AVL F-FEM-DDC User manual

F-FEM-DDC
OPERATING MANUAL
01/2014
AT2868E, Rev. 05
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 2014 AVL List GmbH, Graz - Austria

3
Warnings and safety instructions
F-FEM-DDC — 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 liability 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

Warnings and safety instructions
4
F-FEM-DDC — User’s Guide

5
Grouped Safety Messages
F-FEM-DDC — 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.

Grouped Safety Messages
6
F-FEM-DDC — User’s Guide

7
Table of Contents
F-FEM-DDC — 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 Basic Information.................................................................................................................... 15
2.2 Performance Data .................................................................................................................. 15
2.3 Cascading............................................................................................................................... 16
2.4 Visualization ........................................................................................................................... 17
2.4.1 Status LED at the front side..............................................................................................17
2.4.2 Status LED at the rear side............................................................................................... 17
2.4.3 Seven Segment Display.................................................................................................... 18
2.5 F-FEM-DDC Block Diagram ................................................................................................... 19
3 Installation ....................................................................................................................... 21
3.1 Scope of supply ...................................................................................................................... 21
3.2 Mechanical Installation ........................................................................................................... 21
3.3 Electrical Installation............................................................................................................... 22
3.3.1 Power Cable Inlet.............................................................................................................. 22
3.3.2 Power Cable Module to Module........................................................................................ 23
3.3.3 IEEE1394 Wiring............................................................................................................... 24
3.3.3.1 Cable Design .................................................................................................... 24
3.3.3.2 Recommended Bus Topology .......................................................................... 25
3.3.3.3 About F-FEM Devices, Nodes, Cables and Repeaters .................................... 25
3.3.3.4 Mechanical Layout of a Cable Routing ............................................................. 26
3.3.4 Grounding and Shielding .................................................................................................. 27
3.3.4.1 Grounding ......................................................................................................... 27
3.3.4.2 Shielding ........................................................................................................... 28
3.4 Software Installation ............................................................................................................... 29

Table of Contents
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F-FEM-DDC — User’s Guide
4 Operation.......................................................................................................................... 31
4.1 Analog Outputs....................................................................................................................... 31
4.1.1 Block Diagram...................................................................................................................32
4.1.2 Specification......................................................................................................................33
4.1.2.1 Voltage Output ..................................................................................................33
4.1.2.2 Current Output ..................................................................................................33
4.1.2.3 Analog Outputs, General...................................................................................34
4.2 Digital Inputs........................................................................................................................... 35
4.2.1 Block Diagram...................................................................................................................35
4.2.2 Specification......................................................................................................................36
4.3 Counter Inputs ........................................................................................................................ 36
4.3.1 Block diagram ...................................................................................................................37
4.3.2 Spikefilter ..........................................................................................................................38
4.3.3 Specification......................................................................................................................39
4.3.4 Accuracy ...........................................................................................................................40
4.3.4.1 General about the evaluation of counter signals...............................................40
4.3.5 Parameterization ...............................................................................................................41
4.3.5.1 Mapping between input Channel, Counter and Track.......................................41
4.4 Digital Outputs Relay.............................................................................................................. 42
4.4.1 Block Diagram...................................................................................................................43
4.4.2 Specification......................................................................................................................44
4.5 Digital Outputs Transistor ....................................................................................................... 44
4.5.1 Block Diagram...................................................................................................................45
4.5.2 Specification......................................................................................................................46
4.6 Frequency Outputs ................................................................................................................. 46
4.6.1 Signal Type: Freq..............................................................................................................47
4.6.2 Signal Type: PWM ............................................................................................................47
4.6.3 Specification......................................................................................................................47
4.7 Aging and Calibration ............................................................................................................. 48
4.7.1 General .............................................................................................................................48
4.7.2 Procedure..........................................................................................................................48
4.8 Pin Assignment....................................................................................................................... 49
4.8.1 Locations of Plug Connections..........................................................................................49
4.8.1.1 Front View .........................................................................................................49
4.8.1.2 Back View .........................................................................................................49
4.8.2 Analog Outputs X1... X8....................................................................................................50
4.8.3 Digital Inputs X41 ...X44....................................................................................................51
4.8.4 Digital Outputs Relay X51, X52.........................................................................................52
4.8.5 Digital Outputs Transistor X53, X54..................................................................................53
4.8.6 Power Supply X17, X18 ....................................................................................................54
4.8.7 IEEE1394 X19, X20, X21..................................................................................................54
4.8.8 JTAG X22..........................................................................................................................55
5 Options ............................................................................................................................. 57
5.1 15 pin D-SUB plug for DIO ..................................................................................................... 57
5.2 D-SUB Connector with screw terminals ................................................................................. 58

