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National Instruments ITS-16200 User Manual

National Instruments ITS-16200 User Manual

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ITS-16200 User
Manual
2025-07-09

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Summary of Contents for National Instruments ITS-16200

  • Page 1 ITS-16200 User Manual 2025-07-09...
  • Page 2 ITS-16200 Component Locations ........
  • Page 3 ITS-16200 User Manual Mechanical Stability and Loading ......... . 53 Maintaining Air Flow .
  • Page 4 The ITS-16200Inverter Test System is an application system built to target validation test of automotive traction motor controller software and hardware. © 2021 National Instruments Corporation. All rights reserved. Refer to the <National Instruments>\_Legal Information directory for information about NI copyright, patents, trademarks, warranties, product warnings, and export compliance.
  • Page 5 (protective conductor) for safety. Hardware Overview The ITS-16200 uses the NI PXI platform, SLSC, and modular instruments to enable hardware-in-the-loop (HIL) validation test for your DUT. Use the ITS-16250 Mass Interconnect PCB Assembly to connect the ITS-16200 to the DUT.
  • Page 6 ITS-16200 User Manual Note Detailed specifications for hardware components are available online at ni.com/manuals. Refer to the detailed specifications of OP8911-F, OP8913-F, OP8934-F, OP8935-F, and OP8940-F at www.opal-rt.com. Table 1. Hardware Components Required Quantity Component Part Description Base Two DUT...
  • Page 7 ITS-16200 User Manual Required Quantity Component Part Description Base Two DUT Four DUT Type Configuration Configuration Configuration FPGA, 18-channel AO, 1 MS/s, PXI multifunction reconfigurable I/O module 6-port vehicle multiprotocol interface module, TRC-8543, NI- PXIe-8510 XNET CAN XS (LS/FT, HS/FD) transceiver cable, 18 in.
  • Page 8 ITS-16200 User Manual Required Quantity Component Part Description Base Two DUT Four DUT Type Configuration Configuration Configuration board High-speed digital I/O with OP8913-F FIU SLSC conditioning board 16 Analog OUT differential from single- OP8934-F ended input with FIU SLSC conditioning...
  • Page 9 OPAL-RT Power Electronics Add-On for NI VeriStand User Documentation before you complete any integration or test program development for your Inverter Test System. Test program development for the ITS-16200 occurs in VeriStand, allowing you to quickly develop, debug, and deploy validation test programs. ®...
  • Page 10 Simulink and low-latency FPGA integration, template configurations in VeriStand, and instrument drivers for all NI instruments used with the ITS-16200. The Inverter Test System Software Toolkit also provides templates such as VeriStand projects. NI Measurement & Automation Explorer NI Measurement &...
  • Page 11 ITS-16200 User Manual Figure 1. Left-Side Front Exterior 1 0 0 ( 2 4 1. Exhaust Fan Panel 2. Emergency Power Off (EPO) Button 3. Temperature Controller 4. Main Power Switch 5. Front Cable Entry Brush Panel 6. Mass Interconnect Panel (numbered 1-3 from left to right) 7.
  • Page 12 ITS-16200 User Manual Figure 2. Left-Side Front Interior 1. PXI Chassis 2. Power Distribution Unit (PDU) 3. SLSC Chassis 4. RMX Power Supply Shelf 5. RMX-410x AC Power and Ethernet Cabling ni.com...
  • Page 13 ITS-16200 User Manual Figure 3. Right-Side Front Interior 1. Vertical Cable Raceway 2. RMX-410x AC Power and Ethernet Cabling 3. CAN Transceivers 4. Lower Internal Cable Brush Pass-Through © National Instruments...
  • Page 14 ITS-16200 User Manual Figure 4. Right-Side Rear Exterior ( 2 4 0 1 1 1. Removeable Rear Door 2. Main Circuit Breaker 3. Ethernet Port 4. USB Ports 5. Air Intake Filter Assembly ni.com...
