AVL F-FEM-DIO User manual

F-FEM-DIO
OPERATING MANUAL
09/2013
AT1087E, Rev. 07
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 2013 AVL List GmbH, Graz - Austria

3
F-FEM-DIO — 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

4
F-FEM-DIO — User’s Guide

5
F-FEM-DIO — User’s Guide
Grouped Safety Messages
WARNING
Danger of death from electrical voltage
Any connected equipment that uses higher voltages than 50 VAC 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.
CAUTION
Danger of injury
The device weights more than 18 kg, therefore make sure to use the appropriate
utilities for transportation.

6
F-FEM-DIO — User’s Guide

7
Table of Contents
F-FEM-DIO — User’s Guide
Table of Contents
Warnings and safety instructions ................................................................................................................ 3
Grouped Safety Messages............................................................................................................................ 5
1 Preface ............................................................................................................................... 9
1.1 General Information About the F-FEM-DIO.............................................................................. 9
1.2 Use and Contents of this Manual ............................................................................................. 9
1.3 System Environment .............................................................................................................. 10
1.4 Data Transfer between Test Bed and PUMA Open System .................................................. 11
1.5 Typographic Conventions....................................................................................................... 12
1.6 Online Help............................................................................................................................. 13
1.7 We want to hear from you ...................................................................................................... 13
2 General............................................................................................................................. 15
2.1 Warranty Seal......................................................................................................................... 15
2.2 Intended Use.......................................................................................................................... 15
2.3 Basic Information................................................................................................................... 15
2.4 Performance Data .................................................................................................................. 15
2.5 Block Diagram........................................................................................................................ 16
3 Installation ....................................................................................................................... 17
3.1 Installation .............................................................................................................................. 17
3.1.1 Unpacking.........................................................................................................................17
3.1.2 Scope of Supply................................................................................................................17
3.1.3 Preconditions....................................................................................................................17
3.1.4 Fixing the Module at the Top Hat Rail...............................................................................18
3.1.5 Establishing Connections..................................................................................................18
3.1.6 Troubleshooting................................................................................................................18
3.1.7 External Dimensions.........................................................................................................19
3.2 Software Installation............................................................................................................... 19
3.3 Grounding and Shielding........................................................................................................ 20
3.3.1 Grounding.........................................................................................................................20
4 Operation ......................................................................................................................... 25
4.1 General................................................................................................................................... 25
4.2 Block Diagrams ...................................................................................................................... 25
4.2.1 Digital Inputs X31 and X32 ...............................................................................................25

Table of Contents
8
F-FEM-DIO — User’s Guide
4.2.2 Digital Outputs X33 and X34.............................................................................................26
4.2.3 Digital Outputs X35 ...........................................................................................................28
4.2.4 Digital Outputs X36 ...........................................................................................................29
4.3 Specifications ......................................................................................................................... 30
4.3.1 Input ..................................................................................................................................30
4.3.2 Output ...............................................................................................................................30
4.4 Seven-Segment Display......................................................................................................... 30
4.5 Pin Assignment....................................................................................................................... 32
4.5.1 Location of Plug Connections ...........................................................................................32
4.5.2 Digital Inputs X31 and X32................................................................................................33
4.5.3 Digital Outputs X33 and X34.............................................................................................34
4.5.4 Digital Outputs X35 and X36.............................................................................................35
4.5.5 Add-on Connection: X10...................................................................................................36
4.6 Add-on Cable.......................................................................................................................... 37
4.6.1 Labeling of Front Panel, Channel Assignment..................................................................37
4.7 Information for Operation........................................................................................................ 37
5 Technical Data .................................................................................................................39
5.1 Data........................................................................................................................................ 39
5.2 CE-Conformity........................................................................................................................ 39
6 Glossary ...........................................................................................................................41
Index.............................................................................................................................................................. 43

9
Preface
F-FEM-DIO — User’s Guide
1 Preface
1.1 General Information About the F-FEM-DIO
The F-FEM-DIO (Fast Front End Module Digital In Out) is a new type of FEM
(Front End Module). It is part of a family of Front End Modules that operate
together in a network. This F-FEM belongs to a new generation of devices for
which real time data communication is ensured in the PUMA Open system.
Compatibility FEMs Classic (older generation) and F-FEMs (new generation) can be operated
parallel to each other in the PUMA Open system.
Purpose of the
F-FEM-DIO
An F-FEM-DIO is used for the input and output of digital signals. The signals are
not transferred directly to the PUMA Open test bed workstation but via another
F-FEM type (e.g. F-FEM-DAC, F-FEM-CON, F-FEM-CNT).
Channels Each F-FEM-DIO is equipped with 16 digital input and output channels.
1.2 Use and Contents of this Manual
This manual deals with the I/O component F-FEM-DIO in the PUMA Open
system. It describes the hardware (pin assignment, power supply, etc.) and the
software (function in the PUMA Open system, etc.).
The information in this documentation is meant to be a source of reference when
working with F-FEM-DIOs in the PUMA Open system or an automation system
from another manufacturer at the test bed.
Fig. 1 F-FEM-DIO
NOTICE
The installation (putting into operation) may only be executed by authorised AVL
personnel.

