ETAS ES4455.2 Bedienungsanleitung

ES4455.2 Load Carrier Board

ES4450.3 Load Carrier Board for 4 RB CRS Injectors

ES4451.4 Load Carrier Board for 4 RB GDI Injectors

ES4452.1 Load Carrier Board for 4 RB GDI Injectors, CVO

ES4453.1 Load Carrier Board for 4 RB HDEV6 GDI Injectors, CVO

ES4457.1 Load Carrier Board for 4 RB CRS Injectors, VCC and VCA

ES4458.1 Load Carrier Board for 4 RB PFI Injectors, CVO

User’s Guide

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. Using

and copying is only allowed in concurrence with the specifications stipulated in

the contract.

Under no circumstances may any part of this document be copied, reproduced,

transmitted, stored in a retrieval system or translated into another language

without the express written permission of ETAS GmbH.

The names and designations used in this document are trademarks or brands

belonging to the respective owners.

V1.0.0 R05 EN - 09.2019

ES4455.2 Load Carrier Board - User’s Guide 3

Contents

ETAS Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1.1 Properties of the ES4455.2 Load Carrier Board and its Variants

ES4450.3, ES4451.4, ES4452.1, ES4453.1, ES4457.1 and ES4458.1

Mounted with Load Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.1.2 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.2 Basic Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.2.1 Identification of Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.2.2 General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.2.3 Requirements for Users and Duties for Operators. . . . . . . . . . . . . . . 9

1.2.4 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1.3 Identifications on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.3.1 CE Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.3.2 KC Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.3.3 RoHS Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.3.4 Identification in Accordance with ISO 7010:2011 . . . . . . . . . . . . . 16

1.4 Product Return and Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.5 Materials Subject to Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.6 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.6.1 Working with this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2 Properties and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.1 Design of an Injector Simulation Environment . . . . . . . . . . . . . . . . . . . . . . . 21

2.2 Figures of ES4455.2 and its Mounted Variants ES4450.3, ES4451.4, ES4452.1,

ES4453.1, ES4457.1 and ES4458.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.2.1 ES4455.2 Load Carrier Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.2.2 ES4450.3 Load Carrier Board for 4 RB CRS Injectors . . . . . . . . . . . 25

2.2.3 ES4451.4 Load Carrier Board for 4 RB GDI Injectors. . . . . . . . . . . . 25

2.2.4 ES4452.1 Load Carrier Board for 4 RB GDI Injectors, CVO . . . . . . . 26

ES4455.2 Load Carrier Board - User’s Guide4

Contents ETAS

2.2.5 ES4453.1 Load Carrier Board for 4 RB HDEV6 GDI Injectors, CVO . 26

2.2.6 ES4457.1 Load Carrier Board for 4 RB CRS Injectors, VCC and VCA 26

2.2.7 ES4458.1 Load Carrier Board for 4 RB PFI Injectors, CVO . . . . . . . . 27

2.3 Procedure for Installation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.3.1 Installation in the ES4408.1 Load Chassis. . . . . . . . . . . . . . . . . . . . 29

2.3.2 Installation in the ES5372.1 Carrier for ES4455 Load Boards . . . . . 29

2.3.3 Installation in the ES5300.1-A Housing and the ES5300.1-B Housing

via ES5372.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.3.4 Connecting Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.4 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.4.1 Fuses on the ES4455.2 Load Carrier Board. . . . . . . . . . . . . . . . . . . 31

2.4.2 Replacing Fuses on the ES4455.2 Load Carrier Board. . . . . . . . . . . 31

2.5 Interface for Load Modules on the ES4455.2 Load Carrier Board . . . . . . . . . 34

2.6 Piezo Signal Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.7 Equivalent Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3 Connections and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.1 Backplane Connector CO200 of the ES4455.2 Load Carrier Board . . . . . . . 37

3.2 Plug Connector CO1200 on ES4455.2, CO150 and CO100 on the Load Mod-

ules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.3 Connections and Plug Connections for Installation in the ES4408.1 Load Chassis

3.3.1 Plug Connectors "Load 7", " Load 8-1" and "Load 8-2". . . . . . . . 38

3.3.2 Plug Connector "Meas 7", "Meas 8-1" and "Meas 8-2" on ES4408.1

Load Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.4 Connections and Plug Connections for Installation in the ES5300.1-A Housing

or in the ES5300.1-B Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

3.4.1 "X2 Load" Plug Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.4.2 "X1 Measure" Plug Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4 Technical Data and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

4.2 Meets Norms and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5 Ordering Data and Scope of Delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6 ETAS Contact Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

ES4455.2 Load Carrier Board - User’s Guide 5

ETAS Introduction

1 Introduction

This User's Guide contains the description of the ES4455.2 Load Carrier Board

and its variants ES4450.3, ES4451.4, ES4452.1, ES4453.1, ES4457.1 and

ES4458.1 mounted with load modules.