  • Page 15 ITS-16200 User Manual Figure 5. Right-Side Rear Interior 1. Ethernet Switch (Obscured by Frame) 2. PS-17 3. Primary Internal Cable Brush Pass-Through © National Instruments...
  • Page 16 AC power loss. To maintain this configuration, the user MUST NOT set reset to "True" when initializing the RMX-4102 in software. The ITS-16200 includes up to four rack-mount RMX-410x programmable power supplies assigned to the following IP addresses: ni.com...
  • Page 17 AC and DC power to the ITS-16200 components. The ITS-16200 uses a single-phase PDU that supports global voltages (50 Hz to 60 Hz) and has a 20 A (IEC C19) input connector that cables directly to the power entry panel (PEP).
  • Page 18 • Emergency power off (EPO)—Pressing the EPO button immediately cuts AC power from the PEP and PDU(s). The ITS-16200 will power back on once the EPO button is released unless the main power switch or main breaker is turned off. The ITS-16200 enters the EPO state automatically if the following conditions occur: •...
  • Page 19 ITS-16200 User Manual Figure Description Callout setpoint, refer to the AutomationDirect Solo Temperature Controllers Manual . Notice When temperature setpoint is reached, the temperature controller does not move the system into a shutdown state. Provides a way to control whether the system is powered.
  • Page 20 High levels of leakage current may be present on the measurement rack. Connect the measurement rack to Protective Earthing the protective earth terminal before connecting to AC Ground Stud power. Refer to the ITS-16200 Safety, Environmental, and Regulatory Information document for protective earth terminal wiring specifications. Power Inlet Connector Provides a low power (IEC 60320 C20) power entry.
  • Page 21 Mass Interconnect The ITS-16200 uses the ITS-16250 Mass Interconnect PCB Assembly as the interface between the ITS-16200 and the DUT. You can have up to three ITS-16250 mass interconnects, where the first connects to traction motor inverters 0-1, the second connects to traction motor inverters 2-3, and the third connects to vehicle I/O.
  • Page 22 ITS-16200 User Manual Figure 9. iCon Connector Pinout ni.com...
  • Page 23 ITS-16200 User Manual Figure 10. Upper Receiver Module Pin Map PIN A1 PIN K1 PIN A16 PIN K16 Figure 11. Lower Receiver Module Pin Map PIN A1 PIN K1 12 13 14 15 PIN K10 PIN A10 16 17 18 19 20...
  • Page 24 AIO-DIFF DIO HIGH DIO-SLSC-12201 CAN SPEED Recommended ITA Components NI recommends using the following interchangeable test adapter (ITA) components when connecting to the mass interconnect in the ITS-16200. Table 5. ITAs Part Vendor Description Number 410123101 ITA, iCon, with protective cover...
  • Page 25 ITS-16200 User Manual Table 8. Patchcords Vendor Part Number Description Signal, patchcord, ITA, 36 inch, QuadraPaddle, 5 A, 22 AWG 7-121422000-036 white twisted pair, single-ended Signal, patchcord, ITA, 72 inch, QuadraPaddle, 5 A, 22 AWG 7-121422000-072 white twisted pair, single-ended...
  • Page 26 ITS-16200 User Manual Part Vendor Description Number 610138115 Signal, contact, ITA, QuadraPaddle, 5 A, 0.025 inch round post Signal, contact, ITA, QuadraPaddle, 5 A, 0.025 inch square post for wire wrap 610138122 with anti-rotation 610138123 Signal, contact, ITA, QuadraPaddle, male PCB pin...
  • Page 27 ITS-16200 User Manual Installing and Removing Components on the Mass Interconnect Equipment • #2 Phillips screwdriver 1. Disconnect any ITAs attached to the mass interconnect. Notice Attached ITAs prevent the mass interconnect panel from fully opening and may cause damage to the mass interconnect panel and cables connected to the mass interconnect PCBs.
