ETAS ES4602 User manual

ES4602 Breakout Panel
User’s Guide

ES4602 Breakout Panel2
Copyright
The data in this document may not be altered or amended without special
notification from ETAS GmbH. ETAS GmbH undertakes no further obligation in
relation 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 stip-
ulated in the contract.
Under no circumstances may any part of this document be copied, repro-
duced, transmitted, stored in a retrieval system or translated into another lan-
guage without the express written permission of ETAS GmbH.
© Copyright 1999 - 2002 ETAS GmbH, Stuttgart
The names and designations used in this document are trademarks or brands
belonging to the respective owners.
R1.0.4 EN - 11.2002 TTN F 00K 700 206

Contents 3
Contents
1Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3Technical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Connectors CON-L (1) and CON-S (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Connectors CON-L (2) and CON-S (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4.1 Signal Channel Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4.2 Layout of the Lab Jacks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Safety Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6 Signal Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 ES4602 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.1 Permissible Connector Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.2 Permissible Backplane Load . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1.3 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 Connector Pin Allocations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Contents4
5ETAS Contact Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Introduction 5
1Introduction
So-called breakout boxes are used to divide the signals between the control
unit and the LabCar allowing the user to simulate a cable break simply by pull-
ing a jumper. The center tabs of the jumpers make it possible to access the
individual control unit signals externally.
The chassis of the ES4602 is a backplane type breakout box. All connectors of
the ES4602 are printed versions. Standard connectors have been selected to
ensure compatibility with other products within the ES46xx series and the cou-
pling boards of the ES4500 component rack.
Using a project-specific front panel, the labels of the individual signal channels
can be customized, and it is possible to mask certain jumpers to avoid faulty or
erroneous connections.
The ES4602 breakout panel is designed as a standard 19” rack-mount type
thus allowing its use both as a stand-alone unit in its own housing and rack-
mounted as part of a LabCar system.

Introduction6

Definitions 7
2 Definitions
ES4500 Component Rack Designates a 19” assembly rack system consist-
ing of the assembly rack, power-supply unit,
and a 20-slot backplane (component rack back-
plane) with 340 loop-through signal lines. It
serves as the mounting rack for related test
plug-in cards.
Coupling board Designates a plug-in board of the ES4500
Component Rack. It allows coupling the com-
ponent rack backplane with external devices
such as control unit, breakout box, or signal
box.
Lab jack system Designates the combination of lab jacks and
the associated jumpers and connectors.
Signal channel Designates a specific signal that is uniquely
identified by its current specification and name
(channel number or label).

Definitions8

Technical Description 9
3 Technical Description
3.1 Overview
The ES4602 breakout panel is mechanically and signal-logically divided into
three areas. The connectors to the control unit ("ECU") are mounted on the
right-hand side (see Figure "Front view of the ES4602 Breakout Panel"
on page 9). The connectors to the ES4500 Component Rack (“LOADBOX”) or
signal box are located on the left.
The jumpers are arranged in the center section. The jumpers are designed
based on the current specification of each signal channel. Some signals in the
range of higher currents are protected specially (see Chapter "Safety Mea-
sures" on page 13).
Fig. 3-1 Front view of the ES4602 Breakout Panel
Although the connectors CON-L (3) and CON-S (3) are included in the back-
plane layout, they are not required at this stage and therefore hidden under a
cover.

Technical Description10
3.2 Connectors CON-L (1) and CON-S (1)
ITT Cannon DLM5-260 connectors are used for signals carrying a maximum
current of 3 A. This connector type is a so-called zero-insertion force connector
with 260 pins. Plugging this connector requires no insertion force for connect-
ing the female and male contacts. A tight connection is ensured by simply
pressing the related contacts against each other. The female and male connec-
tors are locked by turning the lever on the cable plug (see Figure "Fixing the
DLM5-260 Connector (Example)" on page 10).
Fig. 3-2 Fixing the DLM5-260 Connector (Example)
note
The connectors CON-L (load/signal box side connectors) and CON-S (ECU side
connectors) are not protected against erroneous insertion (wrong side, etc.). The
user has to take care to insert the connectors on the correct sides.
DLM5-260
position "open"
DLM5-260
position "closed"