEM-CON is in the area of engine test beds, as well as in all types of vehicle testing.
General System Environment The figure below outlines schematically how F-FEM-CON modules are inte- grated with the PUMA Open test bed system. Fig. 2 1..Test bed workstation (on which the PUMA Open system has been installed) 2..F-FEM-AIF, directly connected to the PUMA Open system 3..
2..IEEE 1394 Interface adapter, via which all F-FEM signals are transferred to/from the PUMA Open system. 3..F-FEM-CON – various sensors and actuators of the engine or dyno are connected here. 4..Engine test bed – analog signals (engine speed, vehicle speed) are measured by sensors fixed at/in the engine.
General Cascade The F-FEM-CON is part of a family of Front End Modules that operate together in a network. The other members of this group are: F-FEM-CON Controller with analog and digital inputs and outputs, Counter outputs, frequency outputs F-FEM-DAC...
Installation Scope of Supply Information Normally, the F-FEM-CON is delivered in a cabinet with the wiring already done. Component parts must only be exchanged in the case of replacements or system extensions.. Please check the contents with the items as indicated under Scope of Supply.
The required mounting space on the mounting panel is 110 mm x 264 mm. The mounting depth is 180 mm. With the plugs connected it is 245 mm. W = 110 D = 180 Fig. 5 F-FEM-CON — User’s Guide...
Installation 3.2.2 Fixing the Module at the DIN Rail The F-FEM-CON has been designed for top hat rail mounting (DIN rail; TS35 according to DIN EN 50022). For mounting/dismounting, you need a screw driver size 6. Fig. 6 1..Module locking 2..
Several F-FEMs are connected by connecting their IEEE1394 interfaces (X21, X22, X23). 3.3.1 Power Cable Inlet Fig. 7 Information Pull shield back over isolation and fix it with the screws of the strain to the connector case on both sides! F-FEM-CON — User’s Guide...
3.3.2.1 Cable Design NOTICE For wiring the IEEE1394 bus on the AVL F-FEM, please only use the special cables! (See Tab. 2 on page 25.) Other cables from other manufacturers or office supply or multimedia stores must not be used, as these would lead to various network problems!
Recommended Bus Topology Fig. 9 shows IEEE1394 wiring as recommended. In the parameterization, the F-FEM that has the number 1 should be next to the test bed workstation, most commonly the F-FEM-CON. Fig. 9 3.3.2.3 About F-FEM Devices, Nodes, Cables and Repeaters The maximum distance between any two nodes (e.g.
Installation Information More details about maximum number of channels, sampling rates and network-delay times see the release notes of the according automation system or contact the AVL pruduct management. 3.3.2.4 Mechanical Layout of a Cable Routing NOTICE Please do not undershoot the minimum bending radius R of the cables! Minimum bending radius: (see Fig.
This requires low grounding resistance and compliance with the high frequency rules regarding installation, wire types and contacting. The F-FEM-CON is electrically isolated from the 24 V DC supply. All analog outputs are electrically isolated from each other and from the system. The...
Page 29
Mounting of ground braid at ground terminal Fig. 13 The following materials are recommended for grounding: EX0441 Ground braid: tin-plated Cu 10 mm (rolled) EU1675 Ground terminal 10 mm EU2168 Pin-type cable socket 10 mm F-FEM-CON — User’s Guide...
Page 30
Installation Grounding when using standard cabling Fig. 14 F-FEM-CON — User’s Guide...
Page 31
Installation Grounding when using a fiber optic link Fig. 15 F-FEM-CON — User’s Guide...
Page 32
Installation Grounding when using a fiber optic link and split grounds Fig. 16 F-FEM-CON — User’s Guide...
The ground wire minimizes the effects of ground loops. – All unused connectors should be protected with a dummy plug (con- ductive cover or the connectors or connector housings which are part of the scope of supply). F-FEM-CON — User’s Guide...
The firmware has already been installed. The firmware necessary for operation can be loaded by the automation system during the initialization phase (chapter "The F-FEM Firmware Download Manager (FFDM)" in F-FEM Parameterization, please see Secondary literature on page 13). F-FEM-CON — User’s Guide...
