ETAS ES4441.1 User manual

ES4441.1 Compact Error Simulation Module with
Breakout Frontpanel
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 2019 ETAS GmbH, Stuttgart
The names and designations used in this document are trademarks or brands
belonging to the respective owners.
R1.2.4 EN - 10.2019

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide 3
Contents
ETAS Contents
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Basic Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.1 Labeling of Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.2 General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.3 Connecting/Removing Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1.4 Opening the Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1.5 Requirements for Users and duties for Operators. . . . . . . . . . . . . . . 8
1.1.6 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Identifications on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 CE Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4 RoHS Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.1 European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.2 China . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Taking the Product Back and Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5.1 Using This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Functions and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.1 Error Simulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.2 Connectors, Displays and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2.3 Application Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4 Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5 General Instructions on Operating the ES4441.1 . . . . . . . . . . . . . . . . . . . . . 23
2.6 Table of possible Errors the ES4441.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide4
Contents ETAS
3 Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4 Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.1 Error Simulation for 255 channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.2 Error Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2.1 Error Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.2.2 Pin-to-Pin Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2.3 Relay or MOSFET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2.4 Duration of the Error State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2.5 Simulating Loose Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2.6 Number of Possible Active Error States. . . . . . . . . . . . . . . . . . . . . . 46
4.2.7 Measuring the Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.3 Time Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.4 General Resistor Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.5 Ground Shift Resistor Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.6 Status Displays via LEDs on the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.7 Master/Slave Operation of Several ES4441.1 Systems . . . . . . . . . . . . . . . . . 50
4.8 External Triggering of the ES4441.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.9 IP Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.10 Safety Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.10.1 Resetting on Excess Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.10.2 Protecting the Rails and the Ground Channel Resistor Cascade . . . 50
4.11 Power cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5 Mechanical Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.2 Connectors LOAD (1) and ECU (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.3 Connectors LOAD (2) and ECU (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.4 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.4.1 Signal Channel Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.4.2 Layout of the Lab Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.5 Safety Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5.1 Overview Fuses:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.5.2 Changing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.6 Signal Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.1 Channels 262 to 274. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.2 Channel 326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.3 Channel 328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.4 Channel 330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.5 Channel 332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.6 Channel 338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.6.7 Channel 339 (+UBatt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.6.8 Channel 340 (-UBatt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6 Pin Assignment Back Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.1 ”RAIL 1 & RAIL 2” Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.2 ”+UBATT 1 & -UBATT 1” Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.3 ”+UBATT 2& -UBATT 2” Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.4 ”IMESS 1 & IMESS 2” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.5 ”LC-BRIDGE” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide 5
ETAS Contents
6.6 ”TRIGGER” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.7 ”Ethernet” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7 Pin Assignment Front Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.1 Connector Pin Allocations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.1 General Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.1.1 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.1.2 Fuse power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
8.2 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9 ETAS Contact Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide6
Contents ETAS

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide 7
ETAS General Information
1 General Information
This chapter contains information on the following topics:
• "Basic Safety Instructions" on page 7
• "Identifications on the Product" on page 11
• "CE Marking" on page 11
• "RoHS Conformity" on page 11
• "Taking the Product Back and Recycling" on page 12
1.1 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.
1.1.1 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.
1.1.2 General Safety Information
Please read the product safety advice ("ES4441 Safety Advice") as well as the
following safety instructions to avoid injury to yourself and others as well as
damage to the device.
ETAS GmbH cannot be made liable for damage which is caused by incorrect use
and handling and not adhering to the safety instructions.
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.
Note
Please read the documentation accompanying the product ("ES4441 Safety
Advice" and this User’s Guide) carefully before using the product.

