AVL F-FEM-CON User manual

F-FEM-CON, F-FEM-CON ADVANCED
OPERATING MANUAL
08/2014
AT1199E, 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 82079-1:2012
Certificate n. Z2D 14 03 10049 011

3
Warnings and Safety Instructions
F-FEM-CON — 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-CON — User’s Guide

5
Grouped Safety Messages
F-FEM-CON — 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.

6
F-FEM-CON — User’s Guide

7
Table of Contents
F-FEM-CON — User’s Guide
Table of Contents
Warnings and Safety Instructions................................................................................................................ 3
Grouped Safety Messages ............................................................................................................................ 5
1 What you should know ................................................................................................... 11
1.1 Safety Instructions .................................................................................................................. 11
1.2 Warranty Seal......................................................................................................................... 11
1.3 Intended Application ............................................................................................................... 11
1.4 Product specific information ................................................................................................... 11
1.5 Purpose and Scope of this Documentation ............................................................................ 12
1.5.1 Typographic Conventions ................................................................................................. 13
1.5.2 We want to hear from you................................................................................................. 14
2 General ............................................................................................................................. 15
2.1 Performance Data .................................................................................................................. 15
2.2 System Environment .............................................................................................................. 16
2.3 Data Transfer between Test Bed and PUMA Open System .................................................. 17
2.4 Cascade ................................................................................................................................. 18
2.5 Visualization ........................................................................................................................... 18
2.6 F-FEM-CON Block Diagram ................................................................................................... 19
3 Installation ....................................................................................................................... 21
3.1 Scope of Supply ..................................................................................................................... 21
3.2 Mechanical Installation ........................................................................................................... 22
3.2.1 External Dimensions, Space Requirement ....................................................................... 22
3.2.2 Fixing the Module at the DIN Rail .....................................................................................23
3.2.3 Connections...................................................................................................................... 24
3.2.4 Function Test .................................................................................................................... 24
3.3 Electrical Installation............................................................................................................... 24
3.3.1 Power Cable Inlet.............................................................................................................. 24
3.3.2 IEEE1394 Wiring............................................................................................................... 25
3.3.2.1 Cable Design .................................................................................................... 25
3.3.2.2 Recommended Bus Topology .......................................................................... 26
3.3.2.3 About F-FEM Devices, Nodes, Cables and Repeaters .................................... 26
3.3.2.4 Mechanical Layout of a Cable Routing ............................................................. 27
3.3.3 Grounding and Shielding .................................................................................................. 28
3.3.3.1 Grounding ......................................................................................................... 28
3.3.3.2 Shielding ........................................................................................................... 33
3.4 Software Installation ............................................................................................................... 34

Table of Contents
8
F-FEM-CON — User’s Guide
4 Operation.......................................................................................................................... 35
4.1 Analog Inputs.......................................................................................................................... 35
4.1.1 Block Diagrams .................................................................................................................36
4.1.2 Acquisition Rate and Aliasing............................................................................................38
4.1.3 AC Characteristics ............................................................................................................39
4.1.3.1 Requirements....................................................................................................39
4.1.3.2 Signal Noise Ratio (SNR)..................................................................................39
4.1.3.3 Total Harmonic Distorsion (THD) ......................................................................39
4.1.3.4 Notes.................................................................................................................39
4.1.3.5 Frequency Spectrum.........................................................................................40
4.1.4 Specifications ....................................................................................................................42
4.1.4.1 Voltage ..............................................................................................................42
4.1.4.2 Current ..............................................................................................................43
4.2 Analog Input Load Cell ........................................................................................................... 44
4.2.1 Block Diagram...................................................................................................................44
4.2.2 Specifications ....................................................................................................................45
4.3 Analog Outputs....................................................................................................................... 47
4.3.1 Block Diagram...................................................................................................................47
4.3.2 Specifications ....................................................................................................................48
4.3.2.1 Voltage Output ..................................................................................................48
4.3.2.2 Current Output ..................................................................................................48
4.3.2.3 Analog Outputs, General...................................................................................49
4.4 Digital Inputs........................................................................................................................... 50
4.4.1 Block Diagram...................................................................................................................50
4.4.2 Specifications ....................................................................................................................51
4.5 Digital Outputs ........................................................................................................................ 52
4.5.1 Block Diagram...................................................................................................................52
4.5.2 Specifications ....................................................................................................................53
4.6 Counter Inputs ........................................................................................................................ 54
4.6.1 Input Circuit for Digital Input..............................................................................................54
4.6.2 Input Circuit for Inductive Pick-up .....................................................................................55
4.6.3 Input Circuit for Incremental Rotary Encoder ....................................................................55
4.6.4 Input Circuit for Hall Encoder ............................................................................................56
4.6.5 Description of Function .....................................................................................................57
4.6.6 Evaluation of Edges ..........................................................................................................57
4.6.6.1 Single Edge Evaluation .....................................................................................58
4.6.6.2 Multi Edge Evaluation .......................................................................................58
4.6.7 Toothed Disk with n-2 Teeth .............................................................................................59
4.6.8 Toothed Disk with n-1 Teeth .............................................................................................60
4.6.9 Block Diagram of Counter Channels.................................................................................61
4.6.10 Sensor types and attributes ..............................................................................................62
4.6.11 Accuracy Specification ......................................................................................................62
4.6.12 Sensor Inputs ....................................................................................................................68
4.7 Frequency Outputs ................................................................................................................. 69
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

