ETAS ES420.1 User manual

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ES420.1
Thermo Module
User’s Guide

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
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
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 2019 ETAS GmbH, Stuttgart
The names and designations used in this document are trademarks or brands
belonging to the respective owners.
ES420.1 - User’s Guide R08 EN - 03.2019

ETAS Content
Content
ES420.1 - User’s Guide 3
1 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Identification of Safety Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Presentation of Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Scope of Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Basic Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Requirements for Users and Duties for Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Intended Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 ES400 Product Family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 Wiring Concepts in Test Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Features of the ES400 Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2.1 Advantages of the Decentral Wiring Concept. . . . . . . . . . . . . . . . . . . . . . . 15
3.2.2 Further Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.1 “Sensor” Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.2 Daisy Chain Ports (“IN”, “OUT”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.5 LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.1 Operational State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.2 Service State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5.3 Functional State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Hardware Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Features of the ES420.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 Sensor Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Measurement Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.5 Data Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5.1 Communication Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5.2 Realization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.5.3 Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.6.1 Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.6.2 Supplying the ES400 Modules via the Connecting Line . . . . . . . . . . . . . . 28
4.6.3 Additional Supply of the ES400 Modules via a Y-Boost Cable. . . . . . . . . 28
4.7 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.8 Tool Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.9 Firmware Update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.10 Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Content

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ES420.1 - User’s Guide 4
5 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1 General Installation Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.1.1 Assembly Environment and Components for Attaching the Module. . . 32
5.1.2 Potential Equalization in the Vehicle and Mounting the Modules . . . . . 32
5.1.3 Guarantee of Features as defined by IP67 . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.2.1 How to Connect and Attach ES400 Modules . . . . . . . . . . . . . . . . . . . . . . . 33
5.2.2 Connecting Several ES400 Modules Mechanically . . . . . . . . . . . . . . . . . . 35
5.2.3 Attaching ES400 Modules to Other Components Using the Integrated As-
sembly Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
5.2.4 Attaching ES400 Modules on DIN Rails with the Integrated Assembly Ele-
ments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.2.5 Attaching ES400 Modules to Other Components with Screws. . . . . . . . 41
5.2.6 Attaching ES400 Modules on DIN Rails using Screws . . . . . . . . . . . . . . . 43
5.2.7 Attaching ES400 Modules to Other Components Using Cable Fasteners .
46
5.3 Drilling Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.4 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4.2 ES420.1 with additional ETAS Modules (MC Application) . . . . . . . . . . . . 48
5.4.3 ES420.1 with additional ETAS Modules (Rapid Prototyping Application) . .
49
5.5 Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.5.1 ES400 Modules with additional ETAS Modules (Measurement and Cali-
bration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5.5.2 ES400 Modules with additional ETAS Modules and Drive Recorder (Mea-
surement and Calibration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
5.5.3 ES400 Modules with ES910.3 (Rapid Prototyping) . . . . . . . . . . . . . . . . . . 52
5.5.4 ES400 Modules with ES910.3 and Drive Recorder (Rapid Prototyping) 53
5.5.5 ES400 Modules with ETAS RTPRO-PC (Rapid Prototyping) . . . . . . . . . . 54
5.6 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.6.1 “Sensor” Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.6.2 Daisy Chain Ports (“IN”, “OUT”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6 Troubleshooting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.1 LED Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.2 Troubleshooting ES420.1 Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.3 Problems and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.3.1 Network Adapter Cannot Be Selected via Network Manager . . . . . . . . . 59
6.3.2 Search for Ethernet Hardware Fails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.3.3 Personal Firewall Blocks Communication. . . . . . . . . . . . . . . . . . . . . . . . . . 62
7 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.1 General Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.1.1 Product labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.1.2 Standards and Norms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.1.3 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.1.4 Maintenance the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.1.5 Cleaning the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.1.6 Mechanical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.1.7 Modules in one chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.2 RoHS conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.2.1 European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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7.2.2 China. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.3 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7.4 Product return and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.5 Declarable Substances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.6 Use of Open Source software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.7 System Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.7.1 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.7.2 Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7.8 Electrical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.8.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.8.2 Host Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.8.3 Sensor Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.9 Pin Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.9.1 “IN” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.9.2 “OUT” Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.9.3 “Sensor” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8 Cables and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.1 Combined Ethernet and Power Supply Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.1.2 CBEP410.1 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.1.3 CBEP4105.1 Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.1.4 CBEP415.1 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.1.5 CBEP4155.1 Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.1.6 CBEP420.1 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1.7 CBEP4205.1 Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1.8 CBEP425.1 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.1.9 CBEP4255.1 Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.1.10 CBEP430.1 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.1.11 CBEP4305.1 Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
8.2 Ethernet Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8.2.1 CBE400.2 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8.2.2 CBE401.1 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
8.2.3 CBE430.1 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.2.4 CBE431.1 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.2.5 CBEX400.1 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.2.6 ES4xx_BRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.3 Cables for the connector "Sensor" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.3.1 CBATx400.x-0m3 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
8.3.2 AS_CBATK401.1-1 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.3.3 AS_CBATK402.1-1 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.4 Protective Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.4.1 Protective Caps supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.4.2 Cap CAP_LEMO_1B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.4.3 Cap CAP_LEMO_1B_LC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.4.4 Cap CAP_SOURIAU_8STA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.5 Angle Brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
8.5.1 Angle Bracket Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
8.5.2 Angle Bracket Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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9 Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.1 ES420.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.2.1 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.2.2 Protective Caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.2.3 Angle brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.2.4 Device Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10 ETAS Contact Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

