ETAS ES4408.1 User manual

ES4408.1 Load Chassis
User’s Guide

2
Copyright
The data in this document may not be altered or amended without special noti-
fication from ETAS GmbH. ETAS GmbH undertakes no further obligation in rela-
tion to this document. The software described in it can only be used if the
customer is in possession of a general license agreement or single license. Using
and copying is only allowed in concurrence with the specifications stipulated in
the contract.
Under no circumstances may any part of this document be copied, reproduced,
transmitted, stored in a retrieval system or translated into another language
without the express written permission of ETAS GmbH.
© Copyright 2012 - 2018 ETAS GmbH, Stuttgart
The names and designations used in this document are trademarks or brands
belonging to the respective owners.
V1.0.0 R05 EN - 08.2018

ES4408.1 Load Chassis - User’s Guide 3
Contents
ETAS Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.1 General Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.2 Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.3 Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.4 The System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.5 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Basic Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.1 Correct Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.2 Labeling of Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2.3 Demands made regarding the Technical State of the Product . . . . 11
1.3 Identifications on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 CE Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 RoHS Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.1 European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.2 China . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.6 Taking the Product Back and Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 General Safety Instructions for Operating ES4408.1 Load Chassis . . . . . . . . 15
2.1.1 Installation and Positioning in 19" Rack . . . . . . . . . . . . . . . . . . . . . 15
2.1.2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.3 Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.4 Ground Connection/Protective Contact . . . . . . . . . . . . . . . . . . . . . 15
2.1.5 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2 Connecting/Removing Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.1 Opening the Rear of the Housing . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2.2 Installing and Removing Hardware. . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

ES4408.1 Load Chassis - User’s Guide4
Contents ETAS
2.3.1 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.4 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 The Boards for the ES4408.1 Load Chassis . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1.1 ES4408CON.1 Communication Interface . . . . . . . . . . . . . . . . . . . . 20
3.1.2 ES4434.1 Configurable Load Board . . . . . . . . . . . . . . . . . . . . . . . . 20
3.1.3 ES4435.1 Current Source Load Board . . . . . . . . . . . . . . . . . . . . . . 21
3.1.4 ES4450.2 Load Board for 4 RB CRS Injectors and ES4451.3 Load Board
for 4 RB GDI Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Connecting the Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3 The Backplane of the ES4408.1 Load Chassis . . . . . . . . . . . . . . . . . . . . . . . 22
3.4 The Power Supply of the ES4408.1 Load Chassis . . . . . . . . . . . . . . . . . . . . . 23
3.5 Ventilation of the ES4408.1 Load Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Pin Assignment and Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 “Load 9” ... “Load 15” Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 “Load 1” ... “Load 6” Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.3 “Load 7” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4 “Load 8-1” and “Load 8-2” Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5 Connector “Meas 7” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.6 “Meas 8-1” and “Meas 8-2” Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.7 “Battery IN” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.8 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1.1 “CBAV300.1-2” Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1.2 “CBAV340.1-1” Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.3 “CBAV341.1-1” Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.4 “CBAV342.1-1” Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1.5 “CBAV343.1-1” Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.6 Order Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7 ETAS Contact Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

ES4408.1 Load Chassis - User’s Guide 5
ETAS Introduction
1 Introduction
This User’s Guide describes the ES4408.1 Load Chassis. It consists of the follow-
ing chapters:
• "Introduction" on page 5
This chapter. Here you will find general information on the ES4408.1 Load
Chassis and other system components.
• "Getting Started" on page 15
This section describes general safety measures which you must adhere to
when setting up and operating ES4408.1 Load Chassis.
• "Hardware" on page 19
This chapter contains an overview of boards available for the ES4408.1
Load Chassis and further information on the housing.
• "Pin Assignment and Display Elements" on page 25
This chapter contains a description of the connectors and LEDs of the
ES4408.1 Load Chassis.
• "Accessories" on page 37
This chapter contains a description and order data of ETAS accessories for
the ES4408.1 Load Chassis.
• "Technical Data" on page 47
This chapter contains the technical data of the ES4408.1 Load Chassis.
User’s Guides are available for the various boards. These are supplied with the
products when you purchase them.
Note
Before operating the ES4408.1 Load Chassis and its components, first read the
chapter "Getting Started" on page 15!