For further information, please refer to Analog Input Load Cell on page 44. Each of the 5 analog channels of the F-FEM-CON is equipped with an Analog Digital Converter (ADC). A brief overview of ADC features is given below: Sigma-delta principle ...
1..The electrical isolation between the analog and the digital ground may be removed by bridging X1/5 and X1/9, if necessary. In this case, the specification as given in the column "Without Isolation" applies, please see chapter Specifications on page 42. The pin assignment above applies to X1, X2, X3 and X4. F-FEM-CON — User’s Guide...
Page 37
During parameterization, you specify whether the voltage or the current is to be measured. This determines whether or not a sensing resistor of 500 Ω is to be connected in parallel to the input voltage divider. F-FEM-CON — User’s Guide...
Fig. 21 The frequency f is identical to the sampling rate. The filter cut-off frequency notch is 0.262×f . The low pass filter is of type notch sin x F-FEM-CON — User’s Guide...
Whereby 1000 cycles per second / 5000 correspond to the lowest coherent sampling rate. 83 and 499 are prime numbers. Function generator and F-FEM-CON have been synchronized. All values refer to the full scale value of the ADC (±27 V). Size of dominant ...
Page 41
Operation Enlarged representation of the frequency range in the environment of the domi- nant mode Fig. 23 20 Vpp, 99.8 Hz Fig. 24 F-FEM-CON — User’s Guide...
500 Hz 17 bit 1000 Hz 16 bit + 9 V max. Common Mode Range Common Mode Rejection 80 dB min at 25 °C Input Resistance 1 MΩ Sampling Rates 100 Hz – 1000 Hz Tab. 3 F-FEM-CON — User’s Guide...
Input Resistance Sampling Rates 1 Hz – 1000 Hz Tab. 4 NOTICE All specifications are for T = 0 to 60 °C unless otherwise noted. All values of discrepancy refer to the nominal range + 10 V. F-FEM-CON — User’s Guide...
The signal input is highly resistive to prevent the bridge from being loaded. Thus, the input can move towards its full-scale value when it is left open. The full-scale value indicates that a sensor has not been connected correctly or that a signal line has been interrupted. F-FEM-CON — User’s Guide...
20.0 100 Hz 25.0 200 Hz Tab. 5 *) Since firmware Rev. 5.0.x Conversion from value on scale (phys) into measure value (raw value in mV) Raw value [mV]= Phys * 1000 / (200 * Gain) F-FEM-CON — User’s Guide...
Page 46
----------- - 0.03 % 0.075 % is related to the rated torque value of the dyno. (Factor 1000 / 400 stands for the ratio M The error on account of the F-FEM-CON: × -- - 0.005 % 0.00625 % is related to the rated torque value of the dyno.
DAC, a precision voltage reference and a voltage and current output stage. To achieve the desired accuracies, each output is checked during production testing and the deviations found are stored in the EEPROM of the F-FEM-CON. The F-FEM-CON software takes these deviations into account and corrects them (calibration).
18.6 from 0 to 60 °C Voltage at the load + 11 = 20 mA μH at a load of 500 Ω Load Inductivity Output Bandwidth μA Output Noise 0.1 Hz to 1 MHz Tab. 7 F-FEM-CON — User’s Guide...
External voltage applied at the no persistent damage outputs Tab. 8 NOTICE All specifications are for an ambient temperature between 0 and 60 °C and a supply voltage of 24 V + 20 % unless otherwise noted. F-FEM-CON — User’s Guide...
A group of 8 inputs has a common reference potential (Common). This common reference potential can be connected to +24 V (Common source) or to ground (sink circuit), as shown in the figure above. F-FEM-CON — User’s Guide...
Delay time input to PUMA Open 0.32 (1.2, 1.3) Tab. 9 *) valid for F-FEM-CON Advanced NOTICE All specifications are for an ambient temperature between 0 and 60 °C and a supply voltage of 24 V + 20 % unless otherwise noted.
If this voltage is too high for certain loads, a freewheeling diode must be used to reduce the inductive load dump voltage. A group of 8 outputs has a common power supply (typically 24 V) and a common GND. F-FEM-CON — User’s Guide...
