ETAS ES5095.1 User manual

ES5095.1 Break-Out-Panel (80-CH)
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 2017 ETAS GmbH, Stuttgart
The names and designations used in this document are trademarks or brands
belonging to the respective owners.
V1.0.0 R04 EN - 12.2017

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide 3
Contents
ETAS Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Basic Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.1 Identification of Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.2 Scope of Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.3 General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.4 Connecting/Disconnecting Devices . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2.5 Requirements for Users and Duties for Operators. . . . . . . . . . . . . . . 7
1.2.6 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Identifications on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.1 CE Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.2 RoHS Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Product Return and Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 About this User’s Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Design and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Scope of Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Connections and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Pin Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Connecting Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Connection Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Technical Data, Standards and Order Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Standards Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3 Order Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide4
Contents ETAS
5 ETAS Contact Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide 5
ETAS Introduction
1 Introduction
This chapter features information on the following subjects:
• "Properties" on page 5
• "Basic Safety Notices" on page 6
• "Requirements for Users and Duties for Operators" on page 7
• "Intended Use" on page 7
• "Identifications on the Product" on page 10
• "CE Mark" on page 10
• "RoHS Conformity" on page 10
• "Product Return and Recycling" on page 11
• "About this User’s Guide" on page 11
1.1 Properties
The ES5095.1 Break-Out-Panel is a break-out panel that enables the measure-
ment, interruption and manipulation of signals to the ETAS LABCAR.
Features at a Glance
• 80 channels (separate ground connection (GND) per channel)
• Maximum permissible voltage: 60 V DC
• Maximum permissible current: 10 A
• Pin diameter of short-circuit bars: 4 mm
The two figures below show the ES5095.1 Break-Out-Panel in the front and rear
view:
Fig. 1-1 Front View
Fig. 1-2 Rear View

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide6
Introduction ETAS
The functional units of the ES5095.1 Break-Out-Panel (BoP) are illustrated sche-
matically in the following block diagram:
Fig. 1-3 Block Diagram
The signals are routed from the electronic control unit (ECU) via the short circuit
bridge to the ETAS LABCAR (see Fig. 1-3, red wire). The control unit (ECU) is
connected via channel connection ECU_x and the ETAS LABCAR is connected via
channel connection LC_x. Each signal is assigned a ground line (GND_x). This is
not routed via a short circuit bar and therefore cannot be interrupted or con-
nected by the user (see Fig. 1-3, blue wire).
For more information on how to connect an ECU and an ETAS LABCAR, see
Chapter "Connection Options" on page 18.
1.2 Basic Safety Notices
Please observe the following safety notices to avoid health issues or damage to
the device.
1.2.1 Identification of Safety Notices
The safety notices contained in this manual are marked with the general danger
symbol shown below:
The safety notices shown below are used alongside this symbol. They point out
extremely important information. Please read this information carefully.
CAUTION!
Indicates a hazard with low risk of minor or moderate physical injury
or damage to property if not avoided.
WARNING!
Indicates a possible danger with moderate risk of death or (serious)
physical injury if not avoided.
DANGER!
Indicates an immediate danger with a high risk of death or serious
physical injury if not avoided.

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide 7
ETAS Introduction
1.2.2 Scope of Supply
Prior to the initial commissioning of the product, please check whether the mod-
ule was delivered with all required components (see chapter 2.3 on page 14).
1.2.3 General Safety Information
Please observe the ETAS product safety notices ("ETAS Safety Advice") and the
following safety notices to avoid health issues or damage to the device.
ETAS GmbH does not assume any liability for damages resulting from improper
handling, unintended use or non-observance of the safety precautions.
1.2.4 Connecting/Disconnecting Devices
To avoid injuries and hardware damages, please observe the following precau-
tionary measures:
• Do not apply any voltages to the ES5095.1 connections that do not corre-
spond to the specifications of the respective connection. The exact speci-
fication of the I/O hardware is located in the manuals of the corresponding
boards.
• Do not connect or disconnect any devices while the ETAS LABCAR or
external devices are switched on. First, switch off the ETAS LABCAR by
shutting down the real-time PC and activating the on/off switch on the
rear and unplugging the power cable.
• When plugging in connectors, ensure that they are inserted straight and
no pins are bent.
1.2.5 Requirements for Users and Duties for Operators
The product may be assembled, operated and maintained only if you have the
necessary qualification and experience for this product. Improper use or use by a
user without sufficient qualification can lead to damages or injuries to one's
health or damages to property. The system integrator is responsible for the safety
of systems that use the product.
General Safety at Work
The existing regulations for work safety and accident prevention must be fol-
lowed. All applicable regulations and laws regarding operation must be strictly
adhered to when using this product.
1.2.6 Intended Use
The ES5095.1 Break-Out-Panel is a break-out panel that enables the measure-
ment, interruption and manipulation of signals to the ETAS LABCAR.
The ES5095.1 Break-Out-Panel must only be installed in and operated from a
19” rack.
The purpose of the ES5095.1 Break-Out-Panel is:
• Use in industrial lab facilities or workplaces
Note
Read the documentation supplied with the product (Product Safety Advice and
this user manual) prior to starting up the product.