  • Page 28 ITS-16200 User Manual 1. #10-32 × 1/2 inch Screws 2. Mass Interconnect Panel 3. Mass Interconnect Receivers 3. Grasp the mass interconnect receivers and pull down the mass interconnect panel. ni.com...
  • Page 29 ITS-16200 User Manual 1. Mass Interconnect PCBs 2. Gas Springs The gas springs enable the mass interconnect panel to open and stay at 90° to facilitate cabling reconfiguration. 4. Reconfigure cables as needed. Note Use the ix Industrial Removal Tool (NI part number 755624-01) to remove the ix Industrial connectors if needed.
  • Page 30 2.49 N · m (22 lb · in.) using the #2 Phillips screwdriver. Site Preparation You must follow all safety and site requirements and instructions to properly set up, configure, and use the ITS-16200. Ensure the facility meets the following environmental, physical, and interface requirements before the ITS-16200 arrives.
  • Page 31 ITS-16200. Physical Ensure the location can accommodate the size and weight of the ITS-16200. Test Rack Dimensions 584 mm x 811 mm x 1,362 mm (23 in. x 32 in. x 54 in.)
  • Page 32 ITS-16200 pour éviter tout risque thermique. Power Requirements Note The emergency power off (EPO) button, the power switch, and the circuit breaker do not fully remove power from the ITS-16200. For full EPO functionality, refer to Emergency Power Off Panel. To completely interrupt power to a single phase system, you must disconnect the AC power cable.
  • Page 33 The ITS-16200 shipment contains a power cord that corresponds to your country of operation. Receiving the System When the ITS-16200 shipping crate arrives at the facility, store the crate indoors in an area that meets environmental conditions listed in the ITS-16200 Safety, Environmental, and Regulatory Information document.
  • Page 34 Notice Do not discard any parts or packaging until you complete the ITS-16200 bring-up and setup process. Do not reject the ITS-16200 shipment. 1. Before you open the crate, inspect the tilt sensors on the sides of the crate. Note A red sensor indicates that the sensor was activated during delivery.
  • Page 35 Note The ITS-16200 shipping crate requires a clearance of at least 3.5 meters (11 ft) in front of the crate to lay out the crate ramp and roll the ITS-16200 out of the crate. Equipment •...
  • Page 36 ITS-16200 crate. 6. Inspect the accessories for any physical damage. 7. Remove the plywood shelf from the top compartment of the ITS-16200 crate. 8. Remove the foam padding securing the ITS-16200. 9. Remove the plywood block located at the bottom of the ITS-16200 crate.
  • Page 37 ITS-16200 User Manual 11. Slowly roll the ITS-16200 out of the crate and down the ramp using the green, horizontal straps. 12. Cut and remove the horizontal straps from the ITS-16200. 13. Open and remove the poly antistatic bag from the ITS-16200.
  • Page 38 8. Verify that the CONTROL switch is set to REMOTE. 9. Close and lock the rear cabinet door. 10. Push in the brake lock on the ITS-16200 caster wheels to secure the test rack. 11. Connect the main AC power cable plug to the ITS-16200 power inlet.
  • Page 39 2. Confirm that the primary EPO button is not engaged. 3. Confirm that the programmed temperature shutoff value on the EPO panel thermostat is below the programmed temperature shutoff value. 4. Flip the main power switch to the right to turn on the ITS-16200. Powering Off Caution To completely interrupt power to a single-phase system, you must disconnect the AC power cable.
  • Page 40 PEP. Powering On After Thermal Shutdown The ITS-16200 has two safety shutoff thermostats on the interior of the test rack. hermostats are located in the front and back of the test rack, near the hot air exhaust vent.When triggered by a thermal event, the thermostats shut down the ITS-16200 by cutting power to the power entry AC outlet(s).