This chapter contains information about the following topics:

• "Properties" on page 5

• "Basic Safety Notices" on page 9

• "Identifications on the Product" on page 15

– "CE Mark" on page 15

– "RoHS Conformity" on page 16

– "KC Mark" on page 15

• "Product Return and Recycling" on page 16

• "Materials Subject to Declaration" on page 17

• "About this Manual" on page 18

1.1 Properties

The ES4455.2 Load Carrier Board is a carrier board for load simulations, e.g.

injector loads, in a LABCAR HiL system.

To simulate injector loads, the following variants mounted with load modules

based on the ES4455.2 Load Carrier Board are available:

• ES4450.3 Load Carrier Board for 4 RB CRS Injectors

• ES4451.4 Load Carrier Board for 4 RB GDI Injectors

• ES4452.1 Load Carrier Board for 4 RB GDI Injectors, CVO

• ES4453.1 Load Carrier Board for 4 RB HDEV6 GDI Injectors, CVO

• ES4457.1 Load Carrier Board for 4 RB CRS Injectors, VCC and VCA

• ES4458.1 Load Carrier Board for 4 RB PFI Injectors, CVO

ES4450.3 and ES4451.4 are the successors to ES4450.2 and ES4451.3. The

ES4450.3 and ES4451.4 have the same functions as their respective predecessor

models.

The ES4452.1 Load Carrier Board for 4 RB GDI Injectors, CVO, ES4453.1 Load

Carrier Board for 4 RB HDEV6 GDI Injectors, CVO, the ES4457.1 Load Carrier

Board for 4 RB CRS Injectors, VCC and VCA and the ES4458.1 Load Carrier Board

for 4 RB PFI Injectors, CVO have an expanded scope of functions. They enable an

additional more precise simulation and modulation of the injection time through

integrated functions for the control algorithms of the ECU. These control algo-

rithms are CVO (Controlled Valve Operation) control for gasoline direct injection

in the case of ES4452.1, ES4453.1 and ES4458.1 or VCC (Valve Close Control)

control and VCA (Valve Close Adjustment) control for diesel direct injection in the

case of ES4457.1.

The expanded functions can be deactivated by the user in LABCAR OPERATOR.

After deactivating the function for CVO, the ES4452.1 can be operated analo-

gous to ES4451.4 and ES4451.3. Also, the ES4457.1 can be used in the same

way as ES4450.3 and ES4450.2 after deactivating the function for VCC and

VCA.

ES4455.2 Load Carrier Board - User’s Guide6

Introduction ETAS

The ES4408.1 Load Chassis features three slots of width 14 HP to accept the

ES4455.2 Load Carrier Board and the variants listed above. Fully mounted, it

enables the simulation of 12 injection loads.

In the same way, it is possible to install the ES4455.2 Load Carrier Board and its

mounted variants in the ES5300.1-A Housing and the ES5300.1-B Housing by

means of the ES5372.1 Carrier for ES4455 Load Boards.

In the ES5300.1-A Housing and the ES5300.1-B Housing, it is possible to install

5 boards of width 14 HP. Fully mounted, it enables the simulation of 20 injection

loads per housing.

1.1.1 Properties of the ES4455.2 Load Carrier Board and its Variants ES4450.3,

ES4451.4, ES4452.1, ES4453.1, ES4457.1 and ES4458.1 Mounted with Load

Modules

• 3 U/14 HP add-on card for a LABCAR HiL system.

• Compatibility with the ES4408.1 Load Chassis and, with the use of

adapter card ES5372.1 Carrier for ES4455 Load Boards, also with the

ES5300.1-A Housing and the ES5300.1-B Housing

• Four load inputs for connecting four simulated injection loads to an ECU

• Current measurement for four loads via four galvanically isolated

channels

• Voltage measurement for four loads via four galvanically isolated

channels

• Analog output Online_Probe for current or voltage measurement at one

selectable load

• On-board analysis of load current and load voltage

• Four digital outputs I_Dig_Out_1...I_Dig_Out_4 for outputting the injec-

tion time for each load. Based on the load response, the opening and

closing time of the respective load is also being output

• The signals I_Dig_Out_1, ... I_Dig_Out_4 can be connected to a LABCAR

HiL system.

The variants have the following additional properties:

ES4455.2 Load Carrier Board

• Slot for 4 loads

ES4450.3 Load Carrier Board for 4 RB CRS Injectors

• Simulation for four injectors of the Bosch Common Rail System.

