AVL F-FEM-CNT User manual

F-FEM-CNT
OPERATING MANUAL
03/2014
AT1086E, Rev. 14
User´s Guide

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.
All mentioned trademarks or registered trademarks are owned by their respective owners.
All rights reserved.
Copyright 2014AVL List GmbH, Graz - Austria
DIN EN 62079:11.2001
Certificate n. Z2D 10 03 10049 008

3
Warnings and Safety Instructions
F-FEM-CNT — User’s Guide
Warnings and Safety Instructions
This manual contains important warnings and safety instructions to be
observed by the user.
The product described in this manual is intended for one specific area of applica-
tion which is defined in the instructions. The manual also explains the essential
requirements for the application and operation of the product as well as safety
precautions to ensure smooth operation. AVL can provide no guarantee or
accept any li ability for applications other than those described in this manual or
for applications where the essential requirements and safety precautions are not
met.
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.
The results obtained from this product therefore must be examined by an expert
(e.g. for plausibility) before any action is taken that is based on the results.
All adjustment and maintenance work necessary on instruments when open and
under voltage must be carried out by a professional technician who is aware of
the dangers.
All repairs to the product are to be carried out by the manufacturer or qualified
service personnel only.
When the product is in use, an expert must ensure that neither the test object nor
the testing equipment is operated under conditions that could lead to damage or
injury.
AVL List GmbH

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F-FEM-CNT — User’s Guide

5
Grouped Safety Messages
F-FEM-CNT — User’s Guide
Grouped Safety Messages
WARNING
Danger of death from electrical voltage
Any connected equipment that uses higher voltages than 50 V AC or
75 V DC must satisfy the requirements of the 2006/95/EC.
NOTICE
Only shielded cables may be used with appropriately shielded connectors in
order to comply with the 2004/108/EC Electromagnetic Compatibility Directive.
Power supply connections with standardized connectors and the exceptions
mentioned do not need to be shielded.
WARNING
Danger of explosion and injury
This device must not be used in any environment where there is a danger of
explosion.
CAUTION
Fire hazard: danger of injury and/or device damage
Note the device's degree of protection.
The device may only be opened by qualified staff.
If a foreign body or liquid gets inside the device, disconnect the device from the
power supply and have an expert check it before using it again.
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.

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F-FEM-CNT — User’s Guide

7
Table Of Contents
F-FEM-CNT — User’s Guide
Table Of Contents
Warnings and Safety Instructions................................................................................................................ 3
Grouped Safety Messages ............................................................................................................................ 5
1 What you should know ..................................................................................................... 9
1.1 Safety Instructions .................................................................................................................... 9
1.2 Warranty Seal........................................................................................................................... 9
1.3 Intended Application ................................................................................................................. 9
1.4 Product specific information ..................................................................................................... 9
1.5 About this Documentation ...................................................................................................... 10
1.5.1 Typographic Conventions ................................................................................................. 11
1.5.2 We want to hear from you................................................................................................. 12
2 General ............................................................................................................................. 13
2.1 Performance Data .................................................................................................................. 13
2.2 System Environment .............................................................................................................. 14
2.3 Data Transfer between Test Bed and PUMA Open System .................................................. 15
2.4 Visualization ........................................................................................................................... 16
2.4.1 Seven Segment Display.................................................................................................... 16
2.5 Cascade ................................................................................................................................. 17
2.6 F-FEM-CNT Block Diagram.................................................................................................... 17
3 Installation ....................................................................................................................... 19
3.1 Scope of Supply ..................................................................................................................... 19
3.2 Mechanical Installation ........................................................................................................... 20
3.2.1 External Dimensions, Space Requirement ....................................................................... 20
3.2.2 Fixing the Module at the DIN Rail ..................................................................................... 21
3.2.3 Connections...................................................................................................................... 22
3.2.4 Function Test .................................................................................................................... 22
3.3 Electrical Installation............................................................................................................... 22
3.3.1 Power Cable Inlet.............................................................................................................. 22
3.3.2 IEEE1394 Wiring............................................................................................................... 23
3.3.2.1 Cable Design .................................................................................................... 23
3.3.2.2 Recommended Bus Topology .......................................................................... 24
3.3.2.3 About F-FEM Devices, Nodes, Cables and Repeaters .................................... 24
3.3.2.4 Mechanical Layout of a Cable Routing ............................................................. 25
3.3.3 Grounding and Shielding .................................................................................................. 26
3.3.3.1 Grounding ......................................................................................................... 26
3.3.3.2 Shielding ........................................................................................................... 31
3.4 Software Installation ............................................................................................................... 32