Preface
10
F-FEM-DIO — User’s Guide
This documentation has been written for commissioning engineers, test bed
administrators and test bed operators. It provides support during installation and
is a source of reference when working at the test bed. Basic knowledge of the
following subjects is required:
Electrical engineering
Test bed layout and operation
Automatic control engineering
Functioning of various sensors and actuators
PUMA Open system
Naming F-FEM-DIO: Fast Front End Module Digital In Out
1.3 System Environment
The figure below outlines schematically how F-FEMs are integrated with the
PUMA Open test bed system.
NOTICE
This documentation does not and cannot replace adequate training!
Fig. 2 Example of a system environment
1.....Test bed workstation (on which the PUMA Open system has been
installed)
1
3
45
2
6

11
Preface
F-FEM-DIO — User’s Guide
1.4 Data Transfer between Test Bed and PUMA Open System
Digital signals (voltage/current) are recorded by sensors on the engine test bed
(directly at/in the engine). These signals are transferred to the F-FEM-AIF or AIS
or AIN via a serial line and are then passed on to the PUMA Open system via the
IEEE1394 bus.
Furthermore, digital signals are transmitted from the PUMA Open workstation to
the engine.
Interface adapter The following interface adapter is used in the PUMA Open or EMCON system:
Unibrain FireBoard400TM - OHCI
2.....Engine test bed (engine, dyno)
3.....F-FEM-AIF, directly connected to the PUMA Open system
4.....F-FEM-CON, directly connected to the PUMA Open system
5.....F-FEM-DIO, connected to the PUMA Open system via F-FEM-CON
6.....F-FEM-AIN or F-FEM-AIS (electrically isolated), connected to the PUMA
Open system via F-FEM-CON
Fig. 3 Data transfer between test bed and PUMA Open system
1.....PUMA Open workstation
2.....IEEE 1394 Interface adapter, via which all F-FEM signals are transferred
to/from the PUMA Open system.
3.....F-FEM-DIO, connected to the PUMA Open system via an F-FEM-DAC
(serial line between F-FEM-DIO and F-FEM-CON).
4.....Engine test bed – digital signals are transmitted to/from the engine using
digital sensors (switches, actuators, etc.).
NOTICE
This data transfer will only work if all components are correctly installed and cali-
brated.
1
2
3
4

Preface
12
F-FEM-DIO — User’s Guide
1.5 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.
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

13
Preface
F-FEM-DIO — User’s Guide
Lists:
1.6 Online Help
This printed manual is also available as online Help.
To access online Help:
via the PUMA Open Help menu
or by pressing the control key [F1] for context-sensitive help.
1.7 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
–
–

Preface
14
F-FEM-DIO — User’s Guide

15
General
F-FEM-DIO — User’s Guide
2 General
2.1 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.
2.2 Intended Use
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.
2.3 Basic Information
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.
To meet the growing demands of modern data acquisition, systems have been
designed which acquire the data directly where they are measured and which
output process data where they are needed.
The F-FEM-DIO is provided with an interface for data transfer to an
F-FEM-CON, F-FEM-DAC and F-FEM-CNT. The power supply for the
F-FEM-DIO is also integrated into this interface.
The F-FEM-DIO can be used with PUMA Open or with automation systems from
other manufacturers. FEMs Classic (older generation of FEMs) and F-FEMs
(new generation) can be operated parallel to each other in the PUMA Open
system.
2.4 Performance Data
Each F-FEM-DIO is equipped with 16 digital input and output channels.
Up to 2 F-FEM-DIOs can be connected to a F-FEM-CON, F-FEM-DAC or
F-FEM-CNT. Thus, the total number of possible F-FEM-DIO modules in a
test bed system is limited by the number of available F-FEM-CON,
F-FEM-DAC and F-FEM-CNT modules.
Data transfer to connected F-FEM via serial line
Data transfer from connected F-FEM to test bed workstation via IEEE1394
bus