ETAS About this Manual
ES420.1 - User’s Guide 7
1 About this Manual
This chapter contains information about the following topics:
• “Identification of Safety Notices” on page 7
• “Presentation of Information” on page 8
• “Scope of Supply” on page 8
• “Additional Information” on page 8
1.1 Identification of Safety Notices
The safety notices contained in this manual are identified with the danger sym-
bol shown below:
The safety notices shown below are used for this purpose. They provide notes
to extremely important information. Please read this information carefully.
DANGER
indicates an immediate danger with a high risk of death or serious injury, if
not avoided.
WARNING
indicates a possible danger with moderate risk of death or (serious) injury, if
not avoided.
CAUTION
identifies a hazard with low risk that could result in minor or medium physical
injuries or property damages if not avoided.

ETAS About this Manual
ES420.1 - User’s Guide 8
1.2 Presentation of Information
All activities to be performed by the user are presented in a "Use Case" format.
That is, the goal to be accomplished is briefly defined in the heading, and the
respective steps required for reaching this goal are then presented in a list. The
presentation looks as follows:
Goal definition:
any advance information...
1. Step 1
Any explanation for step 1...
2. Step 2
Any explanation for step 2...
3. Step 3
Any explanation for step 3...
Any concluding comments...
Typographical conventions
The following typographical conventions are used:
Important notes for the user are presented as follows:
1.3 Scope of Supply
Prior to the initial commissioning of the module, please check whether the
module was delivered with all required components and cables (see chapter
9.1 on page 93).
Additional cables and adapters can be obtained separately from ETAS. A list of
available accessories and their order designation is located in chapter “Acces-
sories” on page 93 of this manual or in the ETAS product catalog.
1.4 Additional Information
The configuration instructions for the module under INCA can be found in the
corresponding software documentation.
Bold Labels of the device
Italic Particularly important text passages
TIP
Important note for the user.

ETAS Basic Safety Notices
ES420.1 - User’s Guide 9
2 Basic Safety Notices
This chapter contains information about the following topics:
• “General Safety Information” on page 9
• “Requirements for Users and Duties for Operators” on page 9
• “Intended Use” on page 9
2.1 General Safety Information
Please observe the Product Safety Notices ("ETAS Safety Notice") and the fol-
lowing 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 precau-
tions.
2.2 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. Incorrect operation or
operation by users without sufficient qualification may lead to injuries or death
or property damages.
The safety of systems that are using the product is the responsibility of the
system integrator.
General safety at work
The existing regulations for safety at work and accident prevention must be
followed. All applicable regulations and statutes regarding operation must be
strictly followed when using this product.
2.3 Intended Use
Application area of the product
This product was developed and approved for applications in the automotive
area. The module is suitable for use in interiors, in the passenger cell, in the
trunk, in the engine compartment or in the exterior area of vehicles.
For use in other application areas, please contact your ETAS contact partner.
TIP
Carefully read the documentation (Product Safety Advice and this User's
Guide) that belongs to the product prior to the startup.