  • Page 41 ITS-16200 User Manual needed to configure, install software to, and successfully use all available features with the ITS-16200 controller. To return the ITS-16200 to the base image, complete the following steps: 1. Locate the PXIe-8881 in MAX under Remote Systems.
  • Page 42 ITS-16200 User Manual password. 4. In the Real-Time Software Wizard, select the following items from the Add tab: ◦ FlexRIO ◦ Hardware Configuration Web Support ◦ I/O Variable Remote Configuration Web Service ◦ LabVIEW Control Design and Simulation ◦ LabVIEW Real-Time ◦...
  • Page 43 ITS-16200 User Manual 5. Click Review changes to verify that the summary of software to install is correct. 6. Click Continue to begin the installation 7. When the updates complete, click Close. Maintenance Cleaning the Test Rack Exterior Clean system exterior surfaces with a dry lint-free cloth or a soft-bristle brush. If any dirt remains, wipe with a cloth moistened in a mild soap solution.
  • Page 44 7. Screw in the four screws to secure the inlet panel to the test rack. Calibration NI provides calibration services for instruments in the ITS-16200 that require calibration. NI recommends that you adhere to the calibration interval for all supported instruments in your system. For the latest information about available calibration service levels for your instrument, refer to ni.com/r/nical.
  • Page 45 ITS-16200 User Manual • Verify the shutoff thermostats have been reset if the ITS-16200 shut down due to thermal overload. PXI Chassis Does Not Power On • Confirm that the EPO button is not engaged. • Remove the brush panel and 3U and 1U filler panels to check that the PXI controller is properly seated inside the PXI chassis.
  • Page 46 ITS-16200 User Manual Table 12. Replacement Parts Type NI Part Number Function and Model 783882-01 PXIe-1095 Chassis 784532-01 SLSC-12001 781056-01 CCA, NI PXIe-6363 783800-01 CCA, PXIe-6738, 32 CH AO PXI Instruments 784122-01 CCA, PXIe-8510, HD XNET 6 Port CCA, PXIe-7868R, 512 MB DRAM,...
  • Page 47 ITS-16200 User Manual Type NI Part Number Function and Model OPAL 8935-F, 8 A IN/OUT with 787857-01 FIU SLSC Conditioning Board OP-8940-F Channel 787858-01 Passthrough Board with FIU CCA, RTI-12309 with 8 ix 787766-01 Industrial Connector SET-1210 16 CH Resistor...
  • Page 48 ITS-16200 User Manual Type NI Part Number Function and Model Zlock C19, 2.0 m 14 AWG, 250 V, Zlock C14 to 133087-0R6 Zlock C13, 0.6 m 17 AWG, Zlock C14 to Open, 133114-1R5 Ferrule tips ECUTS, 24 V PS-16 To SLSC...
  • Page 49 ITS-16200 User Manual Type NI Part Number Function and Model GND, 10-32 Ring Terminals, 785631-02 10 AWG, 2 m 861173-01 Display Port to VGA, 7 inch Thermocouple, 24 AWG, Type J, 861182-01 Epoxy Coated Tip, 180 inch Thermostat to Thermostat, BYO...
  • Page 50 ITS-16200 User Manual Type NI Part Number Function and Model EDS-316-T Thermostat, Manual Reset, open 80C, B-203S Mounting 787002-01 Hardware, T-147 Terminals CONN, Compact Splice, 2 Conductor, 6 mm, 10 AWG, 788252-01 Lever Actuation Type, Transparent Bracket, Side, Mount for TRC...
  • Page 51 • 40 °C Ambient: 1,350 W The ambient temperature ratings and power dissipation limitations in the preceding list does not guarantee the thermal performance of components in the ITS-16200, only that the ITS-16200 contains adequate cooling capacity to provide the rated internal rack the ambient temperature needed to support properly rated and installed components.