General
16
F-FEM-DIO — User’s Guide
2.5 Block Diagram
Fig. 4 F-FEM-DIO block diagram
Add-ON
Interface
X10
Internal supply
of Inputs
Digital Outputs 1-8
Power
Supply
LED Status
Display
I/O Shift
Register
from F-FEM-CON,
-DAC, -CNT
16 Digital
Inputs
Digital Outputs 9-16
Watchdog live

17
Installation
F-FEM-DIO — User’s Guide
3 Installation
3.1 Installation
3.1.1 Unpacking
Normally, the F-FEM-DIO is delivered in a cabinet with the wiring already done.
Component parts must only be exchanged in the case of replacements or
system extensions.
3.1.2 Scope of Supply
F-FEM-DIO device
Connector set for all I/O connections
6 x Mini Combicon connector with housing for the wiring of the digital inputs
and outputs
Test protocol of the production test of the module
Test certificate
3.1.3 Preconditions
The FEM-DIO has been designed for top hat rail mounting (DIN rail; TS35
according to DIN EN 50022). For mounting/dismounting, you need a screw
driver size 6.
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.
Information
Please check the contents with the items as indicated under "Scope of Supply".

Installation
18
F-FEM-DIO — User’s Guide
3.1.4 Fixing the Module at the Top Hat Rail
3.1.5 Establishing Connections
To work with the device, connections at the following connectors must be estab-
lished:
F-FEM-CON, F-FEM-DAC or F-FEM-CNT at X10
Digital inputs/outputs at X31 ... X36 acc. to system description
3.1.6 Troubleshooting
If the power supply has been switched on and the pin assignment is correct, a
figure or 2 strokes appear on the seven-segment display on the front side of the
F-FEM-DIO. If this is not the case, check all steps of the installation.
Fig. 5 Fixing the module at the DIN rail
1
2
3
WARNING:
Do not open the closed module case! There are no parts in the interior
of the device that need to be exchanged. Warranty claims can no
longer be asserted if the housing is opened.

19
Installation
F-FEM-DIO — User’s Guide
3.1.7 External Dimensions
3.2 Software Installation
The on-board software necessary for operation has already been installed on the
connected F-FEM-CON, F-FEM-DAC or F-FEM-CNT.
The on-board software can also be loaded by the automation system during the
initialization phase (please see the relevant documents).
Fig. 6 External dimensions of F-FEM-DIO with cable connectors

Installation
20
F-FEM-DIO — User’s Guide
3.3 Grounding and Shielding
3.3.1 Grounding
For grounding, the following must be considered:
Prevent dangerous contact voltage at electrically conductive parts;
Parasitic currents must be led back to their source of origin via the shortest
route possible.
This requires low grounding resistance and compliance with the high frequency
rules regarding installation, wire types and contacting.
The F-FEM-DIO is electrically isolated from the 24 V DC supply. For safety
purposes, the case is connected to the ground via a PE and via the DIN rail (to
avoid radio frequency interferences). The PE is carried via the add-on cable's
shielding.
If several F-FEM clusters are connected with each other in a network, every
cluster should be grounded with low inductance to the ground of its local signal
source.
If an IEEE1394 interface is used, ground wires must be used between the indi-
vidual F-FEM clusters as well as between the first cluster and the host system
(PUMA test bed workstation). Potential equalization is ensured by the PEs,
which are carried in the supply lines. The ground wires minimize the effects of
the ground loop between the different ground potentials of the network (please
refer to Fig. 9 on page 22).
To avoid ground loops completely, a fiber optic link can be used to connect the
clusters or to connect PUMA and the first cluster (please refer to Fig. 10 on
page 23). In this case, a compensatory current over the ground wires and over
the supply wire shielding is possible.
If the ground of the engine in the test cell and of the host system have to be
separated (e.g. due to too great a distance or ground loops), the F-FEM cluster
which is assigned to the engine in the test cell should have its own 24 V power
supply. Then the shielding of the power supply lines of the F-FEM cluster must
be connected via a capacitor to the same PE to which the 24 V power supply is
connected. The ground wire must then be clamped to the 0 V output of the 24 V
power supply (please refer to Fig. 11 on page 24).
Fig. 7 Mounting of the ground braid
Insert nut d9
Contact disk 6.1
Cu-band 11 x 2
Disk 6.4
DIN rail 35 x7.5
7.5
11
35
2
Screw M6 x 25
Mounting panels