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide8
General Information ETAS
1.1.3 Connecting/Removing Devices
Please take the following precautionary measures to avoid any injuries and
damage to hardware:
• Do not apply any voltages to the ports of the ES4441.1 which do not
correspond to the specifications of the relevant port. Refer to the corres-
ponding boards’ manuals for the exact specification of the I/O hardware.
• Do not connect or disconnect any devices while the ES4441.1 or external
devices are powered on.
First, power off the ES4441.1 using the on/off switch on the back of the
device, and detach all power plugs.
• When inserting any connectors, please make sure they are absolutely stra-
ight and that none of the pins are bent.
1.1.4 Opening the Housing
The ES4441.1 must only be opened by qualified technical personnel!
1.1.5 Requirements for Users and duties for Operators
Make sure you only assemble, operate and maintain the product if you have the
relevant qualification for and experience with this product. Incorrect usage or
operation by users without an appropriate qualification can lead to serious or
even fatal injuries as well as damage to property.
General Occupational Health and Safety
The existing regulations on occupational health and safety as well as accident
prevention must be adhered to.
DANGER!
As long as the ES4441.1 is not completely disconnected, there is a
danger of electrocution!
Disconnect the device from the mains by removing the mains cable –
then wait a few minutes until all components (e.g. power pack, capa-
citors) are discharged.
Note
Responsibility for the safety of the system into which the ES4441.1 was integ-
rated lies with the person who assembled the system!

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide 9
ETAS General Information
1.1.6 Intended Use
The ES4441.1 Compact Error Simulation Module is a 19” housing with a height
of 9 HU which can be assembled in a rack using the corresponding mounts.
The ES4441.1 is intended to be used as follows:
• In industrial lab facilities or at industrial workplaces,
• As a hardware interface for ECUs in a Hardware-in-the-Loop test system,
• In conjunction with ETAS software supported by the ES4441.1,
• As an interface together with software programs that serve the standardi-
zed, documented and open APIs of ETAS software products.
The ES4441.1 is not intended to be used:
• In a vehicle on the road,
• As part of a life support system,
• As part of a medical application,
• In applications in which misuse can lead to injury or damage,
• In environments with conditions outside the specified ranges (see "Envi-
ronmental Conditions" on page 78).
Requirements for Operation
The following requirements are made to ensure safe operation:
• Only use the product in accordance with the specifications in the relevant
User’s Guide. Product safety is not guaranteed if the device is used other
than intended.
• Observe all applicable regulations on site concerning electrical safety as
well as the rules and regulations on occupational health and safety!
• Never use the product in a wet or damp environment.
• Never use the product in areas subject to explosions.
• Make sure you keep the surface of the product clean and dry.
Transport
WARNING!
The ES4441.1 must always be integrated in the ETAS LABCAR system
and must not be used as a "standalone" unit.
WARNING!
The ES4441 weighs at least 25.9kg. Always ensure there are two
people to lift and carry the transport box or the housing itself.

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide10
General Information ETAS
Ventilation
If the ES4441.1 is being operated in the ETAS LABCAR system casing (see "Inten-
ded Use" on page 9) make sure you observe the following points:
• The casing and particularly the air vents must be at least 15 cm away from
walls and objects in the environment.
• Leave the casing open at the back.
When the ES4441.1 is being operated in a 19" rack, make sure you observe the
following points:
• The air vents must be at least 15 cm away from walls and objects in the
environment. Make sure there is a gap of at least 1 U to the next compo-
nent, both above and below.
• The ambient temperature in the rack must not exceed the permissible
maximum value (see "Environmental Conditions" on page 78) of 40 °C /
104° F.
Rack System
The ES4441.1 is intended exclusively for operation inside a suitable rack system.
The rack system must have the following properties to ensure protection against
the spread of fire and to prevent contact with a possibly hot-to-the-touch
ES4441.1housing:
• Rack with closed bottom board or bottom with “UL perforation”*. Alter-
natively, the bottom may be covered with drip protection boards. The area
to be covered is defined in EN 61010-1:2010 + Cor.:2011, §9.3 (see in
particular §9.3.2/Image 12 „drip protection“). The drip protection boards
must be installed with overlaps to create a completely covered bottom of
the rack. The bottom board or the drip protection boards must be metal
or another fire-retardant material according to IEC 60695-11-10 V1 (or
better). The bottom board or drip protection boards must be sufficiently
sturdy.
• Closed sides and rear, i.e. fully closed rear door and fully closed panels on
both sides of the rack.
• Sufficient active ventilation. Adequate ventilation must be assured and
verified. If necessary, a suitable temperature sensor in connection with an
power-off switch must be installed to interrupt the power supply in case
of overheating. This power-off mechanism must be fail-safe.
All above properties must be fulfilled and guaranteed. Further it must be ensured
that there are no combustible materials/parts in the vicinity of bottom, lid, side
panels, or pack panel.
*UL Perforation: This refers to perforation according to the guidelines in table 16
„Permissible hole size in the bottom of a housing” of IEC EN 61010-1:2010 +
Cor.:2011, §9.3 “Containment of fire within the equipment, should it occur “