ES4451.4 Load Carrier Board for 4 RB GDI Injectors

• Simulation for injectors of the Bosch HDEV5 gasoline direct injection

ES4452.1 Load Carrier Board for 4 RB GDI Injectors, CVO

• Simulation for injectors of the Bosch HDEV5 gasoline direct injection

• Additional supported functions of the motor ECU:

CVO (Controlled Valve Operation) control

ES4455.2 Load Carrier Board - User’s Guide 7

ETAS Introduction

ES4453.1 Load Carrier Board for 4 RB HDEV6 GDI Injectors, CVO

• Simulation for injectors of the Bosch HDEV6 gasoline direct injection

• Additional supported functions of the motor ECU:

CVO (Controlled Valve Operation)

ES4457.1 Load Carrier Board for 4 RB CRS Injectors, VCC and VCA

• Simulation for injectors of the Bosch Common Rail System CRI2-x

• Additional supported functions of the motor ECU:

VCC (Valve Close Control) and VCA (Valve Close Adjustment)

ES4458.1 Load Carrier Board for 4 RB PFI Injectors, CVO

• Simulation for Bosch PFI EV14 injectors

• Additional supported functions of the motor ECU:

CVO (Controlled Valve Operation)

ES4455.2 Load Carrier Board - User’s Guide8

Introduction ETAS

1.1.2 Block Diagram

Fig. 1-1 shows a block diagram of the ES4455.2 Load Carrier Board with four

loads in the ES4408.1 Load Chassis.

Fig. 1-1 Block diagram of the ES4455.2 Load Carrier Board with loads,

installed in the ES4408.1 Load Chassis.

Fig. 1-2 shows a block diagram of the ES4455.2 Load Carrier Board with four

loads in the ES5300.1-A Housing or ES5300.1-B Housing.

Fig. 1-2 Block diagram of the ES4455.2 Load Carrier Board with loads,

installed in the ES5300.1-A Housing or the ES5300.1-B Housing.

Back-

plane

SPI, I²C, JTAG ES4455.2_E

Control

Interface

Control

Interface

Ribbon

cable

ES4408.1

Load

Chassis

Control, Feedback

Load 1

Load 2

Load 3

Load 4

Speaker

Control

DAC

ADC ADC ADC ADC ADC ADC ADC ADC

Multiplexer 8:1

I_Dig_Out_1

...4

Online_Probe

Piggyback Load

Load 7, Load 8-1, Load 8-2 Meas 7, - 8-1, - 8-2

VG48 CO200

ES4455.2 Load Carrier Board - User’s Guide 9

ETAS Introduction

1.2 Basic Safety Notices

Please observe the following safety notices to avoid health issues or damage to

the device.

1.2.1 Identification of Safety Notices

The safety notices contained in this manual are identified with the danger symbol

shown below:

The safety notices shown below are used for this purpose. They provide notes to

extremely important information. Please read this information carefully.

1.2.2 General Safety Information

Observe the following safety notices to avoid health issues or damage to the

device.

ETAS GmbH does not assume any liability for damages resulting from improper

handling, unintended use or non-observance of the safety precautions.

1.2.3 Requirements for Users and Duties for Operators

The product may be assembled, operated and maintained only if you have the

necessary qualification and experience for this product. Improper use or use by a

user without sufficient qualification can lead to damages or injuries to one's

health or damages to property.

The system integrator is responsible for the safety of systems that use the prod-

uct.

CAUTION!

identifies a hazard with low risk that could result in minor or medium

physical injuries or property damages if not avoided.

WARNING!

indicates a possible danger with moderate risk of death or (serious)

injury, if not avoided.

DANGER!

indicates an immediate danger with a high risk of death or serious

injury, if not avoided.

Note

All product related documentation (product Safety Advice and this User’s

Guide) must be read prior to the startup of the product!

ES4455.2 Load Carrier Board - User’s Guide10

Introduction ETAS

General Safety at Work

Follow the existing regulations for work safety and accident prevention. All appli-

cable regulations and laws regarding operation must be strictly adhered to when

using this product.

1.2.4 Intended Use

The ES4455.2 Load Carrier Board, the ES4450.3, ES4451.4, ES4452.1,

ES4453.1, ES4457.1 and ES4458.1 are plug-in cards for the ES4408.1 Load

Chassis. With the help of ES5372.1 Carrier for ES4455 Load Boards, the plug-in

cards can also be used in the ES5300.1-A Housing or in the ES5300.1-B Housing.

