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"

Technical Description 11
3.3 Connectors CON-L (2) and CON-S (2)
KPTC22-55 type connectors from ITT Cannon are used for signals up to 15 A.
The mating connector has a bayonet catch. Safe contact is only ensured after
the bayonet has been locked.
3.4 Jumpers
Different jumpers – 2 mm and 4 mm contacts – are employed depending on
the current specification of the signals. The 2 mm system is used for signals up
to 3 A while the 4 mm system is used for signals exceeding 3 A.
In both systems, the jumpers include center tabs that enable the user to short-
circuit signals via cable jumpers or to connect external measuring systems.
3.4.1 Signal Channel Labels
As the ES4602 Breakout panel is designed for use in combination with the
ES4500 Component Rack, the standard labels of the individual signal channels
are based on the layout of the ES4500 backplane. The signal channels relevant
to the control unit start at channel #67. The labels of the individual signal
channels are located below the associated jumper (see Figure "Location of the
Channel Label" on page 11).
Fig. 3-3 Location of the Channel Label
A customized front panel can be mounted if the user prefers different labels.
Depending on the particular type, lab jacks that are not in use can be masked.
The panel is made of 1 mm thick anodized aluminum. The labels are printed.
The panel is mounted using the existing screws.
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.
jumper
channel label

Technical Description12
The customized front panel is available as an option.
3.4.2 Layout of the Lab Jacks
Two lab jacks are used for each signal channel and jumper. The upper lab jack
connects the control unit (ECU) while the lower lab jack connects the compo-
nent rack (LOADBOX) / signal box (see Figure "Layout of the Lab Jacks"
on page 12).
Fig. 3-4 Layout of the Lab Jacks
upper lab jack row
lower lab jack row

Technical Description 13
3.5 Safety Measures
Certain signal channels reserved for the battery node circuit and ±Ubat, are
protected by fuses on the control unit side. The fuses are "Minifuse" types
manufactured by Littlefuse.
The fuses have sockets and can be replaced easily. The fuse compartment has
a 1 mm aluminum cover (see Fig. 3-5).
Fig. 3-5 Fuse Compartment Cover
To replace a fuse, remove the cover using a Phillips screwdriver (see figure).
Remove the defective fuse using a pair of flat-nose pliers and replace it with a
new one (see Fig. 3-6 on page 14).

Technical Description14
Fig. 3-6 Fuse Replacement
The location of the fuses is described in Figure "Fuses for Each Signal Channel
and Corresponding Pin on CON-S(2) (Top View)" on page 15.
Table "Allocation of Signal Fuses to the Corresponding Connector Pins"
on page 14 shows the fuse allocation for each signal channel to the corre-
sponding connector pins (see also Chapter "Connector Pin Allocations"
on page 21).
note
Be sure to use 10 A and 15 A rated fuses only. Using fuses with higher ratings
will void the warranty.
Fuse Pin #
[CON-L(2) / (CON-L(3)]
Pin #
[CON-S(2) / CON-S(3)]
330 (i,N) / (H,S) (i,N) / (H,S)
331 (x,EE) / (J,T) (x,EE) / (J,T)
332 (t,F) / (K,U) (t,F) / (K,U)
333 (b,u) / (L,M) (b,u) / (L,M)
Tab. 3-1 Allocation of Signal Fuses to the Corresponding Connector Pins

Technical Description 15
Fig. 3-7 Fuses for Each Signal Channel and Corresponding Pin on CON-
S(2) (Top View)
338 (c,g,v) / (F,G) (c,g,v) / (F,G)
339/1 (d,G,H) / (D,E,R) (d) / (R)
339/2 (d,G,H) / (D,E,R) (G) / (E)
339/3 (d,G,H) / (D,E,R) (H) / (D)
340/1 (e,f,J,K,L,M) / (A,B,N) (J) / (A)
340/2 (e,f,J,K,L,M) / (A,B,N) (e) / (N)
340/3 (e,f,J,K,L,M) / (A,B,N) (f) / (B)
340/4 (e,f,J,K,L,M) / (A,B,N) (L) / n.c.
340/5 (e,f,J,K,L,M) / (A,B,N) (M) / n.c.
340/6 (e,f,J,K,L,M) / (A,B,N) (K) / n.c.
Fuse Pin #
[CON-L(2) / (CON-L(3)]
Pin #
[CON-S(2) / CON-S(3)]
Tab. 3-1 Allocation of Signal Fuses to the Corresponding Connector Pins
10A 15A10A 10A 10A 10A 15A
15A 15A 15A 15A 15A 15A 15A
333 332 331 330 338
340/1 340/2
(b,u)
(F,t)
(x,EE)
(i,N)
(c,g,v)
(J)
(e)
339/3 339/2 339/1 340/6 340/5 340/4 340/3
(H)
(G)
(d)
(K)
(M)
(L)
(f)
Signal Channels
Signal Channels

