ETAS ES4455.2 User manual

ES4455.2 Load Carrier Board
ES4450.3 Load Carrier Board for 4 RB CRS Injectors
ES4451.4 Load Carrier Board for 4 RB GDI Injectors
ES4452.1 Load Carrier Board for 4 RB GDI Injectors, CVO
ES4453.1 Load Carrier Board for 4 RB HDEV6 GDI Injectors, CVO
ES4457.1 Load Carrier Board for 4 RB CRS Injectors, VCC and VCA
ES4458.1 Load Carrier Board for 4 RB PFI Injectors, CVO
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.
V1.0.0 R05 EN - 09.2019

ES4455.2 Load Carrier Board - User’s Guide 3
Contents
ETAS Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 Properties of the ES4455.2 Load Carrier Board and its Variants
ES4450.3, ES4451.4, ES4452.1, ES4453.1, ES4457.1 and ES4458.1
Mounted with Load Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.2 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Basic Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.1 Identification of Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.2 General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.3 Requirements for Users and Duties for Operators. . . . . . . . . . . . . . . 9
1.2.4 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Identifications on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.1 CE Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.2 KC Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.3 RoHS Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.4 Identification in Accordance with ISO 7010:2011 . . . . . . . . . . . . . 16
1.4 Product Return and Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Materials Subject to Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.6.1 Working with this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Properties and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Design of an Injector Simulation Environment . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Figures of ES4455.2 and its Mounted Variants ES4450.3, ES4451.4, ES4452.1,
ES4453.1, ES4457.1 and ES4458.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2.1 ES4455.2 Load Carrier Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2.2 ES4450.3 Load Carrier Board for 4 RB CRS Injectors . . . . . . . . . . . 25
2.2.3 ES4451.4 Load Carrier Board for 4 RB GDI Injectors. . . . . . . . . . . . 25
2.2.4 ES4452.1 Load Carrier Board for 4 RB GDI Injectors, CVO . . . . . . . 26

ES4455.2 Load Carrier Board - User’s Guide4
Contents ETAS
2.2.5 ES4453.1 Load Carrier Board for 4 RB HDEV6 GDI Injectors, CVO . 26
2.2.6 ES4457.1 Load Carrier Board for 4 RB CRS Injectors, VCC and VCA 26
2.2.7 ES4458.1 Load Carrier Board for 4 RB PFI Injectors, CVO . . . . . . . . 27
2.3 Procedure for Installation and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.1 Installation in the ES4408.1 Load Chassis. . . . . . . . . . . . . . . . . . . . 29
2.3.2 Installation in the ES5372.1 Carrier for ES4455 Load Boards . . . . . 29
2.3.3 Installation in the ES5300.1-A Housing and the ES5300.1-B Housing
via ES5372.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.4 Connecting Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.4.1 Fuses on the ES4455.2 Load Carrier Board. . . . . . . . . . . . . . . . . . . 31
2.4.2 Replacing Fuses on the ES4455.2 Load Carrier Board. . . . . . . . . . . 31
2.5 Interface for Load Modules on the ES4455.2 Load Carrier Board . . . . . . . . . 34
2.6 Piezo Signal Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.7 Equivalent Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3 Connections and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.1 Backplane Connector CO200 of the ES4455.2 Load Carrier Board . . . . . . . 37
3.2 Plug Connector CO1200 on ES4455.2, CO150 and CO100 on the Load Mod-
ules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3 Connections and Plug Connections for Installation in the ES4408.1 Load Chassis
38
3.3.1 Plug Connectors "Load 7", " Load 8-1" and "Load 8-2". . . . . . . . 38
3.3.2 Plug Connector "Meas 7", "Meas 8-1" and "Meas 8-2" on ES4408.1
Load Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4 Connections and Plug Connections for Installation in the ES5300.1-A Housing
or in the ES5300.1-B Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4.1 "X2 Load" Plug Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.4.2 "X1 Measure" Plug Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4 Technical Data and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2 Meets Norms and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5 Ordering Data and Scope of Delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6 ETAS Contact Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