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide 11
ETAS General Information
Demands for the Technical State of the Product
This state-of-the-art product adheres to all recognized safety-related regulations.
The product must only be used if it is in full working order, with the relevant
personal only using the device as it was intended, taking all security issues and
risks into account as well as taking into consideration the relevant documenta-
tion at all times. If the product is not used correctly, the protection of the product
may be impaired.
Maintenance and Cleaning
Before cleaning any parts of the housing, disconnect the power cable. To clean
the outside of the device, use a clean, dry cloth. Do not use any cleaning agents
or solvents. Clean the filter of the rear ventilation opening once a year.
1.2 Identifications on the Product
The following symbols are used for identifying the product:
Observe the information in chapter "Technical Data" on page 75.
1.3 CE Marking
ETAS confirms that the product meets the product-specific applicable European
Directives with the CE marking affixed to the product or its packaging. The CE
Declaration of Conformity for the product is available upon request.
1.4 RoHS Conformity
1.4.1 European Union
The EU Directive 2011/65/EU limits the use of certain dangerous materials for
electrical and electronic devices (RoHS conformity).
Symbol Description
Before using the product, carefully read the user’s guide!
Identification for CE (see "CE Marking" on page 11)
Identification for China RoHS (see "RoHS Conformity"
on page 11)
Identification for WEEE directive
(see "Taking the Product Back and Recycling" on page 12)

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide12
General Information ETAS
ETAS confirms that the product corresponds to this directive which is applicable
in the European Union.
1.4.2 China
ETAS confirms that the product meets the product-specific applicable guidelines
of the China RoHS (Management Methods for Controlling Pollution Caused by
Electronic Information Products Regulation) applicable in China with the China
RoHS marking affixed to the product or its packaging.
The concluding chapter "ETAS Contacts" gives you information about the inter-
national ETAS sales and service branch offices.
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 set up throughout the
EU for the collection, treatment 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.
Abb. 1-1 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 79).
1.5.1 Using This Manual
Representation of Information
All activities to be carried out by the user are shown in what we call a "Use-
Case" format, i.e. the target to be achieved is defined briefly in the title and the
individual steps necessary to achieve this target are then listed. The information
is displayed as follows:
Target definition
Any introductory information...
1. Step 1
Possibly an explanation of step 1...
2. Step 2
Possibly an explanation of step 2...

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide 13
ETAS General Information
Any concluding remarks...
Concrete example:
To create a new file
If you want to create a new file, no other file may be open.
1. Select File → New.
The "Create file" dialog box appears.
2. Enter a name for the file in the "File name" field.
The file name must not exceed 8 characters.
3. Click OK.
The new file is created and saved under the name specified. You can now work
with the file.
Typographic Conventions
The following typographic conventions are used:
Important notes for the user are shown as follows:
Select File →Open. Menu commands are shown in boldface/
blue.
Click OK. Buttons are shown in boldface/blue.
Press <ENTER>. Keyboard commands are shown in angled
brackets in block capitals.
The "Open File" dialog box appe-
ars.
Names of program windows, dialog boxes,
fields etc. are shown in quotation marks.
Select the file setup.exe. Text in drop-down lists, program code, as
well as path and file names are shown in
the Courier font.
A conversion between the file types
logical and arithmetic is not pos-
sible.
Content markings and newly introduced
terms are shown in italics
Note
Important note for the user.