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide8
Introduction ETAS
• Hardware interface for ECUs in a hardware-in-the-loop test system
The ES5095.1 is not intended for use:
• Within a vehicle on the road
• As part of a life support system
• In applications where misuse can lead to injuries or damages
• In environments in which conditions prevail that fall outside the specified
ranges: See "Ambient Conditions" on page 22
• With signal conditioning that falls outside the specified ranges: See "Tech-
nical Data, Standards and Order Data" on page 21
Requirements for Operation
The following requirements are necessary for safe operation:
• Use the product only according to the specifications in the corresponding
User's Guide. With any deviating operation, the product safety is no lon-
ger ensured.
• Observe the regulations applicable at the operating location concerning
electrical safety as well as the laws and regulations concerning work
safety!
• Observe the requirements for the ambient conditions.
• Do not use the product in a wet or damp environment.
• Do not use the product in potentially explosive atmospheres.
• Keep the surfaces of the product clean and dry.
Requirements for the Technical State of the Product
The product is designed in accordance with state-of-the-art technology and rec-
ognized safety rules. The product may be operated only in a technically flawless
condition and according to the intended purpose and with regard to safety and
dangers as stated in the respective product documentation. If the product is not
used according to its intended purpose, the protection of the product may be
impaired.
Electrical Safety and Power Supply
• Observe the regulations applicable at the operating location concerning
electrical safety, as well as the laws and regulations regarding safety at
work.
• Connect only current circuits with safety extra-low voltage in accordance
with EN 61140 (degree of protection III) to the connections of the module.
• Ensure that the connection and setting values are adhered to (see the
information in the chapter "Technical Data").
• Do not apply any voltages to the connections of the module that do not
correspond to the specifications of the respective connection.

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide 9
ETAS Introduction
Grounding / Protective Contact
To avoid danger due to insufficient grounding, please observe the following
safety measure:
De-energizing the module
The module does not have a supply voltage switch. It can be de-energized by
disconnecting the cables from all signal inputs.
Approved cables
• Adhere to the maximum permissible cable lengths.
• Do not use any damaged cables.
• Never apply force to insert a plug into a socket.
• Ensure that there is no contamination in and on the socket, that the plug
fits the socket, and that you correctly aligned the plugs with the socket.
Requirements for the installation location
Observe "Ambient Conditions" on page 22.
Requirements for the ventilation
There are no special requirements for the ventilation of the product.
Transport
To avoid damages to the hardware from electrostatic discharge, please observe
the following precautionary measures:
Maintenance
There is no need for the maintenance of the product.
Repair
If an ETAS hardware product needs to be repaired, return the product to ETAS.
Cleaning the module
• Use a dry, soft, lint-free cloth to clean the module front panel.
DANGER!
If there is no appropriate and correct grounding, exposed parts of the
module can be current-carrying. This can lead to serious injury or
even death! Be sure to verify that the module is correctly grounded,
according to IEC 61010-1!
CAUTION!
Some components of the ES5095.1 may be damaged or destroyed by
electrostatic discharges. Leave the ES5095.1 in its transport packag-
ing until installation. The ES5095.1 must only be removed from the
transport packaging, configured and installed at a workplace that is
secured against electrostatic discharges. Avoid any contact with the
connections of the ES5095.1 or with conductor paths on the card.

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide10
Introduction ETAS
• Do not use any sprays, solvents or abrasive cleaners which could damage
the product.
• Ensure that no moisture enters the product. Never spray cleaning agents
directly onto the product.
1.3 Identifications on the Product
The Following Symbols are Used for Product Labeling:
Please observe the information in the chapter "Technical Data" on page 21.
1.3.1 CE Mark
With the CE mark attached to the product or its packaging, ETAS confirms that
the product corresponds to the product-specific, applicable European Directives.
The CE Declaration of Conformity for the product is available upon request.
1.3.2 RoHS Conformity
European Union
The EU directive 2002/95/EU limits the use of certain dangerous materials for
electric and electronic devices (RoHS conformity).
ETAS confirms that the product meets this directive applicable in the European
Union.
China
With the China RoHS identification attached to the product or its packaging,
ETAS confirms that the product meets the guidelines of the "China RoHS" (Man-
agement Methods for Controlling Pollution Caused by Electronic Information
Products Regulation) applicable in the People's Republic of China.
Symbol Description
The User's Guide must be read prior to the startup of the prod-
uct
Marking for CE conformity
(see "CE Mark" on page 10)
Marking for China RoHS, see chapter
(see "RoHS Conformity" on page 10)
Marking for conformity with WEEE directive
(see "Product Return and Recycling" on page 11)