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Table of Contents
F-FEM-DDC — User’s Guide
5.3 Digital I/O Connection Box DCB............................................................................................. 60
5.3.1 Mounting the DCB............................................................................................................. 63
5.4 Counter Signal Adapter "CSA-Connector" ............................................................................. 64
5.4.1 Assembling ....................................................................................................................... 65
5.4.2 Block Diagram................................................................................................................... 66
5.4.3 Specification ..................................................................................................................... 67
5.4.4 Parameterization............................................................................................................... 69
5.4.5 Connecting an RS422 Sensor .......................................................................................... 70
5.4.6 Connecting an Inductive Sensor....................................................................................... 71
5.4.7 Connecting an analog Sensor and using a variable Threshold ........................................ 73
5.4.8 Using a different supply voltage........................................................................................ 75
5.5 Cable Adapter for CSA to F-FEM-CNT or -CON .................................................................... 76
5.6 Counter Signal Adapter Advanced ......................................................................................... 77
5.7 Valve Connectors according to DIN 43650 ............................................................................ 78
6 Technical Data .................................................................................................................79
6.1 Electrical, mechanical and environmental Specifications ....................................................... 79
6.2 CE-Conformity ........................................................................................................................ 79
7 Glossary of Terms and Abbreviations .......................................................................... 81
Index.............................................................................................................................................................. 83

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

11
What you should know
F-FEM-DDC — User’s Guide
1 What you should know
1.1 Safety Instructions
This documentation contains important warnings and safety instructions 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 (Fast–Front End Module) represents the current generation of
Front End Modules (FEMs). Data communication happens via an IEEE1394
interface to PUMA test bed workstation. Thus, within a PUMA system real time
data communication is ensured.
Compatibility The F-FEM-DDC can be used with PUMA Open automation system.
Function of the
F-FEM-DDC
The F-FEM-DDC has outputs for voltages and currents, as well as In- and
Outputs for digital signals. The digital Inputs are equipped with a counter func-
tion.
Front view for F-FEM-DDC IP20:
Drawing of the front view for F-FEM-DDC IP20:
Fig. 1

What you should know
12
F-FEM-DDC — User’s Guide
1.5 Purpose and Scope of this Documentation
Target group This documentation addresses commissioning engineers, test bed operators
and system administrators.
The F-FEM-DDC manual supports you in planning and installation as well in
your daily work at the test bed.
Requirements It assumes that you are familiar with:
basic knowledge of electro engineering
understanding of the structure and operation of the test bed
basic knowledge of control technology
characteristics of various sensors and actuators
basic knowledge in the PUMA open system
Contents & Scope This manual documents the I/O components when using the F-FEM-DDC in a
test bed system and describes the hardware:
Connector pin out,
Mechanical and electrical requirements
Connectable Sensor types
Naming The Module name F-FEM-DDC is coming from its I/O combination:
F: Fast
FEM: Front End Module
D: DAC (analog output) channels
D: DIO (digital input and output) channels
C: Counter functions (with digital inputs).
AVL Secondary
literature
F-FEM Parameterization
Safety Manual
PUMA Open Operator Interface
Fig. 2
Information
This documentation does not and cannot replace adequate training.
NOTICE
The installation (putting into operation) may only be executed by authorised AVL
personnel.
Information
Further abbreviations you will find in chapter Glossary of Terms and Abbrevia-
tions on page 81.

13
What you should know
F-FEM-DDC — User’s Guide
1.5.1 Typographic Conventions
Safety messages:
Additional safety symbols:
Additional messages:
Standard text styles:
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.
Example
Gives an example that applies to the current topic.
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

What you should know
14
F-FEM-DDC — User’s Guide
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!
1.
2.
Step-by-step procedures with a given sequence
•One-step instructions


Unordered series of concepts, items or options
–
–

15
General
F-FEM-DDC — User’s Guide
2 General
2.1 Basic Information
The AVL Fast-Front End Modules were designed to meet the growing demands
of modern data acquisition. By using the F-FEM-DDC, a broad range of perfor-
mance features, with respect to the data acquisition rate, accuracy and resolu-
tion, are at your disposal. Also, the expense of installing the F-FEMs is relatively
low compared to that of other data acquisition systems.
The main application areas of these modules are test benches for combustion
engines and all kinds of vehicle tests.
2.2 Performance Data
The F-FEM-DDC performs the following kind of channels and features:
High speed network interface with IEEE1394
24 V Power supply
8 analog output channels with 16 bit resolution
2 groups of 4 channels each
16 digital inputs, 4 groups of 4 channels each
8 counter channels for 2 track signals up to 500 kHz
16 digital outputs
2 groups of 4 relays with change over contacts and
2 groups of 4 high side power switches each
Digital I/Os have Quick Lock™ D-SUB connectors