Delay time PUMA Open (1.2, 1.3) to output Tab. 10 *) valid for F-FEM-CON Advanced NOTICE All specifications are for an ambient temperature between 0 and 60 °C and a supply voltage of 24 V + 20 % unless otherwise noted.
The input circuits are shown below to help you choose the appropriate input for each sensor type. 4.6.1 Input Circuit for Digital Input Fig. 29 Both digital inputs can be used for counter funtionality or as standard digital inputs. The pin assignment above applies to X17 and X18. F-FEM-CON — User’s Guide...
Inductive 1- 2.7k 2.7 k 56 k Fig. 30 The pin assignment above applies to X17 and X18. 4.6.3 Input Circuit for Incremental Rotary Encoder Fig. 31 The pin assignment above applies to X17 and X18. F-FEM-CON — User’s Guide...
Input Circuit for Hall Encoder 100 k Ω X17/14 Track A Hall 1 A X17/2 Hall 1_GND 100 k Ω X17/15 Track B Hall 1 B Fig. 32 The pin assignment above applies to X17 and X18. F-FEM-CON — User’s Guide...
(low-pulse) is a falling edge. Signal The evaluation of levels to countable pulses can happen either as: Single Edge Evaluation on page 58, or as Multi Edge Evaluation on page 58. F-FEM-CON — User’s Guide...
90°) impact the measurement signal in form of speed fluctuations and jitter (see red arrows). To minimize these impacts use the incremental (RS422) input, whenever possible. Try to avoid the digital input, because it can increase the jitter due to different high-low edge transistions. F-FEM-CON — User’s Guide...
The minimum speed is 500 rpm, below that the gaps are not detected due to the limited counter width. At the F-FEM-CON Advanced this limit is 625 rpm. These speed limits are based on a 60 teeth disk. For a toothed disk with other teeth count use the frequency value related to the respective speed limit to calculate the rpm-limit (in inverse proportion to the tooth count ratio, i.e.
The minimum speed is 428 rpm, below that the gaps are not detected due to the limited counter width. At the F-FEM-CON Advanced this limit is 535 rpm. These speed limits are based on a 35-1 teeth disk. For a toothed disk with other teeth count use the frequency value related to the respective speed limit to calculate the rpm-limit (in inverse proportion to the tooth count ratio).
32 bit floating point according to IEEE notation Tab. 12 *) valid for F-FEM-CON Advanced The measuring time influences the accuracy of the speed acquisition in the following ways: With a measuring time of 1 ms and a quartz frequency of 20 MHz (accuracy 25 ppm), the quantization error is 50 ns.
Page 63
The following figures show how the quartz reference and the measuring time influence the error and the accuracy. A similar calculation for the F-FEM-CON Advanced with 20 ns reference clock shows a quantization mistake of 20 ns or an accuracy of 15.61 bit. The blue curve displaces itself around 30 ppm downward.
Page 64
Operation Measuring error depending of measuring time for F-FEM-CON Advanced: Fig. 37 Absolute speed error as a function of the speed and the update rate: Fig. 38 F-FEM-CON — User’s Guide...
Page 65
Operation Absolute speed error for F-FEM-CON Advanced as a function of the speed and the update rate: Fig. 39 Due to the measurement method applied, the accuracy does not depend on the frequency (and not on the number of teeth) but only on the reference frequency and the measuring time.
Page 66
Operation Pulse duration measurement: Fig. 40 DC error at digital input: Fig. 41 F-FEM-CON — User’s Guide...
Page 67
(1 ms). The resulting maximum frequency is 500 Hz. This value is sufficient because this pulse is generated only once per revolution. This corresponds to a maximum speed of 30000 rpm. F-FEM-CON — User’s Guide...
(at 60 °C) Output Voltage at Pins 13,16 Output Current at Pins 13,16 Frequency for n-2 tooth gap recognition and correction 625 **) Tab. 13 *) between 0 and 400 kHz **) for F-FEM-CON Advanced F-FEM-CON — User’s Guide...
Example The desired analog value (demand engine speed of 900 – 8000 rpm) is mapped to a duty-cyle range of 5 % to 95 %. The frequency is set to 1 kHz. F-FEM-CON — User’s Guide...