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide 11
ETAS Introduction
1.4 Product Return and Recycling
The European Union (EU) released the Directive for Waste Electrical and Elec-
tronic Equipment - WEEE to ensure the setup of systems for collecting, treating
and recycling electronic waste in all countries of the EU.
This ensures that the devices are recycled in a resource-friendly way that does not
represent any risk to personal health and the environment.
Fig. 1-4 WEEE Symbol
The WEEE symbol on the product or its packaging identifies that the product may
not be disposed of together with the remaining trash.
The user is obligated to separately collect old devices and provide them to the
WEEE return system for recycling.
The WEEE Directive applies to all ETAS devices, but not to external cables or bat-
teries.
Additional information about the recycling program of ETAS GmbH is available
from the ETAS sales and service locations (see "ETAS Contact Addresses"
on page 23).
1.5 About this User’s Guide
This User’s Guide contains the following chapters:
• "Introduction" on page 5
• "Design and Installation" on page 13
• "Connections and Connectors" on page 15
• "Technical Data, Standards and Order Data" on page 21
• "ETAS Contact Addresses" on page 23

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide12
Introduction ETAS

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide 13
ETAS Design and Installation
2 Design and Installation
2.1 Design
The ES5095.1 Break-Out-Panel (see Fig. 2-1) consists of a front panel to which
two PCBs are attached. The short circuit bars are attached to the front panel from
the front.
The perforated rail attached to the rear is used for mechanical strain relief of the
cables. It is also used to support cable shielding and contributes to the mechani-
cal stability of the complete assembly.
10-pin picoMAX pin strips are located on the back of the PCB. Corresponding
picoMAX female multipoint connectors can be connected to these (see Chapter
"Connectors" on page 15).
Fig. 2-1 Side View
Fig. 2-2 Top View
Note
The perforated rail improves the mechanical stability of the ES5095.1 and
therefore should not be removed.

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide14
Design and Installation ETAS
2.2 Installation
The ES5095.1 is provided for assembly in a 19” rack.
The cables must be secured to the perforated rail on the back of the ES5095.1
for strain relief. If necessary, cable shielding can be fitted on top of this. The
perforated rail has an electrical connection to the housing ground.
The installation of the ES5095.1 may be performed only by trained personnel in
an ESD-safe area.
2.3 Scope of Supply
The scope of delivery of the ES5095.1 Break-Out-Panel includes the assembly
described in Chapter 2.1, including the short circuit bar.
The bolts and cage nuts for assembly in a 19” rack as well as the picoMAX
female multipoint connectors are not included in the scope of delivery.
CAUTION!
Some components of the ES5095.1 may be damaged or destroyed by
electrostatic discharges. Leave the break-out panel in its transport
packaging until installation. The ES5095.1 must only be removed
from the transport packaging, configured and installed at a work-
place that is secured against electrostatic discharges. Avoid any con-
tact with the connections of the ES5095.1 or with conductor paths
on the card.
CAUTION!
Do not install the ES5095.1 while the ETAS LABCAR is switched on.
First, switch off the ES5300.1-A housing or the ES5300.1-B housing
by shutting down the real-time PC and by activating the On/Off
switch at the rear.
WARNING!
Danger of overheating and fire caused by exceeding the specified val-
ues.
Make sure that the product is only operated in the specified range.

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide 15
ETAS Connections and Connectors
3 Connections and Connectors
3.1 Connectors
The ES5095.1 is connected using the picoMAX connector system. The technical
data and order data for the connectors are listed below:
Pin Strip on the PCB
Female Multipoint Connector
Short Circuit Bar
Type picoMAX 3.5 pin strip with straight solder pins
Order no. 2091-1410
Manufacturer WAGO
Type 1.)
picoMAX 3.5 female multipoint connector with con-
ductor terminal
Order no. 2091-1130
2.)
picoMAX 3.5 female multipoint connector with con-
ductor terminal, with handle plate
Order no. 2091-1110
3.)
picoMAX 3.5 female multipoint connector with con-
ductor terminal, with handle plate and release catch
ETAS order no. F-04A-111-047
WAGO order no. 2091-1110/002-000
Manufacturer WAGO
Scope of supply No
Type Short circuit bar
Order no. KURZ 8454 / 11-4 IG MB / ETAS / Ni / SW
Manufacturer Schützinger
Scope of supply yes

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide16
Connections and Connectors ETAS
3.2 Pin Assignment
The connectors on the rear of the ES5095.1 make it possible to connect to an
electronic control unit (ECU) or to the ETAS LABCAR.
The pin assignment is illustrated in Fig. 3-1. The figure shows the maximum pos-
sible pin assignment.
Note
The x in the connection group designations GND_x, LABCAR_x and ECU_x rep-
resents the respective channel. For example, the ground connection for chan-
nel 0 is called: GND_0.
Note
The ground connections GND_x of the respective channels are not connected
to each other.