ES4408.1 Load Chassis - User’s Guide6
Introduction ETAS
1.1 Features
The ES4408.1 Load Chassis is a 19”/4 U housing for creating a system to simu-
late electric loads.
Using various boards makes it possible to simulate various loads to test the
behavior of ECUs in an HIL system. These particularly include pull-up/pull-down
loads with currents up to 150 mA and the simulation of electromagnetic injec-
tors up to 20 A.
The ES4408.1 Load Chassis can hold up to 12 boards which enables very flexible,
customized configuration.
The ES4408CON.1 Communication Interface both monitors internal functions
and enables communication with the environment. Addressing takes place
directly from the test system (e.g. LABCAR-OPERATOR) via an Ethernet interface
with standard connectors.
In detail, the ES4408.1 Load Chassis has the following features:
1.1.1 General Features
• Customized configuration thanks to modular structure
• Can be used in all standard test systems
• Can be used in many applications worldwide thanks to a wide-range
power supply of 100 - 230 VAC
• Minimal cabling necessary thanks to standardized connections
• Easy to expand thanks to modular system architecture
• Simple integration into the ETAS HIL system LABCAR thanks to a standard-
ized dummy load concept
• Complete integration into the LABCAR-OPERATOR software (from V4.1)
• Other technical features;
– Dimensions: 4 U x 19” x 480 mm (height x width x depth)
– Power supply: wide-range power supply unit
(secondary ±12 V, +5 V, +3.3 V, +24 V, GND)
– Active housing ventilation with six cooling vents
1.1.2 Slots
The ES4408.1 Load Chassis has slots with the following dimensions (see Fig. 1-1
on page 9):
• Five 3 U slots for high current loads of which:
– Three (14 HP) for injection loads (slot 0...slot 2)
– One 6 HP and one 4 HP slot for loads with position feedback, such as
the throttle valve, EGAS, etc. (slot 3and slot 4)
• Seven 3 U slots (of 4 HP each) for low current loads (slot 5...slot 11)
For more details of the loads available for these slots, refer to the section "The
System Components" on page 7.

ES4408.1 Load Chassis - User’s Guide 7
ETAS Introduction
1.1.3 Control Unit
The ES4408.1 Load Chassis has one further slot on the rear for the optional
ES4408CON.1 Communication Interface for the following functions:
• Master controller for all boards in the ES4408.1 Load Chassis
• Ethernet interface
– for communication with LABCAR-RTPC (and also with LABCAR-OPER-
ATOR)
or
– for controlling the ES4408.1 Load Chassis with SCPI commands
For more details, refer to the ES4408CON.1 Communication Interface User’s
Guide.
1.1.4 The System Components
In addition to the ES4408.1 Load Chassis and the optional ES4408CON.1 Com-
munication Interface, the following boards are also available for the load system:
• ES4434.1 Configurable Load Board
The ES4434.1 is a manually configurable board with 24 channels for pull-
up/pull-down loads (equipped with 24 510 Ω/3 W resistors).
• ES4435.1 Current Source Load Board
The ES4435.1 is a board with 24 current sources up to 150 mA which can
be controlled using software
• ES4455.1 Load Board
The ES4455.1 is a carrier board with four channels for piggybacks with
ohmic, capacitive and inductive loads to 90 V and to 20 A (with battery
voltage).
The following piggybacks are currently available
– PB4451CR Piggyback for 2 RB CRS Injectors
– PB4451GDI Piggyback for 2 RB GDI Injectors
The ES4455.1 Load Board can also be supplied as an assembled version
with these modules:
– ES4450.2 Load Board for 4 RB CRS Injectors
The ES4450.2 enables the simulation of four injectors of the Bosch
Common Rail System (CRS). It consists of the ES4455.1 Load Board
and two piggybacks of the type “PB4451CR Piggyback for 2 RB CRS
Injectors”.
– ES4451.3 Load Board for 4 RB GDI Injectors
The ES4451.3 enables the simulation of four injectors of the Bosch
gasoline direct injection system. It consists of the ES4455.1 Load Board
and two piggybacks of the type “PB4451GDI Piggyback for 2 RB GDI
Injectors”.
The relevant User’s Guides contain detailed descriptions of the individual compo-
nents.

ES4408.1 Load Chassis - User’s Guide8
Introduction ETAS
1.1.5 Connectors
The ES4408.1 Load Chassis has various connectors on the back (see Fig. 1-1
on page 9) for the following purposes:
• for connecting the various loads
• for the measure signals of the high current loads
• for the measure values of the position feedback for slot 3 and slot 4
• for supplying battery voltage
• for the Ethernet connection (with an ES4408CON.1 Communication Inter-
face)
• for the battery node control signals of the ES1391.1 Power Supply Con-
troller Board (with an ES4408CON.1 Communication Interface)
For a detailed description of the connectors, refer to the chapter "Pin Assign-
ment and Display Elements" on page 25 – the cables obtainable from ETAS for
connecting the loads to the PT-LABCAR are described in the chapter "Accesso-
ries" on page 37.