General
16
F-FEM-DDC — User’s Guide
2.3 Cascading
The F-FEM-DDC is part of a family of Front End Modules that operate together
in a network. An interface up to 400 MBaud IEEE1394 is used to connect them
for data transmission. The other members of this group are:
Because it has an RS485 interface, the FEM-P is an exception in this group. It is
therefore operated as a submodule of a F-FEM-AIS, -CAIS, -AIN, -CAIN. The
F-FEM-DIO is connected via a serial interface at F-FEMs of other types
(F-FEM-CON, -DAC, -CNT).
Several F-FEMs can be connected with the IEEE1394 interface to a bus. The
restrictions on the number of nodes, total sampling rate and number of channels
are dependent on the licence and version of the PUMA Open Software.
You will find further information in the corresponding F-FEM parameterizing
manual.
F-FEM-CON Controller with analog and digital input and
output, Counter outputs, frequency outputs
F-FEM-DAC for analog output
F-FEM-CNT for Counter input
F-FEM-AIF for analog measurements,
with bayonet locking
F-FEM-AIN for analog measurements without galv.
isolation, with bayonet locking
F-FEM-CAIS for analog measurements with galv. isola-
tion, with screw-type locking
F-FEM-CAIN for analog measurements without galv.
isolation, with screw-type locking
F-FEM-AIT for temperature measurements without galv.
isolation, with screw-type locking, reduced
accuracy and sampling rate
BASIS-FEM-AIN for analog measurements without galv.
isolation, with bayonet locking
BASIS-FEM-CON Controller with analog and digital input and
output, Counter outputs, frequency outputs
with reduced accuracy and sample rate
F-FEM-DIO for digital input and output
FEM-P for measuring pressure

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General
F-FEM-DDC — User’s Guide
2.4 Visualization
The data sampled by the F-FEM-AIx modules is visualized in connection with the
AVL PUMA system, using the program POI (Puma Operator Interface) under
Windows.
You will find further information from POI User’s Guide.
2.4.1 Status LED at the front side
At the module front down to the right there is a green LED, that announces the
existence of the operating voltage. Further functions that are dependent on the
installed firmware are described in the SW Release Notes.
LED is ON: F-FEM is provided with voltage
LED is OFF: F-FEM is not provided with voltage
LED blinks: Identification of F-FEM is activated
2.4.2 Status LED at the rear side
There are 6 LED at the rear side of the module with these functions.
If the identification of the respective F-FEM is activated, all LED blink synchrono-
souly at the rear side (except LED 1).
Layout LED No. Description
1 "Happy LED“ = FPGA loaded, blinks with 3 Hz
2 „Blinky“ = 1 Hz blinking
Trigger for all F-FEM-AIx blinks with 1 Hz
Trigger master: short time dark
Trigger slave: short time light
3 „TX“ = Transmit LED blinks on each thousandth data package
4 „RX“ = Receive LED blinks on each thousandth data package
5 „Load“ = CPU utilization
6 „SW Download“ is running
Do not break power while downloading!
Tab. 1
Status-LED-No.
642
531

General
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F-FEM-DDC — User’s Guide
2.4.3 Seven Segment Display
Also at the rear side of the module there is a binary seven-segment display,
where different characters are displayed depending on the operating mode.
The table below gives an overview of the displayed numbers and their meaning:
Display Function Description, Remedy
. . Hardware reset Is shown briefly when the module is started (for approx. 2 - 3 sec).
Intermittently 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 No. 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.: H-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.
(blinking)
Identification The identification of F-FEM has been activated.
Tab. 2

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General
F-FEM-DDC — User’s Guide
2.5 F-FEM-DDC Block Diagram
Fig. 3
IEEE1394 Interface
X21
X20
X18
Power
supply
X41
X42
X43
X44
X19
Processor
Core
SSN
Counter
RAM
FLASH
VCXO
EEPROM
Dig Out
Transistor
X51
X3
Digital
Input
Digital
Input
Digital
Input
Digital
Input
X2
X4
X1
Analog
Output
X7
X6
X8
X5
Analog
Output
Digital Out
Relais
Digital Out
Relais
Dig Out
Transistor
X52
X53
X54
4
4
4
44
4
4
4
4
4
X17

General
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F-FEM-DDC — User’s Guide