ETAS Basic Safety Notices
ES420.1 - User’s Guide 10
Requirements for the technical state of the product
The product is designed in accordance with state-of-the-art technology and
recognized safety rules. The product may be operated only in a technically flaw-
less 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.
Requirements for operation
• Use the product only according to the specifications in the correspond-
ing User's Guide. With any deviating operation, the product safety is no
longer ensured.
• Observe the requirements on the ambient conditions.
• Do not use the product in potentially explosive atmospheres.
Electrical safety and power supply
• Observe the regulations applicable at the operating location concerning
electrical safety as well as the laws and regulations concerning work
safety!
• Connect only current circuits with safety extra-low voltage in accordance
with EN 61140 (degree of protection III) to the connections of the mod-
ule.
• Ensure the compliance with the connection and adjustment values (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.
Power supply
• The power supply for the product must be safely disconnected from the
supply voltage. For example, use a car battery or a suitable lab power
supply.
• Use exclusively lab power supplies with double protection to the supply
system (with double insulation / with reinforced insulation (DI/ RI)).
• The lab power supply must be approved for an operating altitude of
5,000 m and for an ambient temperature of up to 120 °C.
• For normal operation of the modules as well as for very long standby
operation, it is possible that the vehicle battery will be drained.
Connection to the power supply
• The power cable may not be connected directly to the vehicle battery or
the lab power supply, but only via a suitable fuse.
• Ensure that the connections of the lab power supply, the power supply at
the module and the vehicle battery are easily accessible!

ETAS Basic Safety Notices
ES420.1 - User’s Guide 11
• Route the power cable in such a way that it is protected against abrasion,
damages, deformation and kinking. Do not place any objects on the
power cable!
De-energizing the module
The module does not have an operating voltage switch. The module can be de-
energized as follows:
• Disconnecting the cables from the measurement inputs
and
• Disconnecting the module from the power supply
– Switching off the lab power supply
or
– Disconnecting the module from the lab power supply
Separating device is the lab plug of the power cable or the plug of the
power cable at the connection of the module
or
– Disconnecting the module from the vehicle battery
Separating device is the lab plug of the power cable or the plug of the
power cable at the connection of the module
or
– Disconnecting the vehicle battery.
Cabling
Approved cables:
• Use exclusively ETAS cables at the connections of the module!
• Adhere to the maximum permissible cable lengths!
• Do not use any damaged cables! Cables may be repaired only by ETAS!
DANGER
Dangerous electrical voltage!
Connect the power cable only with a suitable vehicle battery or with a suitable
lab power supply! The connection to power outlets is not allowed!
To prevent an inadvertent insertion in power outlets, ETAS recommends to
equip the power cables with safety banana plugs in areas with power outlets.
CAUTION
Never apply force to insert a plug into a socket.
Ensure that there is no contamination in and on the connection, that the plug
fits the socket, and that you correctly aligned the plugs with the connection.
CAUTION
Damage possible to connectors of the modules or the ES4xx_BRIDGE!
Fasten the two modules with screws to the stop inside the module without
canting them.

ETAS Basic Safety Notices
ES420.1 - User’s Guide 12
For detailed information about cabling, see the User's Guide of the module.
Requirements for the place of installation
• Place the module or the module block on a smooth, even and firm foun-
dation.
• The module or module block must always be securely fastened.
Requirements on the ventilation
• Keep the module away from heat sources and protect it against direct
exposure to the sun.
• The free space above and behind the module must be selected so that
sufficient air circulation is ensured.
Fixing the module on a carrier system
When selecting the carrier system, observe the static and dynamic forces that
could be created by the module or the module block at the carrier system.
CAUTION
Potential equalization in the vehicle is possible via the shield of the
connecting cables of the modules!
Install the modules only at locations with the same electrical potential or iso-
late the modules from the installation location.
CAUTION
Damage or destruction of the module is possible.
The modules of series ES400 are approved only for installation and operation
at components or locations that ensure compliance with the technical data of
the modules, such as:
• the resistance to vibration of the modules (for example, install modules
only on spring-loaded bodies, not on wheel suspensions or directly at the
motor) and
• the temperature resistance of the modules (for example, do not install
modules on the motor, turbocharger, exhaust manifold or their environ-
ments).
CAUTION
During the installation of the modules, observe the permissible temperature
range of the cable ties being used!