The desired frequency is output by halves at tracks A and B, whereby the phase shift of both tracks corresponds to the desired duty cycle (0 - 100% corresponds to 0 - 180°) F-Out PWM tracks Z, A, B: Fig. 44 F-FEM-CON — User’s Guide...
The desired frequency is output at the zero track. Tracks A and B, which are in quadrature, output the desired frequency multiplied by the number of teeth. · Z The WD-Live signal is output at the single channel. Fig. 46 Simulate ABZ block diagram: Fig. 47 F-FEM-CON — User’s Guide...
F-OUT zero track are phase locked). As a result of the conver- sion of tracks A and B, the phase relation between A, B and Z at the output is lost, although A and B remain in quadrature. F-FEM-CON — User’s Guide...
Page 73
A/B to Z marks plication/divi- sion) Simulate ABZ – – 16 values in calibration table SiSp Counter n DABZ SiSp Counter n DZ SiSp Counter n (Full Split) yes first value in calibration table Tab. 14 F-FEM-CON — User’s Guide...
Hz and then have them recalculated every milli- second. As a rule of thumb: Output Frequency > Update Frequency The errors and their interrelationships are shown in the diagrams below. Relationship between Duty-cyle errors and frequency: Fig. 52 F-FEM-CON — User’s Guide...
Page 75
Operation Relationship between duty cycle error and duty cycle at different frequencies: Fig. 53 Relationship between frequency error and frequency: Fig. 54 F-FEM-CON — User’s Guide...
= parameterized Counter Update periode Tab. 15 *) valid for F-FEM-CON Advanced Positive and negative frequencies can be generated. Interpretation: The output of a positive frequency corresponds to a right-hand rotation. Track A leads with respect to track B. If the frequency turns negative, this indicates that...
For our purposes, it is sufficient to assume that the integration time constant is at least 100 times higher than the carrier frequency. Thus, a resistance of 100 Ohm and a capacity of approx. 47 µF is recommended. F-FEM-CON — User’s Guide...
Page 78
This kind of the demand value is suitable only for small claims of the default and to employ only in a closed control loop because of the bad absolute accuracy. The resolution on the other hand is very high. F-FEM-CON — User’s Guide...
If the required trigger frequency is not kept, the relay is immediately released, which indicates a malfunction. If several F-FEM-CON modules are used, it is sufficient that one of these F-FEM-CONs performs this function (according to the wiring and as determined in the software).
Operation CAN Interface This interface is available only at F-FEM-CON Advanced. It is a galvanically separate interface CAN 2.0B according to ISO 11898 with a transmission rate up to 1 Mbps. 4.10 Status Displays Two vertical rows of LEDs are arranged on the front side of the module. These indicate the states of the digital inputs and outputs and of the counter inputs.
S-XXX F-FEM It is needed with the parameterization in the Config table. Serial number e.g.: S-123 H-XXX Hardware e.g.: H-350 Revision number Root The Clockmaster is the corresponding F-FEM Tab. 19 F-FEM-CON — User’s Guide...
4.11 Aging and Calibration Intervals Due to the use of most up-to-date technologies, the F-FEM-CON reaches accuracy levels which in the past were reserved to laboratory equipment. These accuracy levels can thus only be checked using laboratory equipment that has an accuracy that is at least four times higher.
GND_24 NC (+ 24 V *) NC (+ 24 V *) DGND DGND Case Shielding Shielding Tab. 20 *) Only for F-FEM-CON Advanced Signal at X3 Signal at X4 U/I in3– U/I in4– U/I in3+ U/I in4+ AIGND_3 AIGND_4 AIGND_3 (opt.) AIGND_4 (opt.)
+24V (out) +24V (out) GND_24 GND_24 Case Tab. 25 These inputs and outputs can either be used directly or with an adapter (SUB-D to terminal screws) or with the EMCON Strip (see EMCON Strip on page 101). F-FEM-CON — User’s Guide...
Operation 4.12.6 Digital Inputs and Outputs X12 Fig. 63 Signal at X12 24 V (out) COMM_1-2 (for DI) GND_24 6-42 V (in for DO) GND_12 (for DO) Case Shielding Tab. 26 F-FEM-CON — User’s Guide...