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide 17
ETAS Connections and Connectors
Fig. 3-1 Pin Assignment (Rear)

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide18
Connections and Connectors ETAS
3.3 Connecting Cable
Use only approved cables for creating cable assemblies (e.g. for connecting the
ECU or ETAS LABCAR I/O cards).
The permissible conductor data is listed below:
3.4 Connection Options
The four options for connecting to the ES5095.1 Break-Out-Panel are listed
below:
1. Signals with own Ground Line
Signals with their own ground line can be connected as shown in Fig. 3-2:
Fig. 3-2 Connecting Signals with own Ground Line
The signal lines of the ECU and the ETAS LABCAR are connected to the ECU_x-
channel or LC_x-channel respectively (see Fig. 3-2, red wires). The ground lines of
the ECU and the ETAS LABCAR are connected to the GND_x-channel (see
CAUTION!
The cables used must be particularly suited for occurring currents,
voltages and temperatures and flame-retardant in accordance with
one of the following standards IEC60332-1-2, IEC60332-2-2,
UL2556/UL1581VW-1!
Note
The signal lines may not exceed a maximum length of 3 m!
Items Data
Connection technology Push-in CAGE CLAMP
Conductor cross-section: Single wire 0.2 to 1.5 mm2
Conductor cross-section: Fine wire 0.2 to 1.5 mm2
Conductor cross-section: Fine wire 0.25 to 0.75 mm2 (with end splice with
plastic collar)
Conductor cross-section: Fine wire 0.25 to 1.5 mm2 (with end splice with-
out plastic collar)
Conductor (AWG) 24... 14, 14: THHN, THWN
Stripping length 8 to 9 mm/0.31 to 0.35 in.

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide 19
ETAS Connections and Connectors
Fig. 3-2, blue wires). When connecting the signal line and the ground line,
ensure that both wires remain twisted together until shortly before the
ES5095.1.
With this connection option, up to 80 signals, each with their own ground lines,
can be connected. 32 picoMAX female multipoint connectors are required.
2. Differential Signals
Differential signals can be connected as shown in Fig. 3-3:
Fig. 3-3 Connecting Differential Signals
The wire pair of the ECU (see Fig. 3-3, red and blue ECU wires) is connected to
two adjacent ECU_x-channels. The wire pair of the ETAS LABCAR Fig. 3-3, red
and blue ETAS LABCAR wires) is connected to two adjacent LC_x-channels.
When connecting, ensure that both differential signal lines remain twisted
together until shortly before the ES5095.1. The GNC_x-channels remain unused.
With this connection option, up to 40 differential signals can be connected. 16
picoMAX female multipoint connectors are required.
3. Signals without own Ground Line
Signals without their own ground line can be connected as shown in Fig. 3-4:
Fig. 3-4 Connecting Signals without own Ground Line
Low-frequency signals with a general ground reference (e.g. UBATT), without
their own ground line, can be connected individually to the ECU_x-channels or
LC_x-channels. When connecting, ensure that the ECU and LABCAR lines are
twisted together over as long a section as possible.
With this connection option, up to 80 signals can be connected. If the GND_x-
channels remain completely unused, only 16 picoMAX female multipoint con-
nectors are required.

ES5095.1 Break-Out-Panel (80-CH) - User’s Guide20
Connections and Connectors ETAS
4. Signals without own Ground Line, with Failure Injection
Signals without their own ground line, with failure injection, can be connected
as shown in Fig. 3-5:
Fig. 3-5 Connection of Signals without own Ground Line, with Failure Injec-
tion
Low-frequency signals with a general ground reference (e.g. UBATT), without
their own ground line, can be connected directly to the ES5095.1 with a failure
injection unit (FIU, e.g. ES5398.1 or ES4440.2). When connecting, ensure that
the supply and return lines are twisted together over as long a section as possi-
ble.
With this connection option, up to 80 signals can be connected. 32 picoMAX
female multipoint connectors are required.
5. Differential Signals with Failure Injection
Differential signals with failure injection can be connected as shown in Fig. 3-6:
Fig. 3-6 Connection of Differential Signals with Failure Injection
Differential signals can be connected directly to the ES5095.1 with a failure injec-
tion unit (FIU, e.g. ES5398.1 or ES4440.2). When connecting, ensure that the
two wire pairs are twisted together over the entire cable length.
With this connection option, up to 40 differential signals can be connected. 32
picoMAX female multipoint connectors are required.