ETAS Basic Safety Notices
ES420.1 - User’s Guide 13
Damage of the module and loss of properties acc. to IP67
Transport
• Mount and connect the modules only at the location of their startup!
• Do not transport the modules at the cable of the module or any other
cables.
Maintenance
The product is maintenance-free.
Repair
If a repair of an ETAS hardware product should become necessary, send the
product to ETAS.
Cleaning the module housing
• Use a dry or lightly moistened, soft, lint-free cloth for cleaning the module
housing.
• Do not user any sprays, solvents or abrasive cleaners which could dam-
age the housing.
• Ensure that no moisture enters the housing. Never spray cleaning agents
directly onto the module.
CAUTION
Loss of Features as defined by IP67!
Water standing at the pressure balance element damages the membrane!
Please observe which way the module is pointing when installing vertically!

ETAS ES400 Product Family
ES420.1 - User’s Guide 14
3 ES400 Product Family
This chapter contains information on the following topics:
• “Wiring Concepts in Test Vehicles” on page 14
• “Features of the ES400 Line” on page 15
• “Housing” on page 16
• “Ports” on page 17
• “LED” on page 18
3.1 Wiring Concepts in Test Vehicles
For the test phase, several hundred sensors must be installed in a test vehicle
in various areas, e.g. in the engine compartment and in the floor area. The sen-
sors, which are positioned all over the vehicle, then have to be connected to the
measuring instruments of the test setup.
Today’s standard solutions with their central setup of measuring instruments
inside the vehicle require complex cabling to connect the widely distributed
sensors with the measuring instruments. Numerous, usually long connection
cables between the sensors and the measuring instruments, bundled together
to form several fat wiring harnesses, require a highly modified splash wall of
the test vehicle. This involves long setting-up times as well as high costs.
Fig. 3-1Central and Decentral Sensor Cabling
With the ES400 modules, ETAS provides a decentral solution which consider-
ably simplifies the test setup of the sensors.
The basic idea of this concept is to install the modules of the ES400 family as
close as possible to the sensors, to concatenate the modules with each other
and to connect just the first module of this chain with the laptop in the vehicle.
Sensor 1
Sensor 2
Sensor 3
Sensor n
Sensor 1
Sensor 2
Sensor 3
Sensor n
Sensor 1
Sensor 2
Sensor 3
Sensor n
Sensor 1
Sensor 2
Sensor 3
Sensor n
Sensor 1
Sensor 2
Sensor 3
Sensor n

ETAS ES400 Product Family
ES420.1 - User’s Guide 15
3.2 Features of the ES400 Line
3.2.1 Advantages of the Decentral Wiring Concept
• The compact ES400 modules can be mounted close to the sensors with
short connection cables.
• The simple assembly and wiring principle (daisy chain topology) of the
modules
– requires only one common cable between the modules for power
supply and data transfer
– considerably reduces the setting-up times for tests
– simplifies the maintenance and the extension of the test setup
• The only item in the vehicle is the laptop which is connected to the mod-
ules with just one cable.
• Test vehicles equipped with an ES400 measurement system can be
used flexibly because the vehicles do not have to be modified for
changed or new test tasks.
3.2.2 Further Features
This list provides an overview of the other features of the ES400 line in addition
to decentral cabling:
• The ES400 modules have a very compact design.
• Each module has an LED for localizing the module.
• The Thermo Modules of the ES400 family use a XCP-based protocol
which is compatible to the existing ETAS Ethernet topology.
The concept fulfills the following requirements:
– high bandwidth to be able to realize lots of channels with high resolu-
tions (typical in measuring and calibration applications) with fast
sampling rates
– simple application based on the Ethernet integration in INCA, no com-
plicated setting of bus parameters,
– simple to integrate in measurement and calibration tools manufac-
tured by third-party suppliers due to the use of XCP as application
protocol
– support of all probes and pressure sensors used in the automotive
industry
• Innovative, battery-saving power supply management
– automatic power-saving feature (“Standby”)
– “Wake Up” via the Ethernet interface
• Part of the ETAS Tool Suite
• Daisy Chain Configuration Tool (stand-alone operation)