Operation 4.12.7 Digital Outputs X14 Fig. 64 The RSM8 module can be connected at this socket, using a straight-through ribbon cable (see options). Signal at X14 +24 V (out) GND_24 Case Shielding Tab. 27 F-FEM-CON — User’s Guide...
Track A Hall1 B Hall2 B Track B GND_17 GND_18 for Hall Shielding Shielding Shielding Shielding Case Shielding Shielding Tab. 28 If two sensors are connected at X17 or X18, two cables lead into the connector housing. F-FEM-CON — User’s Guide...
Please take care that the total current consumption on X11 is less than 2 A. This can be calculated by adding the ruccents of all internal supplied loads (incl. Add-On1 and 2) to the own consumption fo the module. F-FEM-CON — User’s Guide...
WDOG_NO (24 V) DGND DGND GND_24 GND_24 + 24 V + 24 V + 24 V + 24 V GND_24 GND_24 Case Shielding Shielding Tab. 32 NOTICE At connector X24 and X25 only prefabricated cables may be used. F-FEM-CON — User’s Guide...
Operation 4.12.13 CAN Interface X40 Fig. 70 Signal at X40 CAN Low CAN_GND Shielding (opt.) CAN_GND CAN High Case Shielding Tab. 33 F-FEM-CON — User’s Guide...
4.12.14 Debug/JTAG Connection: X27 NOTICE This connector may only be used for the production test. No cable may be connected during regular operation. This connector is assembled on the rear side of the F-FEM-CON Advanced. Fig. 71 Signal at X27 Description...
Operation 4.12.15 IEEE1394 Network: X21 ... X23 NOTICE Only prefabricated AVL cables may be used at this connector. Only prefabricated cables have a screw-type locking, thus ensuring proper operation. Fig. 72 Signal at X21 ... X23 Description + 24 V...
To cover distances of more than 10 m, a repeater must be used. This is a small "black box" with 3 network sockets for the IEEE1394 network. Each F-FEM module also acts as a repeater, even without power supply. Description AVL part number IEEE 1394 Repeater TP08BB011B.01 Tab. 36 F-FEM-CON — User’s Guide...
Options F-FEM-DIO Module F-FEM-DIO: Fig. 74 An F-FEM-DIO can be connected at X24 and/or X25 as extension to the F-FEM-CON. For details, please refer to the AVL Operating Manual F-FEM-DIO AT1087E. Description AVL part number F-FEM-DIO TP08BB010A.01 Tab. 37 F-FEM-CON — User’s Guide...
RSM8 Module EU0857 Tab. 38 EMCON Strip EMCON Strip: Fig. 76 The sockets X19 and X20 can be used to connect an "EMCON-Strip" extension using a ribbon cable. Description AVL part number RSM8 Module BB0666 Tab. 39 F-FEM-CON — User’s Guide...
2 frequency outputs 1 watchdog Interfaces: 3 x IEEE1394 2 x Add-on 1 CAN 2.0B *) Cable lengths: IEEE1394 max. 10 m, for longer cables: repeater Add-on max. 15 m Weight: 1.99 kg *) Only for F-FEM-CON Advanced F-FEM-CON — User’s Guide...
2006/95/EC Low Voltage Directive met with the following standards complied: EN 61010-1:10 Safety Requirements for Electrical Equipment for Measure- ment, Control and Laboratory Use. F-FEM-CON — User’s Guide...
Converts proportional analog quantities into digital numbers. A name for the F-FEM-DIO. It has no IEEE1349 network connection but must be Add-on connected to an F-FEM-DAC, F-FEM-CNT or F-FEM-CON using the add-on interface. In principle, every sampling system requires an analog input filter, to attenuate Antialiasing Filter lower frequencies, called aliasing.
Page 106
This signal can be used by the automation system to indicate the proper func- Watchdog live tioning of the system. Watch dog A speed encoder with a zero track (Z) can detect a reference mark. The zero Zero track track indicates e.g. the top dead center (reference pulse). F-FEM-CON — User’s Guide...
Need help?
Do you have a question about the F-FEM-CON and is the answer not in the manual?
Questions and answers