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide14
General Information ETAS

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide 15
ETAS Introduction
2 Introduction
This User’s Guide contains a description of the ES4441.1 Compact Error Simula-
tion Module with Breakout Frontpanel.
It consists of the following chapters:
• Introduction
• "Hardware Features" on page 43
This chapter contains a detailed description of the features of the
ES4441.1 Compact Error Simulation Module.
• "Mechanical Construction" on page 53
This chapter contains a detailed description of the mechanical construc-
tion of the ES4441.1 Compact Error Simulation Module.
• "Pin Assignment Back Side" on page 63
This chapter contains a description and assignment of all connectors on
the rear of the housing.
• "Pin Assignment Front Side" on page 65
This chapter contains a description and assignment of all connectors on
the front panel of the housing.
• "Technical Data" on page 75
This contains details of the technical data of the ES4441.1 Compact Error
Simulation Module.
• "Accessories" on page 78.

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide16
Introduction ETAS
2.1 Applications
The ES4441.1 Compact Error Simulation Module with Breakout Frontpanel is
used for real-time error simulation for ECUs. It is intended for use in a HiL system,
e.g. for
• tests on engine test beds
• tests on roller dynamometers
• error simulation in a stationary vehicle.
The ES4441.1 Compact Error Simulation Module is a 19” housing with a height
of 9 HU which can be assembled in a rack using the corresponding mounts.
The Breakout Frontpanel of the ES4441.1 Compact Error Simulation Module is
used to divide the signals between the control unit and the ETAS LABCAR all-
owing the user to simulate a cable break simply by pulling a jumper. The center
tabs of the jumpers make it possible to access the individual control unit signals
externally.
All connectors of the Breakout Frontpanel are printed versions. Standard connec-
tors have been selected to ensure compatibility with other products within the
ES46xx series and the coupling 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 ES4441.1 Compact Error Simulation Module is addressed via the Ethernet
interface. The PINCONTROL software provided, offers simple and user-friendly
interfaces for operating and configuring the ES4441.1 via Ethernet.
The individual functions are described in detail in the following section.
WARNING!
The ES4441.1 Compact Error Simulation Module is not
intended for operation in a traveling vehicle!
WARNING!
The ES4441.1 Compact Error Simulation Module must not
be operated over 2000m!
WARNING!
Danger of overheating and fire caused by exceeding the specified val-
ues.
Due to overheating, the short circuit bar’s plastic parts can melt and
may drop.
Make sure that the product is only operated in the specified range.
In case that plastic drops due to unplanned faulty operation, ensure
that the dropping material is collected by special assembly measures
for the LABCAR system.

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide 17
ETAS Introduction
2.2 Functions and Features
This section provides a short overview of the functions and features of the
ES4441.1 Compact Error Simulation Module. A detailed description can be
found in the chapter "Hardware Features" on page 43.
2.2.1 Error Simulation
The ES4441.1 Compact Error Simulation Module makes it possible to simulate
errors in real time for 255 ECU channels (per ES4441.1).
Error Channels
The 255 failure simulation channels are for voltages up to 30 V and currents up
to 40 A.
• 40 A, 30V for 1 channel
• 20 A, 30V for 4 channel
• 15 A, 30V for 2 channel
• 7,5 A, 30V for 31 channel
• 3 A, 30V for 15 channel
• 1 A, 30V for 202 channel
Error Types
The following errors can be simulated for these 255 channels:
• "Open load"
• "Short cut" to +UBATT1, -UBATT1, +UBATT2, -UBATT2 for several signals
• "Pin to pin" with or without resistor
• "Resistor in line"
• Pull up/down resistor to +UBATT1, -UBATT1, +UBATT2, -UBATT2 for seve-
ral signals ("Leakage Current")
• "Loose Contacts"
• "Ground shift"
• "Loose Ground contact" (channel 340)
• "Loose Power contact" (channel 339)
Load can be disconnected while performing an error via relay or jumper.
Error Paths
There is a special low current path available for simulating errors with very low
current (50mA or less). In this path special low current MOSFETs are used in order
to reduce channel resistance and parasitic capacity. The path has to be chosen
before activating the error simulation by sending the ChooseCurrentPath com-
mand. If you do not send this command the high current path will be used for
error simulation.
Time Response
Errors can be switched via relay or MOSFET. The difference between switching an
error via a relay or via MOSFET is particularly seen in the time response. Whereas
MOSFETs have negligible switch times (approx. 50 μs), relays have high switch