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Table of Contents
F-FEM-CON — User’s Guide
4.7.4 Specifications.................................................................................................................... 76
4.7.4.1 Timing Values ................................................................................................... 76
4.7.4.2 Electrical Values ............................................................................................... 77
4.7.5 Realization of an Analog Output by F-Out (PWM)............................................................ 77
4.8 Watchdog Outputs.................................................................................................................. 79
4.8.1 Block Diagram................................................................................................................... 79
4.8.2 Description of Function ..................................................................................................... 80
4.8.3 Specification ..................................................................................................................... 80
4.9 CAN Interface ......................................................................................................................... 81
4.10 Status Displays....................................................................................................................... 81
4.10.1 Seven-Segment Display ................................................................................................... 82
4.11 Aging and Calibration Intervals............................................................................................... 83
4.11.1 Procedure ......................................................................................................................... 83
4.12 Pin Assignment....................................................................................................................... 84
4.12.1 Location of Plug Connections ...........................................................................................84
4.12.2 Analog Inputs X1 ... X4 ..................................................................................................... 86
4.12.3 Analog Input Load Cell X26 ..............................................................................................87
4.12.4 Analog Outputs X5 ... X8 ..................................................................................................88
4.12.5 Digital Inputs and Outputs X19, X20................................................................................. 89
4.12.6 Digital Inputs and Outputs X12 ........................................................................................ 90
4.12.7 Digital Outputs X14 .......................................................................................................... 91
4.12.8 Counter Inputs X17, X18 ..................................................................................................92
4.12.9 Frequency Outputs X15, X16............................................................................................ 93
4.12.10 Watchdog Output X13 ......................................................................................................93
4.12.11 Voltage Supply X11 .......................................................................................................... 94
4.12.12 Add-on Connection: X24, X25 .......................................................................................... 95
4.12.13 CAN Interface X40............................................................................................................ 96
4.12.14 Debug/JTAG Connection: X27..........................................................................................97
4.12.15 IEEE1394 Network: X21 ... X23........................................................................................ 98
5 Options............................................................................................................................. 99
5.1 IEEE 1394 Repeater............................................................................................................... 99
5.2 F-FEM-DIO ........................................................................................................................... 100
5.3 RSM8 Module....................................................................................................................... 101
5.4 EMCON Strip........................................................................................................................ 101
5.5 Counter Signal Adapter Advanced ....................................................................................... 102
6 Appendix ........................................................................................................................ 103
6.1 Technical Data...................................................................................................................... 103
6.2 CE Compliance..................................................................................................................... 104
7 Glossary and Abbreviations......................................................................................... 105
Index............................................................................................................................................................ 107

Table of Contents
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F-FEM-CON — User’s Guide

11
What you should know
F-FEM-CON — 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-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.
FEMs Classic (older generation) and F-FEMs (new generation) can be operated
parallel to each other in the PUMA Open system.
An F-FEM-CON enables the user to acquire speeds, frequencies, time periods
and events and to output demand values (such as voltages, currents, frequen-
cies or digital signals).
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 15.
Information
You will find abbreviations in chapter Glossary and Abbreviations on page 105.

What you should know
12
F-FEM-CON — User’s Guide
Front view for F-FEM-CON:
1.5 Purpose and Scope of 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-CON 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
characteristics of various sensors and actuators
basic knowledge in the PUMA Open system
Fig. 1
Information
This documentation does not and cannot replace adequate training.