Table Of Contents
8
F-FEM-CNT — User’s Guide
4 Operation.......................................................................................................................... 33
4.1 Frequency Input...................................................................................................................... 33
4.1.1 Input Circuit for Digital Input..............................................................................................33
4.1.2 Input Circuit for Inductive Pick-up .....................................................................................34
4.1.3 Input Circuit for Incremental Rotary Encoder ....................................................................34
4.1.4 Description of Function .....................................................................................................35
4.1.5 Evaluation of Edges ..........................................................................................................35
4.1.5.1 Single Edge Evaluation .....................................................................................36
4.1.5.2 Multi Edge Evaluation .......................................................................................36
4.1.6 Toothed Disk with n-2 Teeth .............................................................................................37
4.1.7 Toothed Disk with n-1 Teeth .............................................................................................38
4.1.8 Block Diagram of Counter Channels.................................................................................39
4.2 Parameterization .................................................................................................................... 40
4.3 Specifications ......................................................................................................................... 40
4.3.1 Accuracy Specification ......................................................................................................40
4.3.2 Sensor Inputs ....................................................................................................................44
4.4 Pin Assignment....................................................................................................................... 45
4.4.1 Location of Plug Connections ...........................................................................................45
4.4.2 Sensor Inputs: X17, X18, X29, X30 ..................................................................................46
4.4.3 Power Supply: X11............................................................................................................47
4.4.4 Add-on Connection: X24, X25...........................................................................................48
4.4.5 Debug/JTAG Connection: X27..........................................................................................49
4.4.6 IEEE1394 Network: X21 ... X23 ........................................................................................50
5 Options ............................................................................................................................. 51
5.1 Repeater................................................................................................................................. 51
5.2 F-FEM-DIO ............................................................................................................................. 52
6 Appendix .......................................................................................................................... 53
6.1 Technical Data........................................................................................................................ 53
6.2 CE-Conformity ........................................................................................................................ 54
7 Glossary and Abbreviations........................................................................................... 55
Index.............................................................................................................................................................. 57

9
What you should know
F-FEM-CNT — User’s Guide
1 What you should know
1.1 Safety Instructions
This documentation contains important warnings and safety instructionns to
be observed by the user. Smooth operation only is ensured, if the necessary
prerequisites and safety measures are kept.
1.2 Warranty Seal
For safety reasons the product is provided with a special seal which may only be
broken by AVL personnel. Any unauthorized damage to the seal is considered
an unauthorized change to the product which will cease AVL's warranty obliga-
tion.
1.3 Intended Application
The product is only intended for the area of application described in the docu-
mentation. We do not give any warranty and do not accept any liability for appli-
cations outside the described utilization or in the event of noncompliance with
the necessary conditions and safety instructions. The supported protection of the
product could be affected.
1.4 Product specific information
The F-FEM-CNT (Fast Front End Module Digital Counter) is a data sampling
device which is used for measuring speeds, frequencies, periods and events. It
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 Open system real time data communication is ensured.
The signals can be transferred directly to/from the PUMA test bed computer or
via another type of F-FEM module (e.g. F-FEM-CON).
Using an F-FEM-CNT, analog signals (e.g. speeds, frequencies, etc.) can be
acquired and transferred to the PUMA Open system.
The F-FEM-CNT is equipped with 4 interfaces (SUB D) and has 6 independent
counter channels. Different types of sensors for the acquisition of different
signals can be connected to these interfaces.
A number of F-FEMs and Basis-FEMs can be used with the PUMA Open
system. The total sampling rate for all connected F-FEMs depends on the
applied PUMA Open version.
For details, please refer to Performance Data on page 13.
Information
You will find abbreviations and descriptions in chapter Glossary and Abbrevia-
tions on page 55.

What you should know
10
F-FEM-CNT — User’s Guide
1.5 About this Documentation
Target group This documentation turns to test bed engineers that set the filter functions of
PUMA Open channels (normnames) and use them in PUMA Open.
The F-FEM-CNT manual supports you in planning and installation as well as in
your daily work at the test bed.
Requirements It assumes that you are familiar with:
basic knowledge of electro-technology
understanding of the structure and operation of the test bed
basic knowledge in the controlling equipment and automatic control
basic knowledge of various sensors and actuators
basic knowledge in the PUMA Open system
Fig. 1 Front view for F-FEM-CNT
Information
This documentation does not and cannot replace adequate training.