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide18
Introduction ETAS
times (the time it takes from activating the error in the software to acknowled-
ging the error, approx. 5 ms). The disadvantage when using MOSFETs is to do
with the leakage currents which occur; these do not occur with relays.
If conventional relays are used for an error type, the delay between setting the
error and closing the corresponding relay is measured on a reference relay and
then sent to the application. This enables the precise measuring of the time the
error actually occurs and also, for example, the duration of the error state.
Resistor Cascade
To simulate, for example, contact corrosion in a line and crosstalk between lines,
there is a resistor cascade with which the corresponding resistances (line resis-
tance and finite resistance between lines) can be simulated.
This is a 18-bit cascade with resistors from 0,5 Ωto 65536 Ω, with which resis-
tances from 0,5 Ωto approx. 128 kΩcan be displayed in 0,5 Ωintervals. For
more information on the resistor cascade, refer to the section "General Resistor
Cascade" on page 48.
Ground Shift Cascade
A high current resistor cascade is used to simulate a ground shift on the ground
channel (340). The Cascade is realised with resistors linked in parallel. The follo-
wing resistor values are available: 0.50, 0.57, 0.66, 0.80, 1.00, 1.33, 2.00 and
4.00Ω.
A melting fuse in the ground channel is protecting only the wire and not the
resistors. The protection of the resistors is done by measuring the current and
controlling the relays and MOSFETs.
2.2.2 Connectors, Displays and Fuses
Connectors on the Front Panel and Rear
The ES4441.1 Compact Error Simulation Module has several connectors on the
front and rear for connecting the ECU and loads, addressing the ES4441.1 and
for master/slave operation.
The following connectors are on the front panel:
• DLM5-260 connector for Load (LOAD 1)
• KPTC22-55 connector for Load (LOAD 2)
• DLM5-260 connector for ECU (ECU 1)
• KPTC22-55 connector for ECU (ECU 2)
• Jumper for measurement and cutting for 268 channel
• Labels for Jumpers (easy customizable)
•Fuses
CAUTION!
All external I/O-lines must be less than 3m.

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide 19
ETAS Introduction
Abb. 2-1 shows the front of the housing (with mounts for rack assembly).
Abb. 2-1 Front View of the ES4441.1 Compact Error Simulation Module
The following connectors are on the rear:
• Connector for Rail1 and Rail2, to cascade two or more ES4441 (two green
screw pads)
• Connector for +UBATT1, –UBATT1, +UBATT2 and –UBATT2 (two red and
two black screw pads)
• Connector for current measurement (two yellow screw pads)
• Connector for optional LC-Bridge (DSUB)
• Connector for external Synchronisation and Trigger (DSUB)
• Ethernet interface (RJ45)
• Powerline connector

ES4441.1 Compact Error Simulation Module with Breakout Frontpanel - User´s guide20
Introduction ETAS
Abb. 2-2 shows the back of the housing.
Abb. 2-2 Back View of the ES4441.1 Compact Error Simulation Module
Status Displays via LEDs on the Front Panel
There are several LEDs on the front panel of the ES4441.1 Compact Error Simu-
lation Module which provide information on operating states of the ES4441.1
and the communication interfaces. For more details on the LEDs, refer to the
section "Status Displays via LEDs on the Front Panel" on page 49.
2.2.3 Application Environment
Master/Slave Operation of Several ES4441.1 Systems
If greater demands are made of the number of channels than can be catered for
with one ES4441.1 Compact Error Simulation Module, you can use several
ES4441.1s. A dedicated master synchronizes error simulation on the connected
slave systems.
This takes place by connecting the error rails and the synchronization lines of the
ES4441.1s involved and assigning corresponding IP addresses in the operating
software PINCONTROL.
Note
This feature is not implemented in version ES4441.1!
Note
It is not possible to cascade an ES4440.1 Module together with
ES4441.1 Compact Error Simulation Modules in one System.