13
What you should know
F-FEM-CON — User’s Guide
Contents & Scope This manual documents the I/O component when using the F-FEM-CON 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
EMCON 400 Standalone Users Guide
CDC-BME-EMCON-UUC 400 System Guide
1.5.1 Typographic Conventions
Safety messages:
Additional safety symbols:
Notes:
NOTICE
This documentation is also valid for the F-FEM-CON Advanced. If necessary
there are notes to show differences.
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
14
F-FEM-CON — 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
–
–

15
General
F-FEM-CON — User’s Guide
2 General
2.1 Performance Data
The F-FEM-CON (Fast Front End Module Controller) was designed to meet the
growing demands of modern data acquisition. The F-FEM-CON offers a broad
range of performance features, with respect to data acquisition rate, accuracy,
resolution, etc. 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.
3 interfaces for IEEE1394
2 SUB-D sockets for the connection of the following sensors:
– Digital inputs (digital pick-up): 1 or 2 phases;
electrically isolated from 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 system, connected to digital GND.
– Hall speed encoder: 1 or 2 phases
4 independent counter channels for data acquisition
18 digital inputs
26 digital outputs
4 analog inputs
1 analog input for strain gauge
4 analog outputs
2 frequency outputs
1 watchdog function for test bed monitoring
Connection of 2 F-FEM-DIO modules with 16 digital inputs and 16 digital
outputs each
CAN 2.0 B interface (only for F-FEM-CON Advanced)

General
16
F-FEM-CON — User’s Guide
2.2 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.....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

17
General
F-FEM-CON — User’s Guide
2.3 Data Transfer between Test Bed and PUMA Open System
Analog signals (voltage/current) are recorded by sensors on the engine test bed
(directly at/in the engine). The signals are transferred to the F-FEM-CON where
they are converted into digital signals and passed on to the PUMA Open system
via the IEEE1394 bus.
In the PUMA test bed workstation, control algorithms are used to calculate new
demand values from the measured actual values and to transfer these to the
output channels. At the F-FEM-CON, the digital demand values are converted
into analog quantities (current/voltage) again, e.g. to control a throttle actuator.
Data transfer between test bed and PUMA Open system:
The time-synchronized acquisition of the measured values from various
measuring modules is a particularly important feature of this type of high-resolu-
tion, fast analog data acquisition with digital evaluation. It is ensured by using the
IEEE1394 bus system with real-time capability in combination with a voltage
controlled quartz oscillator (VCXO). A clockmaster (which is selected automati-
cally in the system) synchronizes all other F-FEM modules via their PLL (phase
locked loop).
In this way, the distributed system is phase locked and time-synchronous!
Interface adapter The following interface adapter is used in the PUMA Open or EMCON system:
Unibrain FireBoard400TM - OHCI
Fig. 3
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-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.
Information
This data transfer will only work if all components are correctly installed and cali-
brated.
1
2
3
4

General
18
F-FEM-CON — User’s Guide
2.4 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:
An interface up to 400 MBaud IEEE1394 is used to connect them for data trans-
mission.
The F-FEM-DIO is connected to other types of F-FEMs via a serial interface.
Several F-FEM modules can be connected to a measurement system via the
IEEE1394 interface. In principle, 62 IEEE1394 nodes can be addressed in such
an F-FEM network. However, there are the following restrictions:
The total sampling rate is limited by the interface to the host system (e.g.
PUMA Open with 64 k samples).
All other F-FEMs in the network which require node addresses as well as
communication bandwidth (e.g. F-FEM-DAC, F-FEM-CNT or F-FEM-AIF)
have to be figured into the calculation as well.
2.5 Visualization
In the AVL PUMA Open system, the data sampled by the F-FEM-CON are visu-
alized using the Windows-based application POI (PUMA Operator Interface).
F-FEM-CON Controller with analog and digital inputs and outputs,
Counter outputs, frequency outputs
F-FEM-DAC for analog output
F-FEM-CNT for Counter input
F-FEM-AIF for analog measurement
F-FEM-AIS for analog measurement with electrical isolation
F-FEM-AIN for analog measurement without electrical isolation
F-FEM-CAIS for analog measurement with electrical isolation
F-FEM-CAIN for analog measurement without electrical isolation
F-FEM-DIO for digital I/O

19
General
F-FEM-CON — User’s Guide
2.6 F-FEM-CON Block Diagram
Fig. 4
1
1..... Only for F-FEM-CON Advanced

General
20
F-FEM-CON — User’s Guide