ETAS ES400 Product Family
ES420.1 - User’s Guide 16
• Modules suitable for use in automotive applications; suitable for use in
the development environment and in the vehicle on test drives:
– Housing, connectors and cables waterproof and dustproof in acc.
with IP65 or IP67; designed for use in the engine compartment or the
outside area of the vehicle
– rugged to acceleration or mechanical damage
– rugged to extreme environmental conditions (temperature, damp-
ness, EMC)
– very low temperature coefficients contribute to the reduction in the
number of measurement errors
For the complete technical data of the ES420.1, refer to the chapter “Technical
Data” on page 65.
3.3 Housing
A sturdy metal housing is used for the ES420.1; it has ports on the front of the
device so it can fit into tight spaces. The ES420.1 is specifically designed to be
installed in engine compartment, but also in the passenger cell.
The housings of the ES400 family can quickly and easily be connected to one
another to create a measurement system (see section 5.2 on page 33). The
modules can easily be screwed directly to a carrier system or attached to it
using cable fasteners both in the vehicle and in the lab.
These simple and uncomplicated ways of attaching the modules make them
flexible in terms of assembly. These methods of attachment can also be used
in harsh environmental conditions (salt fog, dirt).
CAUTION
Loss of Features as defined by IP67!
Do not open or change the module housing!
Works on the module housing may be executed only by qualified technical
personnel.

ETAS ES400 Product Family
ES420.1 - User’s Guide 17
3.4 Ports
All ports of the ES400 measuring modules are on the front of the device (see
Fig. 3-2 on page 17).
The LEMO and Souriau connectors used adhere to protection class IP67. All
ports are reverse-polarity protected due to the exclusive use of coded LEMO or
Souriau connectors.
Fig. 3-2Front
3.4.1 “Sensor” Port
The front of the ES420.1 features a 22-pin Souriau port to which four sensors
can be connected using a adapter cable. An individual sensor power supply
port is available for each sensor.
The use of a “cable tail” or “whip” solution with just one connector makes it
possible to change the modules quickly within complex test setups.
3.4.2 Daisy Chain Ports (“IN”, “OUT”)
The modules are connected using a daisy chain topology. This means each
module has an explicit input socket and an explicit output socket. The Ethernet
data line and the supply voltage are routed through the daisy chain ports of the
module:
• “IN” (input)
• “OUT” (output)
The PC, the modules ES523, ES59x, ES600.2, ES891, ES910.3 or the Drive
Recorder ES720 are connected at the “IN” port (input). The “OUT” port (output)
is connected to the following module of the ES400 line or remains free on the
last module of the chain.
IN
OUT
Sensor

ETAS ES400 Product Family
ES420.1 - User’s Guide 18
3.5 LED
Every module has an LED. It indicates the following states of the module:
3.5.1 Operational State
3.5.2 Service State
3.5.3 Functional State
Display State
off No power supply to the mod-
ule
yellow flashing
0,25 s on / 0,25 s reduced
Initialization of the module
not yet complete -
Further modules in a chain
not initialized yet
green illuminated
semi bright
Normal
yellow illuminated
semi bright
At least one sensor supply
voltage is activated.
green flashing
0,1 s on / 1,9 s off
Standby
No Ethernet connection
established
Display State
red flashing
0,25 s on / 0,25 s reduced
Module identification
red flashing
0,1 s on / 0,6 s off
Update of the firmware /
HDC
Display State
yellow-red flashing
0,5 s yellow reduced /
0,5 s red reduced
Warning
Overload on a sensor supply
voltage channel
red illuminated
fully bright
Error during self-test
red illuminated
semi bright
Internal error