ES4408.1 Load Chassis - User’s Guide 9
ETAS Introduction
The following figure shows the front and rear of the ES4408.1 Load Chassis.
Fig. 1-1 Front (Right) and Rear (Left) of the ES4408.1 Load Chassis
Load 1 Load 2 Load 3 Load 4 Load 5 Load 6
Meas 7 Meas 8-1 Meas 8-2
Battery
IN
Load 7
Load 8-1
Load 8-2
Load 15
Load 9
Load 10
Load 11
Load 12
Load 13
Load 14
ES4408
CON.1
ETAS
PC
SwCtrl SwCtrl
L0ER L1
ETAS
ES4455.
1
Threshold high Load 0 Threshol d low Loa d 0 Threshold high Load 1 Threshol d low Loa d 1 Threshold high Load 2 Threshol d low Loa d 2 Threshold high Load 3 Threshol d low Loa d 3
Threshold calibration connection
!
Load0 Load1 Load2 Load3
ETAS
ES4455.1
Threshold high Load 0 Threshold low Load 0 Threshold high Load 1 Threshold low Load 1 Threshold high Load 2 Threshold low Load 2 Threshold high Load 3 Threshold low Load 3
Threshold calibration connection
!
Load0 Load1 Load2 Load3
ETAS
ES4455.1
Threshold high Load 0 Threshold low Load 0 Threshold high Load 1 Threshold low Load 1 Threshold high Load 2 Threshold low Load 2 Threshold high Load 3 Threshold low Load 3
Thresh old calibration connection
!
Load0 Load1 Load2 Load3
ES4434.1
1
ETAS
2
34 56 78 910
11 12 13 14 15 16 17 18 19 20 21 22 23 24
ES4434.1
1
ETAS
2
34 56 78 910
11 12 13 14 15 16 17 18 19 20 21 22 23 24
ES4434.1
1
ETAS
2
34 56 78 910
11 12 13 14 15 16 17 18 19 20 21 22 23 24
ES4435.1
ETAS
ES4435.1
ETAS
+ 5 V
+ 3.3 V
- 12 V
+ 12 V
+ 24 V

ES4408.1 Load Chassis - User’s Guide10
Introduction ETAS
1.2 Basic Safety Instructions
Please adhere to the safety instructions in this manuals to avoid injury to yourself
and others as well as damage to the device.
ETAS GmbH cannot be made liable for damage which is caused by incorrect use
and not adhering to the safety instructions.
1.2.1 Correct Use
The ES4408.1 Load Chassis is a system housing for creating a hardware-in-the-
loop test system. The ES4408.1 based hardware-in-the-loop test system consists
of:
• A dummy load simulation for connecting to ECU final stages. The dummy
load simulation can be installed in the ES4408.1 Load Chassis in the form
of SPI or I²C based boards.
The ES4408.1 Load Chassis is always delivered/installed in a casing (19" rack
system) and must not be operated as a standalone unit.
The use of the ES4408.1 Load Chassis is as follows:
• In industrial lab facilities or at industrial workplaces,
• As a hardware interface for ECUs in a hardware-in-the-loop test system,
• In conjunction with ETAS software which supports the ES4408.1 Load
Chassis,
• As an interface together with software programs that serve the standard-
ized, documented and open APIs of ETAS software products.
The ES4408.1 Load Chassis is not intended to be used as follows:
• In a vehicle on the road,
• As part of a life support system,
• As part of a medical application,
• In applications in which misuse can lead to injury or damage,
• In environments with conditions outside the specified ranges -> see the
section Environmental Conditions.
Demands made of Operation
The following requirements are made to ensure safe operation:
• Only use the product in accordance with the specifications in the relevant
User’s Guide. Product safety is not guaranteed if the device is used other
than intended.
• Observe all applicable regulations on site concerning electrical safety as
well as the rules and regulations on occupational health and safety!
• Never use the product in a wet or damp environment.
• Never use the product in areas subject to explosions.
• Make sure you keep the surface of the product clean and dry.
Demands made re the Technical State of the Product
This state-of-the-art product adheres to all recognized safety-related regulations.
The product must only be used if it is in full working order, with the relevant
personal only using the device as it was intended, taking all security issues and

