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 “