ETAS ES4455.1 User manual

ES4455.1 Load Board
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 - 2014 ETAS GmbH, Stuttgart
The names and designations used in this document are trademarks or brands
belonging to the respective owners.
V1.0.0 R03 EN - 01.2014

ES4455.1 Load Board - User’s Guide 3
Contents
ETAS Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Load Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Basic Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4.1 Correct Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4.2 Labeling of Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Taking the Product Back and Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Numbering the Loads on an ES4455.1 Load Board . . . . . . . . . . . . . . . . . . . 11
2.1.1 Load Signals to the Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.2 Connecting Loads and Measuring the Signals . . . . . . . . . . . . . . . . 12
2.2 Current Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.1 Configuring the Current Transducers . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.3 Overcurrent Protection of the Measure Outputs. . . . . . . . . . . . . . . 15
2.3 Digital Current Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3.1 Configuring Current Measuring. . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3.2 LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.3 Acoustic Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Settings in LABCAR-RTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 Pin Assignment and Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 “Threshold Calibration Connection” Connector . . . . . . . . . . . . . . . . . . . . . 19
3.2 LEDs for Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 PB4451CR Piggyback for 2 RB CRS Injectors . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 PB4451GDI Piggyback for 2 RB GDI Injectors . . . . . . . . . . . . . . . . . . . . . . . 22

ES4455.1 Load Board - User’s Guide4
Contents ETAS
5 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 ETAS Contact Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

ES4455.1 Load Board - User’s Guide 5
ETAS Introduction
1 Introduction
This User’s Guide describes the ES4455.1 Load Board. It consists of the following
chapters:
• "Introduction" on page 5
This chapter – here you will find general information on the ES4455.1
Load Board.
• "Hardware" on page 11
This chapter describes the individual function units of the ES4455.1 Load
Board in more detail.
• Pin Assignment and Display Elements
This chapter contains a description of the pins and LEDs on the front panel
of the ES4455.1 Load Board.
• "Accessories" on page 21
This chapter describes the dummy loads available to date which are
assembled as piggybacks on the board of the ES4455.1 Load Board.
• "Technical Data" on page 23
This chapter contains the technical data of the ES4455.1 Load Board.
CAUTION!
Some components of the ES4455.1 Load Board may be damaged or
even destroyed by static discharge. Leave the board in its transport
package until you want to install it.
The ES4455.1 Load Board should only be taken from its package,
configured and installed at a working place that is protected against
static discharge.
WARNING!
The components, connectors and conductors of the ES4455.1 Load
Board may carry dangerous voltages. These voltages may even exist if
the ES4455.1 is not installed in the ES4408.1 Load Chassis or the
ES4408.1 Load Chassis is powered off.
Make sure the ES4455.1 is protected against contact during opera-
tion. Disconnect all connectors to the ES4455.1 before removing the
board.
CAUTION!
If cards are unlocked (e.g. during setup or calibration) but not com-
pletely removed from the housing, they nevertheless have to be
pulled 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.

ES4455.1 Load Board - User’s Guide6
Introduction ETAS
1.1 Applications
The ES4455.1 Load Board is a carrier board for accommodating two modules
(each with two channels) for simulating high-current loads (to 60 V and to 20 A),
such as injection loads.
In the ES4408.1 Load Chassis there are three 14 HP slots for accommodating
ES4455.1 Load Boards or pre-assembled variants (see "“Pre-Assembled Solu-
tions” with Integrated Load Modules" on page 8).
When fully assembled, the injection loads of a 12-cylinder engine can be simu-
lated.
1.2 Features
The ES4455.1 Load Board has the following features:
• 3 U plug-in board (14 HP, 3400 mm x 100 mm)
• Four channels for load simulations to 20 A
• Four galvanically isolated analog or digital channels for current measuring
• Four galvanically isolated analog channels for voltage measuring
• To date, modules for the Bosch Common Rail System (two modules each
with two loads) and Bosch GDI (two modules each with two loads) are
available
Fig. 1-1 shows the block diagram of the ES4455.1 Load Board.
Fig. 1-1 Block Diagram of the ES4455.1 Load Board
PLD
EEPROM
Load 1
I
Output
Protection
Output
Protection
Output
Protection
DAC
I_Ana_Out
I_Dig_Out
V_Out
Load 2
I
Output
Protection
Output
Protection
Output
Protection
DAC
I_Ana_Out
I_Dig_Out
V_Out
Load 3
I
Output
Protection
Output
Protection
Output
Protection
DAC
I_Ana_Out
I_Dig_Out
V_Out
Load 4
I
Output
Protection
Output
Protection
Output
Protection
DAC
I_Ana_Out
I_Dig_Out
V_Out

ES4455.1 Load Board - User’s Guide 7
ETAS Introduction
The following figure shows the front panel of the ES4455.1 Load Board.
Fig. 1-2 Front Panel of the ES4455.1 Load Board
The elements of the front panel are:
• The „Loadn“ LEDs indicating load current
• The LEDs which light up when the currents exceed a threshold set in the
(LABCAR-RTC) software
• The potentiometers for setting the lower and upper thresholds for digitiz-
ing the output signal
• The “Threshold Calibration” connector at which the thresholds set using
the potentiometers are output
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

ES4455.1 Load Board - User’s Guide8
Introduction ETAS
1.3 Load Modules
The following load modules are currently available for the ES4455.1 Load Board:
• PB4451CR Piggyback for 2 RB CRS Injectors
Simulation for injectors of the Bosch Common Rail System
• PB4451GDI Piggyback for 2 RB GDI Injectors
Simulation for injectors of the Bosch HDEV GDI system
For more information on the modules, refer to the chapter "Accessories"
on page 21.
“Pre-Assembled Solutions” with Integrated Load Modules
The ES4455.1 Load Board can also be supplied as an assembled version with
these modules under the following names:
• ES4450.2 Load Board for 4 RB CRS Injectors
The ES4450.2 enables the simulation of four injectors of the Bosch Com-
mon 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 gaso-
line direct injection system. It consists of the ES4455.1 Load Board and
two piggybacks of the type “PB4451GDI Piggyback for 2 RB GDI Injec-
tors”.
Order Data
Tab . 1 -1 Order Data for Load Modules and Pre-Assembled Solutions
Order Name Short Name Order Number
PB4451CR Piggyback for 2 RB CRS Injectors PB4451CR F-00K-106-323
PB4451GDI Piggyback for 2 RB GDI Injectors PB4451GDI F-00K-106-324
ES4450.2 Load Board for 4 RB CRS Injectors ES4450.2 F-00K-106-167
ES4451.3 Load Board for 4 RB GDI Injectors ES4451.3 F-00K-106-171

ES4455.1 Load Board - User’s Guide 9
ETAS Introduction
1.4 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.
1.4.1 Correct Use
ETAS GmbH cannot be made liable for damage which is caused by incorrect use
and not adhering to the safety instructions.
1.4.2 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.
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.

ES4455.1 Load Board - User’s Guide10
Introduction ETAS
1.5 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. 1-3 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 25).