Technical Description16
3.6 Signal Routing
In general, all connections between the CON-L(1),(2),(3) and CON-S(1),(2),(3)
connections are point-to-point links that can be opened with the use of jump-
ers.
Exceptions are the +Ubat and –Ubat signals. For some control units, the +Ubat
and –Ubat voltages are applied to separate inputs of the control unit. These
voltages must therefore exist on the breakout panel individually.
Fig. 3-8 Signal Channel Routing on the ES4602 Breakout Panel
Loads / Signalbox
ECU
channels
#67 - #106
channels
#107 - #281
channels
#282 - #321
channels
#330 - #333,
#338
channels
#322- #329,
#336, #337
channels #339
channel
#339(1)
channel
#339 (2)
channel
#339 (3)
channels #340
channel
#340 (1)
channel
#340 (2)
channel
#340 (3)
channel
#340 (4)
channel
#340 (5)
channel
#340 (6)

Technical Description 17
For the ES4602 Breakout Panel, the +Ubat and –Ubat signals on the CON-L(2)
side are routed to three (+Ubat) or six (–Ubat) lab jacks (see Figure "Signal Chan-
nel Routing on the ES4602 Breakout Panel" on page 16 "Channel #339" and
"Channel #340"). After the jumper, the signals are then split into three (+Ubat)
or six
(-Ubat) individual signals (see Figure "Signal Channel Routing on the ES4602
Breakout Panel" on page 16 and Figure "Distribution of the Battery Nodes to
the Plug-In Bridges" on page 17). This meets the requirement for supply volt-
ages that can be split into individual voltages. The individual +/–Ubat signals are
protected towards the control unit side by means of a miniature car fuse (15 A)
(see also Table "Current-Carrying Capacity of the Backplane" on page 19).
Fig. 3-9 Distribution of the Battery Nodes to the Plug-In Bridges
CON-S
CON-L
340/1 340/2
340/3 340/4 340/5
340/6
339/1
339/2
339/3

Technical Description18

Appendix 19
4Appendix
4.1 ES4602 Specifications
4.1.1 Permissible Connector Load
4.1.2 Permissible Backplane Load
The backplane is designed for a dielectric strength between the individual con-
nections of 300 V.
4.1.3 Fuses
The fuses to be employed are "Minifuse" types manufactured by Littlefuse.
The following ratings are used:
•10A(red)
•15A(blue)
Connector Max. load [A] Dielectric strength [V]
DLM5-260 4.0 A 1000 V
KPTC22-55 7.5 A 1500 V
lab jack system 2 mm 10.0 A
lab jack system 4 mm 18.0 A
Tab. 4-1 Maximum Load and Dielectric Strength of the Connectors
Signal channel range Current-carrying
capacity [A]
(signal box side)
Current-carrying
capacity [A]
(control unit side)
67 – 281 1.5 A 1.5 A
282 – 321 6.0 A 6.0 A
322 – 329 10.0 A 10.0 A
330 – 333, 338 25.0 A 25.0 A
336, 337 10.0 A 10.0 A
339, 340 40.0 A 15.0 A
Tab. 4-2 Current-Carrying Capacity of the Backplane

Appendix20
4.2 Accessories
Connection cable ES4602 to ES4510
Connection chord with 2 mm banana plug (black)
Plug-in bridge 2 mm
Plug-in bridge 4 mm
Fuse 10 A
Fuse 15 A
Customized front panel
English Manual:
ES4602 Breakout Panel User’s Guide (TTN: F 00K 700 206)
German Manual:
ES4602 Breakout Panel Benutzerhandbuch (TTN: F 00K 700 205)
The accessories are available on request.