ES4408.1 Load Chassis - User’s Guide 11
ETAS Introduction
risks into account as well as taking into consideration the relevant documenta-
tion at all times. If the product is not used correctly, the protection of the product
may be impaired.
To ensure safe operation of the ES4408.1 Load Chassis, ensure you read and
follow the guidelines set out in the section "General Safety Instructions for Oper-
ating ES4408.1 Load Chassis" on page 15.
Maintenance and Cleaning
To clean the outside of the device, use a clean, dry cloth. To clean the inside and
the air filter, see the section on "Cleaning" on page 15.
1.2.2 Labeling of Safety Instructions
The safety instructions contained in this manual are shown with the standard
danger symbol shown below:
The following safety instructions are used. They provide extremely important
information. Please read this information carefully.
1.2.3 Demands made regarding the Technical State of the Product
To ensure safe operation of the ES4408.1 Load Chassis, read and adhere to the
information in the chapter "Getting Started" on page 15.
CAUTION!
indicates a low-risk danger which could result in minor or less serious
injury or damage if not avoided.
WARNING!
indicates a possible medium-risk danger which could lead to serious
or even fatal injuries if not avoided.
DANGER!
indicates a high-risk, immediate danger which could lead to serious
or even fatal injuries if not avoided.

ES4408.1 Load Chassis - User’s Guide12
Introduction ETAS
1.3 Identifications on the Product
The following symbols are used for identifying the product:
Observe the information in chapter "Technical Data" on page 47.
1.4 CE Marking
ETAS confirms that the product meets the product-specific applicable European
Directives with the CE marking affixed to the product or its packaging. The CE
Declaration of Conformity for the product is available upon request.
1.5 RoHS Conformity
1.5.1 European Union
The EU Directive 2002/95/EU limits the use of certain dangerous materials for
electrical and electronic devices (RoHS conformity).
ETAS confirms that the product corresponds to this directive which is applicable
in the European Union.
1.5.2 China
ETAS confirms that the product meets the product-specific applicable guidelines
of the China RoHS (Management Methods for Controlling Pollution Caused by
Electronic Information Products Regulation) applicable in China with the China
RoHS marking affixed to the product or its packaging.
Symbol Description
Before using the product, carefully read the user’s guide!
Identification for CE (see "CE Marking" on page 12)
Identification for China RoHS (see "RoHS Conformity"
on page 12)
Identification for WEEE directive
(see "Taking the Product Back and Recycling" on page 13)

ES4408.1 Load Chassis - User’s Guide 13
ETAS Introduction
1.6 Taking the Product Back and Recycling
The European Union has passed a directive called Waste Electrical and Electronic
Equipment, or WEEE for short, to ensure that systems are setup throughout the
EU for the collection, treating and recycling of electronic waste.
This ensures that the devices are recycled in a resource-saving way representing
no danger to health or the environment.
Fig. 1-2 WEEE Symbol
The WEEE symbol on the product or its packaging shows that the product must
not be disposed of as residual garbage.
The user is obliged to collect the old devices separately and return them to the
WEEE take-back system for recycling.
The WEEE directive concerns all ETAS devices but not external cables or batteries.
For more information on the ETAS GmbH Recycling Program, contact the ETAS
sales and service locations (see "ETAS Contact Addresses" on page 49).