ETAS Hardware Description
ES420.1 - User’s Guide 19
4 Hardware Description
This chapter contains information on the following topics:
• “Features of the ES420.1” on page 19
• “Block Diagram” on page 20
• “Sensor Channels” on page 20
• “Measurement Accuracy” on page 21
• “Data Transfer” on page 23
• “Power Supply” on page 28
• “Configuration” on page 31
• “Tool Integration” on page 31
• “Firmware Update” on page 31
• “Calibration” on page 31
4.1 Features of the ES420.1
Fig. 4-1ES420.1 Housing
The ES420.1 Thermo Module is a member of the family of ES400 Modules. The
ES420.1 can acquire temperatures at eight input channels.
Overview of the major features of the ES420.1:
• 8 galvanically isolated measurement channels for thermocouples
• Measuring range from -210 °C to +1,820 °C (depending on type of ther-
mocouple)
• Measurement channels galvanically isolated from each other and from
the supply voltage
• Settable acquisition rate per channel
• Parameterized software filters for signal smoothing with adaptive cutoff
frequency
• High resolution
For the complete technical data of the ES420.1, refer to the chapter “Technical
Data” on page 65.

ETAS Hardware Description
ES420.1 - User’s Guide 20
4.2 Block Diagram
Fig. 4-2Block Diagram
The ES420.1 is a module with eight identical sensor channels with common
Cold Junction Compensation, two shared Ethernet interfaces and a power sup-
ply.
4.3 Sensor Channels
All sensor channels of the ES420.1 are identical. The thermocouple cold junc-
tion channels have a resolution of 24 bits. You can use thermocouple cold junc-
tions of types B, E, J, K, N, R, S and T. The maximum measurement range,
distributed over all thermocouple cold junction types, is -210 °C to +1820 °C.
To operate different thermocouple cold junctions on the ES420.1, you can
order special splitter cables from ETAS for the relevant thermocouple cold
junction types (see the section 9.2.1 on page 93).
The special splitter cables for the individual thermocouple cold junction types
are made of the same material combination as the thermocouple cold junc-
tions. To ensure a high level of accuracy over the entire temperature range,
thermo lines of the relevant type are used with the splitter cables (e.g. NiCr and
Ni with the splitter cable CBATK).
The material transition from the thermo line to the gold-plated contacts of the
master plug is the cold point. The cold point is measured together for all chan-
nels with a PT100 embedded in a solid copper core. The copper core ensures a
very even distribution of the cold point temperature of all channels. The cold
point is protected against fast or erratic temperature changes of the environ-
ment with a thermally highly isolating design. The design of the master plug
guarantees that the measure result is only influenced by a few tenths of a Kel-
vin even with fast temperature changes or uneven temperature distribution
(e.g. if installed near the exhaust system or air vents).
The thermocouple channels are galvanically isolated from one another, from
the supply voltage and from the device ground. This makes it possible to use
non-isolated thermocouple cold junctions in non-potential-free systems with-
out any negative effect on the accuracy.
FPGA
Open TC
Det ection
Channel 8
Channel ...
Channel 1
ES4 2 0
Et her net
Ph y
Et her net
Tra f f i c
Det ect i on
100
MBit/s
Et her net
Co nnector
(Ho st
direction )
Synchronous Sampling
.
.
.
Measurement Con troller
24-Bit A/D
Conver ter
24- Bit A/D
Conver ter
Splitter
Ca b l e
Co nnector
Splitter cable
CBATx4xx
TEDS
Open TC
Det ect i on
Diagn ost i c
Unit
TEDS
In terf ace
Ti m e
Synchr onization
Unit
Et h er n et
Ph y
100
MBit/s
Et h er n et
Connector
On
Automatic
On-board
t emp eratu re
Protocol Engine
Fr a m e
Ge n er at o r
Cold Junction

Volt age
Regulat or
5...50V