The ES4455.2 Load Carrier Board consists of the following:

• Slot for a load emulation for simulating injection valves with connections

to ECU output stages

• Digital and analog output interfaces for the ES4408.1 or ES5300.1-A-

based hardware-in-the-loop system or for connecting oscilloscopes or

other measurement devices

• SPI Interface to the ES4408.1 Load Chassis or the ES5300.1-A Housing or

the ES5300.1-B Housing

The ES4450.3, ES4451.4, ES4452.1, ES4453.1, ES4457.1 and ES4458.1 plug-in

cards consist of the following:

• Load emulation for simulating injection valves with connections to ECU

output stages

• Digital and analog output interfaces for the ES4408.1 or ES5300.1-A

based hardware-in-the-loop system or for connecting oscilloscopes or

other measurement devices

• SPI Interface to the ES4408.1 Load Chassis or the ES5300.1-A Housing

and to the ES5300.1-B Housing

The ES4455.2 and its variants ES4450.3, ES4451.4, ES4452.1, ES4453.1,

ES4457.1 and ES4458.1 mounted with load modules may be operated only in

the ES4408.1 Load Chassis, ES5300.1-A Housing and in the ES5300.1-B Hous-

ing.

The intended use of the ES4455.2 and its variants ES4450.3, ES4451.4,

ES4452.1, ES4453.1, ES4457.1 and ES4458.1 mounted with load modules is as

follows:

• Use in industrial lab facilities or workplaces

• Hardware interface for ECUs in a hardware-in-the-loop test system

• Cooperation with ETAS software which supports the ES4408.1 Load

Chassis or ES5300.1-A Housing or the ES5300.1-B Housing

• Interface in cooperation with software programs that operate the stan-

dardized, documented and open APIs of ETAS software products

The ES4455.2 and its variants ES4450.3, ES4451.4, ES4452.1, ES4453.1,

ES4457.1 and ES4458.1 mounted with load modules are not intended to be

used as follows:

• Within a vehicle on the road

• As part of a life support system

Dieses Handbuch passt für folgende Modelle

Inhaltsverzeichnis

Andere ETAS Steuereinheit Handbücher

ETAS

ETAS ES523.1 Bedienungsanleitung

ETAS

ETAS ES511.1 Bedienungsanleitung

ETAS

ETAS ES595.1 Bedienungsanleitung

ETAS

ETAS ES415.1 Bedienungsanleitung

ETAS

ETAS ES585.1 Bedienungsanleitung

ETAS

ETAS ES5385.1 Bedienungsanleitung

ETAS

ETAS XETK-V2.0 Series Bedienungsanleitung

ETAS

ETAS FETK-T5.0A Bedienungsanleitung

ETAS

ETAS ES583.1 Bedienungsanleitung

ETAS

ETAS ES592.1 Bedienungsanleitung

ETAS

ETAS ES581.4 Bedienungsanleitung

ETAS

ETAS PB1651PWM1 Bedienungsanleitung

ETAS

ETAS ES582.1 Bedienungsanleitung

ETAS

ETAS ES4720.1 Bedienungsanleitung

ETAS

ETAS ES413.1 Bedienungsanleitung

ETAS

ETAS ES910.3-A Bedienungsanleitung

ETAS

ETAS ES420.1 Bedienungsanleitung

ETAS

ETAS ES430.1 Bedienungsanleitung

ETAS

ETAS FlexRay ES920.1 Bedienungsanleitung

ETAS

ETAS ES420.1 Bedienungsanleitung

ETAS

ETAS ES313.1 Bedienungsanleitung

ETAS

ETAS ES441.1 Bedienungsanleitung

ETAS

ETAS ES4350.1 Bedienungsanleitung

ETAS

ETAS ES584.1 Bedienungsanleitung

Beliebte Steuereinheit Handbücher anderer Marken

Festo

Festo Compact Performance CP-FB6-E Stücklistenhandbuch

Elo TouchSystems

Elo TouchSystems DMS-SA19P-EXTME Bedienungsanleitung

JS Automation

JS Automation MPC3034A Bedienungsanleitung

JAUDT

JAUDT SW GII 6406 Series Kurzanleitung

Spektrum

Spektrum Air Module System Bedienungsanleitung

BOC Edwards

BOC Edwards Q Series Bedienungsanleitung

KHADAS

KHADAS BT Magic Bedienungsanleitung

Etherma

Etherma eNEXHO-IL Bedienungsanleitung

PMFoundations

PMFoundations Attenuverter Bedienungsanleitung

GEA

GEA VARIVENT Bedienungsanleitung

Walther Systemtechnik

Walther Systemtechnik VMS-05 Bedienungsanleitung

Altronix

Altronix LINQ8PD Montageanleitung

Eaton

Eaton Powerware Series Bedienungsanleitung

WAGO

WAGO 750-407/040-000 Bedienungsanleitung

Sony

Sony CCU-590 Bedienungsanleitung

Graco

Graco 25D614 Bedienungsanleitung

Task Force Tips

Task Force Tips YE-RF-900 Programmierhandbuch

Shini

Shini SPV-U Series Bedienungsanleitung