11
What you should know
F-FEM-CNT — User’s Guide
Contents & Scope This manual documents the I/O component when using the F-FEM-CNT in a test
bed system and describes the hardware used:
Connector pin out
Power supply
Grounding and shielding
Sensor types
Secondary litera-
ture
F-FEM Parameterization
1.5.1 Typographic Conventions
Safety messages:
Additional safety symbols:
Notes:
NOTICE
The installation (putting into operation) may only be executed by commissioning
engineers or authorized AVL personnel.
WARNING
Indicates a hazardous situation which – if not avoided – could result in death or
serious injury.
CAUTION
Indicates a hazardous situation which – if not avoided – could result in minor or
moderate injury.
Voltage hazard warning
NOTICE
This text indicates situations or operation errors which could result in property
damage or data loss.
Information
This text indicates important information or operating instructions. Not observing
these instructions could inhibit or impede you from successfully completing the
tasks described in this documentation.

What you should know
12
F-FEM-CNT — User’s Guide
Standard text styles:
Lists:
1.5.2 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:
[email protected]
We look forward to hearing from you!
Bold Parameters; control elements in windows and
dialog boxes; important text
Italics Cross-references; foreign-language or new
terms; wild-card for elements that need to be
entered by the user, i.e. characters or text. If you
read, for example, macro name, you are required
to type the name of a macro.
UPPERCASE LETTERS Operating modes
Courier
Programming examples; source code
Times New Roman Formulas
Menu | Option Description of how to select a menu item from a
given menu
1.
2.
Step-by-step procedures with a given sequence
•One-step instructions


Unordered series of concepts, items or options
–
–

13
General
F-FEM-CNT — User’s Guide
2 General
2.1 Performance Data
The F-FEM-CNT offers a broad range of performance features, with regret to
data acquisition rate, accuracy and resolution etc. Furthermore, the use of the
F-FEM-CNT minimizes the installation effort compared to other data acquisition
systems.
The main application of the Fast Front End Modules is in the area of engine test
beds, as well as in all types of vehicle testing.
For example, the sensors can be connected directly to the F-FEM-CNT.
The F-FEM-CNT can be used with PUMA Open. FEMs Classic (older generation
of FEMs) and F-FEMs (new generation) can be operated parallel to each other in
the PUMA Open system.
4 SUB-D sockets for the connection of the following sensors:
– Digital inputs (digital pick-up): 1 or 2 phases;
electrically isolated from the system and from other channels.
– Inductive pick-up: 1 phase; electrically isolated from system
– Incremental rotary encoder RS422:
1 or 2 phases, with reference point processing (3-track);
5 V encoder supply;
electrically isolated from the system, connected to digital GND.
6 independent counter channels for data acquisition
3 IEEE1394 interfaces
Connection of 2 F-FEM-DIO modules with 16 digital inputs and 16 digital
outputs each
Data transfer to PUMA test bed workstation via IEEE1394 bus

General
14
F-FEM-CNT — User’s Guide
2.2 System Environment
The figure below outlines schematically how F-FEMs are integrated with the
PUMA Open test bed system.
Fig. 2 Example of a system environment
1.....Test bed workstation (on which the PUMA Open system has been
installed)
2..... F-FEM-AIF connected to the PUMA Open system
3.....Engine test bed (engine, dyno)
4..... F-FEM-AIN or F-FEM-AIS (electrically isolated), connected to the PUMA
Open system via F-FEM-CON
5..... F-FEM-DIO, connected to the PUMA Open system via F-FEM-CON
6.....F-FEM-CON directly connected to the PUMA Open system
1
3
4
5
2
6

15
General
F-FEM-CNT — User’s Guide
2.3 Data Transfer between Test Bed and PUMA Open System
Angle pulses are recorded by sensors on the engine test bed (directly at/in the
engine). These signals are converted into speeds in the F-FEM-CNT and are
transferred as actual values to the PUMA Open system via the IEEE 1394 bus.
Interface adapter The following interface adapter is used in the PUMA Open or EMCON system:
Unibrain FireBoard400TM - OHCI
Fig. 3 Data transfer between test bed and PUMA Open system
1..... Test bed workstation
2..... IEEE 1394 Interface adapter, via which all F-FEM signals are transferred
to/from the PUMA Open system.
3..... F-FEM-CNT – conversion of the angle signals of the sensors.
4..... Engine test bed – analog signals (engine speed, vehicle speed) are
measured by sensors fixed at/in the engine.
Information
This data transfer will only work if all components are correctly installed and cali-
brated.
1
2
3
4