  • Page 52 The power dissipation for each subsystem is dependent on configuration and usage. The table below shows the maximum power of each subsystem in the ITS-16200. Table 13. ITS-16200 Maximum Power Consumption and Dissipation Maximum...
  • Page 53 Mechanical Stability and Loading Each ITS-16200 configuration is designed to ensure physical stability of the test rack and to prevent overbalancing or tipping. When adding additional instruments or components to the ITS-16200, it is important to preserve stability.
  • Page 54 (NI part number 787805-01) at the bottom of the test rack. Maintaining Air Flow Air flow inside the ITS-16200 is separated into a cool air intake column and a hot air exhaust column. The ITS-16200 pulls fresh air from the bottom rear of the test rack, and the column of cool air is guided toward the hot air exhaust vent on top of the test rack.
  • Page 55 • Do not block the air intake or exhaust path of any component that is part of the original shipping configuration of the ITS-16200. Cabling Best Practices The Inverter Test System provides the following components to organize cables and reduce strain: •...
  • Page 56 ITS-16200 User Manual Figure 15. Vertical Cable Tray—Right-Side Front View of the Test Rack 1. Vertical Cable Tray • SLSC Cable Management Shelf—Use the SLSC cable management shelf to route cables from the cold aisle to the hot aisle and to pass through cables connected from SLSC to the mass interconnect with tie-down points.
  • Page 57 ITS-16200 User Manual Figure 16. SLSC Cable Management Shelf—Right-Side Bottom View of the Test Rack 1. SLSC Cable Management Shelf • Mass Interconnect Panel Integrated Strain Relief—Install cable ties and use the slotted tie-down points on the mass interconnect panel integrated strain relief to relieve strain and organize cables connected to the mass interconnect PCBs.
  • Page 58 ITS-16200 User Manual Figure 17. Mass Interconnect Panel Integrated Strain Relief—Inside View of the Test Rack 1. Mass Interconnect Panel Integrated Strain Relief • Mounting Rack Rail (x3)—To avoid blocking component airflow paths, install cable ties and route cables along the mounting rack rails when possible. Additional cable tie mounts are available on the right mounting rack rail in the rack front to facilitate CAN cable routing.
  • Page 59 ITS-16200 User Manual Figure 18. Mounting Rack Rail—Left-Side Rear View of the Test Rack 1. Mounting Rack Rails • Horizontal Finger Cable Manager (x2)—Route cables through the horizontal finger cable managers to avoid covering the inlet to cooling fans of the test rack.
  • Page 60 ITS-16200 User Manual Figure 19. Horizontal Finger Cable Manager—Left-Side Top View of the Test Rack 1. Horizontal Finger Cable Managers ITA Cabling Best Practices Refer to the following ITA cabling best practices when you connect cables from the mass interconnect to the DUT.
  • Page 61 ITS-16200 User Manual Figure 20. VPC iCon ITA connector 1. #6 Grounding Screw NI Services Visit ni.com/support to find support resources including documentation, downloads, and troubleshooting and application development self-help such as tutorials and examples. Visit ni.com/services to learn about NI service offerings such as calibration options, repair, and replacement.
  • Page 62 ITS-16200 User Manual You can request support from NI if the available online resources do not meet your needs. Provide as much information as possible in your support request so NI service representatives fully understand the issue you are experiencing. NI can work with you to gather all the necessary information but preparing it ahead of time can reduce the amount of time it takes to process the support request.
  • Page 63 3. Use the Service Request Manager to request technical support. Additional Resources ITS-16200 Documentation To ensure you have the most recent version of the ITS-16200 documentation, visit ni.com/manuals. You can find the readmes in the %Public%\Documents\NI\ Inverter Test System\Documentation directory.
  • Page 64 Refer to the following list for recommended instrument and software documentation for the ITS-16200. Note This list is not exhaustive and does not include all available documentation for instruments or software in the ITS-16200. Document Description Power Electronics Add-On for NI VeriStand User...