ES4408.1 Load Chassis - User’s Guide14
Introduction ETAS

ES4408.1 Load Chassis - User’s Guide 15
ETAS Getting Started
2 Getting Started
This section describes general safety measures which you must adhere to when
setting up and operating ES4408.1 Load Chassis.
Before you start the set-up procedure, read the following sections carefully, pay-
ing particular attention to all notes and warnings.
2.1 General Safety Instructions for Operating ES4408.1 Load Chassis
Before you launch the ES4408.1 Load Chassis, please read this section carefully.
2.1.1 Installation and Positioning in 19" Rack
When choosing a place to set-up the ES4408.1 Load Chassis, please take the
following into consideration:
• Only operate the ES4408.1 Load Chassis if it has been integrated in a 19"
rack or in the ETAS casing specially designed for this purpose (ES4015.2
Housing 9U, F-00K-107-884). During operation, particularly heed the
safety instructions on "Ventilation" on page 15.
• Also make sure that there are no heat sources in the vicinity, e.g. radiators
or other heat-producing devices.
• The ES4408.1 Load Chassis and its components are not waterproof. Avoid
contact with water and any other liquids.
• Lay cables so that nobody can step on them or trip over them and make
sure that they cannot be jammed or caught up in any other way.
2.1.2 Ventilation
When the ES4408.1 Load Chassis is being operated in a 19" rack, make sure you
observe the following points:
Never block the cooling vents – these are absolutely necessary to ensure suffi-
cient ventilation inside the housing. Make sure there is a space of at least 15 cm
between the ES4408.1 Load Chassis and walls or any other objects.
2.1.3 Connecting Cables
When creating wiring harnesses (e.g. when connecting the ECU and external
loads) only use permissible cables (UL-certified).
2.1.4 Ground Connection/Protective Contact
The ground connection of the overall system is ensured via the protective earth
conductor of the power cable. Avoid electric shocks when touching housing
parts by ensuring that the mains socket used has correctly connected protective
contacts.
2.1.5 Cleaning
Before cleaning the housing parts, remove the power cable. Only clean the
device with a damp cloth. Never use detergents or solvents.
Note
During a thunderstorm, disconnect the ES4408.1 Load Chassis from the power
supply or install corresponding safety devices.

ES4408.1 Load Chassis - User’s Guide16
Getting Started ETAS
For details of how to clean the cooling vent filter mat, refer to the section "To
clean the filter mat" on page 24.
2.2 Connecting/Removing Devices
To avoid injury and damage to the hardware, please observe the following pre-
cautionary measures:
• Do not apply any voltages to the connectors of the ES4408.1 Load Chassis
which do not correspond to the specification of the relevant connector.
For details of the exact specification of the I/O hardware, consult the man-
ual of the relevant board.
• Please observe the maximum permissible currents of the individual signal
lines.
• Do not connect or remove any devices when the ES4408.1 Load Chassis
or external devices are powered on.
• Make sure that all connectors are inserted straight to ensure that the pins
are not bent.
2.2.1 Opening the Rear of the Housing
The rear of the ES4408.1 Load Chassis must only be opened by qualified techni-
cal personnel!
Disconnect from the power supply by removing the power cable; then wait a few
minutes until all components (e.g. power supply unit, capacitors) are discharged.
2.2.2 Installing and Removing Hardware
To avoid the hardware being damaged by electrostatic discharge, please observe
the following precautionary measures:
• The boards in the ES4408.1 Load Chassis can be damaged or even
destroyed by electrostatic discharge.
• Boards should only be taken from their package, configured and installed
at a working place that is protected against static discharge. Avoid touch-
ing the board’s connectors and any conductors on it.
DANGER!
As long as the ES4408.1 Load Chassis is connected to the power
supply, you risk getting an electric shock!
CAUTION!
If cards are unlocked (e.g. during setup or calibration) but not com-
pletely removed from the housing, they nevertheless have to be pul-
led out of the housing so that the distance between the card and the
backplane of the housing is at least 1 cm! Otherwise there could be
contacts between the cards which could then be destroyed as a
result.

ES4408.1 Load Chassis - User’s Guide 17
ETAS Getting Started
2.3 Power Supply
The ES4408.1 Load Chassis can be operated between 100 V and 230 V at 50 Hz
- 60 Hz; the maximum current consumption is 3,15 A.
2.3.1 Power Cables
Due to regional differences in the power supply, ETAS does not supply power
cord cables with the ES4408.1 Load Chassis. The following table contains details
of the relevant requirements and the ETAS order numbers.
DANGER!
Before you open the device, disconnect it from the power supply by
unplugging it.
Region Description Order
Number
General AC supply cable with IEC 60320 C13 plug on
one end and a non-locking plug approved by
the national safety standards (with earth
contacts) on the other end. Plugs and cable
must be rated for min. 250 VAC/10 A or
125 VAC/15 A.
-
China AC supply cable China for various ETAS
devices with PRC/3 and IEC 60320 C13 plug.
Rated for 250 VAC/10 A, 2.50 m length
F-04A-109-512
Europe AC supply cable Europe for various ETAS
devices with CEE7/7 and IEC_60320 C13
plug. Rated for 250 VAC/10 A, 2.50 m length
F-04A-109-513
India AC supply cable India for various ETAS devices
with IS 1293 (D) and IEC 60320 C13 plug.
Rated for 250 VAC/10 A, 2.50 m length
F-04A-109-514
Japan AC supply cable Japan for various ETAS
devices with JIS C 8303 and IEC 60320 (C)13V
plug. Rated for 125 VAC/15 A, 2.50 m length
F-04A-109-515
North America AC supply cable North America for various
ETAS devices with NEMA 5/15 - IEC 60320
C13M plug. Rated for 125 VAC/15 A, 2.50 m
length
F-04A- 109-445
United
Kingdom
Power cord cable UK for various ETAS devices
with BS 1363/A and IEC 60320 C13 plug.
Rated for 250 VAC/10 A, 2.50 m length
F-04A-109-516