General
16
F-FEM-CNT — User’s Guide
2.4 Visualization
The AVL PUMA Open system visualizes the data sampled by the F-FEM-CNT by
using the Windows-based application POI (PUMA Operator Interface).
2.4.1 Seven Segment Display
The seven-segment display shows the F-FEM number, according to parameter-
ization.
A summery of the numbers displayed with their meaning can be found in Tab. 1.
Display Function Description, Remedy
. . Hardware reset Is shown briefly when the module is started (for approx. 2 … 3 sec). Cyclical
flashing dots indicate a hardware fault. Please send the device in for repair!
Bl Boot-Load A new firmware is being transferred.
Fl Flash The new firmware is being stored in the permanent memory (Flash EPROM).
This takes approx. 15 seconds. During this time, the power supply must not
be interrupted, as otherwise an incomplete system would be created which
cannot be rebooted.
F-xxx F-FEM number The parameterized F-FEM number of Config table is displayed at PAM,
dependent on the employed version PUMA Open
S-XXX F-FEM
Serial number
It is needed with the parameterization in the Config table.
e.g.: S-123
H-XXX Hardware
Revision number
e.g.: S-350
r Root The Clockmaster is the corresponding F-FEM
Depending on the firmware used there may also be other characters
that are displayed, e. g. a scrolling text from right to the left. They are not
relevant for users.
If errors occur, error numbers will be displayed (e.g. E1, E2, ...).
8.8. Identification The identification of F-FEM has been activated.
Tab. 1 Explanation of error numbers

17
General
F-FEM-CNT — User’s Guide
2.5 Cascade
The F-FEM-CNT is part of a family of Front End Modules that operate together
on a network:
An interface up to 400 MBaud IEEE1394 is used to connect them for data trans-
mission.
The F-FEM-DIO is connected via a serial interface to F-FEM modules of other
types (F-FEM-CON, -DAC, -CNT).
Several F-FEM modules can be connected to form a whole system via the IEEE
bus. The restrictions on the number of nodes, sampling rate and number of
channels depend on the license and the version of the PUMA Open software in
use.
2.6 F-FEM-CNT Block Diagram
F-FEM-DAC for analog output
F-FEM-AIF for analog input
F-FEM-AIS for analog measurement with electrical isolation
F-FEM-AIN for analog measurement without electrical isolation
F-FEM-CON for controller
F-FEM-DIO for digital I/O
Fig. 4 F-FEM-CNT block diagram
IEEE1394 Interface
X21
X22
X11
Power
Supply
Add-On
Interface
X24
X25
to F-FEM-DIO
X17
X18
X29
X30
Signal
Conditioning
X23
Processor
Core
Signal
Conditioning
Signal
Conditioning
Signal
Conditioning
Program-
mable
Logic
Thermo-
meter etc.
Counter
1 ... 6
RAM
FLASH
VCXO
EEPROM

General
18
F-FEM-CNT — User’s Guide

19
Installation
F-FEM-CNT — User’s Guide
3 Installation
3.1 Scope of Supply
F-FEM-CNT device
Connector set for all I/O connections
– P-SUB socket with case for 24 V supply
– 6 x D-SUB connector with housing for the wiring of the analog inputs
and frequency outputs
Test and calibration protocol with the measured accuracies of all output
channels (The serial number on the protocol must correspond with the
serial number on the type plate on the device).
Test certificate
User’s Guide
Software: The firmware has been already installed.
Information
Normally, the F-FEM-CNT 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 following.
Information
If the actual necessary firmware for operation is not installed, it will be loaded by
the automation system during the initialization phase (chapter "The F-FEM Firm-
ware Download Manager (FFDM)" in F-FEM Parameterization, please see
Secondary literature on page 11).
Information
Further installation material please see chapter Options on page 51).

Installation
20
F-FEM-CNT — User’s Guide
3.2 Mechanical Installation
3.2.1 External Dimensions, Space Requirement
The required mounting space on the mounting panel is 55 mm x 264 mm. The
mounting depth is 180 mm. With the plugs connected it is 245 mm.
Fig. 5 External dimensions
W = 55
H=264
H/2=132
245
D = 180