ES4408.1 Load Chassis - User’s Guide18
Getting Started ETAS
2.4 Environmental Conditions
Only operate the ES4408.1 Load Chassis under the following environmental
conditions:
Environment Only use indoors
Operating temperature 5 °C to 35 °C (41 °F to 95 °F)
Relative humidity 0 to 95% (non-condensing)
Power supply 100 - 240 V/50 - 60 Hz, 3 A

ES4408.1 Load Chassis - User’s Guide 19
ETAS Hardware
3 Hardware
This chapter contains an overview of boards available for the ES4408.1 Load
Chassis and further information on the housing.
These are:
• "The Boards for the ES4408.1 Load Chassis" on page 20
This section contains an overview of the boards which can be used in the
ES4408.1 Load Chassis for controlling and load simulation.
– "ES4408CON.1 Communication Interface" on page 20
– "ES4434.1 Configurable Load Board" on page 20
– "ES4435.1 Current Source Load Board" on page 21
– "ES4450.2 Load Board for 4 RB CRS Injectors and ES4451.3 Load
Board for 4 RB GDI Injectors" on page 21
• "The Backplane of the ES4408.1 Load Chassis" on page 22
This section describes the backplane of the ES4408.1 Load Chassis.
• "The Power Supply of the ES4408.1 Load Chassis" on page 23
• "Ventilation of the ES4408.1 Load Chassis" on page 24
For more detailed information, refer to the User’s Guides for the relevant boards.

ES4408.1 Load Chassis - User’s Guide20
Hardware ETAS
3.1 The Boards for the ES4408.1 Load Chassis
This section contains an overview of the boards which can be used in the
ES4408.1 Load Chassis for controlling and load simulation.
3.1.1 ES4408CON.1 Communication Interface
The ES4408CON.1 Communication Interface is used in the ES4408.1 Load Chas-
sis to communicate with the boards in the chassis.
Features
Via the 100-MBit Ethernet interface, the ES4408.1 Load Chassis can be inte-
grated into the HIL system with the LABCAR-OPERATOR software, the simulation
target with LABCAR-RTPC and the relevant hardware. The Ethernet interface can
also be used to control a standalone ES4408.1 Load Chassis with SCPI com-
mands.
The status signals of the battery nodes can be supplied (from the ES1391.1
Power Supply Controller Board) and led through again (to the ES1392.2 High
Current Switch Board) at the ES4408CON.1 Communication Interface. These sig-
nals are routed to the backplane of the ES4408.1 Load Chassis and used there
for the ES4434.1 Configurable Load Board to switch battery nodes or on the
ES4435.1 Current Source Load Board to activate current sources.
Place of Installation and Connections
The slot for the ES4408CON.1 Communication Interface is on the rear of the
housing, on the left (see Fig. 3-1 on page 22).
The Ethernet cable and the cables for the status signals of the battery nodes must
be connected.
Configuration
The configuration is taken care of in the software (in LABCAR-RTC) and primarily
concerns communication settings such as the Ethernet address, the Ethernet
adapter used on the Real-Time PC etc.
3.1.2 ES4434.1 Configurable Load Board
The ES4434.1 Configurable Load Board is used to simulate low current loads in
the ES4408.1 Load Chassis. It is equipped with 24 configurable loads: Each one
can be configured to a specific battery node.
A total of seven boards of the type ES4434.1 Configurable Load Board or
ES4435.1 Current Source Load Board can be used in an ES4408.1 Load Chassis.
Place of Installation and Connections
The ES4434.1 Configurable Load Boards are installed (mixed with ES4435.1 Cur-
rent Source Load Boards – see section 3.1.3 on page 21) in slot 5 - slot 11 of the
ES4408.1 Load Chassis (see "The Slots of the ES4408.1 Load Chassis (View from
the Front)" on page 22).
The channels of the boards can be accessed at connectors “Load 9” ...
“Load 15” on the rear of the ES4408.1 Load Chassis.