ES4455.2 Load Carrier Board - User’s Guide 5
ETAS Introduction
1 Introduction
This User's Guide contains the description of the ES4455.2 Load Carrier Board
and its variants ES4450.3, ES4451.4, ES4452.1, ES4453.1, ES4457.1 and
ES4458.1 mounted with load modules.
This chapter contains information about the following topics:
• "Properties" on page 5
• "Basic Safety Notices" on page 9
• "Identifications on the Product" on page 15
– "CE Mark" on page 15
– "RoHS Conformity" on page 16
– "KC Mark" on page 15
• "Product Return and Recycling" on page 16
• "Materials Subject to Declaration" on page 17
• "About this Manual" on page 18
1.1 Properties
The ES4455.2 Load Carrier Board is a carrier board for load simulations, e.g.
injector loads, in a LABCAR HiL system.
To simulate injector loads, the following variants mounted with load modules
based on the ES4455.2 Load Carrier Board are available:
• ES4450.3 Load Carrier Board for 4 RB CRS Injectors
• ES4451.4 Load Carrier Board for 4 RB GDI Injectors
• ES4452.1 Load Carrier Board for 4 RB GDI Injectors, CVO
• ES4453.1 Load Carrier Board for 4 RB HDEV6 GDI Injectors, CVO
• ES4457.1 Load Carrier Board for 4 RB CRS Injectors, VCC and VCA
• ES4458.1 Load Carrier Board for 4 RB PFI Injectors, CVO
ES4450.3 and ES4451.4 are the successors to ES4450.2 and ES4451.3. The
ES4450.3 and ES4451.4 have the same functions as their respective predecessor
models.
The ES4452.1 Load Carrier Board for 4 RB GDI Injectors, CVO, ES4453.1 Load
Carrier Board for 4 RB HDEV6 GDI Injectors, CVO, the ES4457.1 Load Carrier
Board for 4 RB CRS Injectors, VCC and VCA and the ES4458.1 Load Carrier Board
for 4 RB PFI Injectors, CVO have an expanded scope of functions. They enable an
additional more precise simulation and modulation of the injection time through
integrated functions for the control algorithms of the ECU. These control algo-
rithms are CVO (Controlled Valve Operation) control for gasoline direct injection
in the case of ES4452.1, ES4453.1 and ES4458.1 or VCC (Valve Close Control)
control and VCA (Valve Close Adjustment) control for diesel direct injection in the
case of ES4457.1.
The expanded functions can be deactivated by the user in LABCAR OPERATOR.
After deactivating the function for CVO, the ES4452.1 can be operated analo-
gous to ES4451.4 and ES4451.3. Also, the ES4457.1 can be used in the same
way as ES4450.3 and ES4450.2 after deactivating the function for VCC and
VCA.

ES4455.2 Load Carrier Board - User’s Guide6
Introduction ETAS
The ES4408.1 Load Chassis features three slots of width 14 HP to accept the
ES4455.2 Load Carrier Board and the variants listed above. Fully mounted, it
enables the simulation of 12 injection loads.
In the same way, it is possible to install the ES4455.2 Load Carrier Board and its
mounted variants in the ES5300.1-A Housing and the ES5300.1-B Housing by
means of the ES5372.1 Carrier for ES4455 Load Boards.
In the ES5300.1-A Housing and the ES5300.1-B Housing, it is possible to install
5 boards of width 14 HP. Fully mounted, it enables the simulation of 20 injection
loads per housing.
1.1.1 Properties of the ES4455.2 Load Carrier Board and its Variants ES4450.3,
ES4451.4, ES4452.1, ES4453.1, ES4457.1 and ES4458.1 Mounted with Load
Modules
• 3 U/14 HP add-on card for a LABCAR HiL system.
• Compatibility with the ES4408.1 Load Chassis and, with the use of
adapter card ES5372.1 Carrier for ES4455 Load Boards, also with the
ES5300.1-A Housing and the ES5300.1-B Housing
• Four load inputs for connecting four simulated injection loads to an ECU
• Current measurement for four loads via four galvanically isolated
channels
• Voltage measurement for four loads via four galvanically isolated
channels
• Analog output Online_Probe for current or voltage measurement at one
selectable load
• On-board analysis of load current and load voltage
• Four digital outputs I_Dig_Out_1...I_Dig_Out_4 for outputting the injec-
tion time for each load. Based on the load response, the opening and
closing time of the respective load is also being output
• The signals I_Dig_Out_1, ... I_Dig_Out_4 can be connected to a LABCAR
HiL system.
The variants have the following additional properties:
ES4455.2 Load Carrier Board
• Slot for 4 loads
ES4450.3 Load Carrier Board for 4 RB CRS Injectors
• Simulation for four injectors of the Bosch Common Rail System.
ES4451.4 Load Carrier Board for 4 RB GDI Injectors
• Simulation for injectors of the Bosch HDEV5 gasoline direct injection
ES4452.1 Load Carrier Board for 4 RB GDI Injectors, CVO
• Simulation for injectors of the Bosch HDEV5 gasoline direct injection
• Additional supported functions of the motor ECU:
CVO (Controlled Valve Operation) control

ES4455.2 Load Carrier Board - User’s Guide 7
ETAS Introduction
ES4453.1 Load Carrier Board for 4 RB HDEV6 GDI Injectors, CVO
• Simulation for injectors of the Bosch HDEV6 gasoline direct injection
• Additional supported functions of the motor ECU:
CVO (Controlled Valve Operation)
ES4457.1 Load Carrier Board for 4 RB CRS Injectors, VCC and VCA
• Simulation for injectors of the Bosch Common Rail System CRI2-x
• Additional supported functions of the motor ECU:
VCC (Valve Close Control) and VCA (Valve Close Adjustment)
ES4458.1 Load Carrier Board for 4 RB PFI Injectors, CVO
• Simulation for Bosch PFI EV14 injectors
• Additional supported functions of the motor ECU:
CVO (Controlled Valve Operation)

ES4455.2 Load Carrier Board - User’s Guide8
Introduction ETAS
1.1.2 Block Diagram
Fig. 1-1 shows a block diagram of the ES4455.2 Load Carrier Board with four
loads in the ES4408.1 Load Chassis.
Fig. 1-1 Block diagram of the ES4455.2 Load Carrier Board with loads,
installed in the ES4408.1 Load Chassis.
Fig. 1-2 shows a block diagram of the ES4455.2 Load Carrier Board with four
loads in the ES5300.1-A Housing or ES5300.1-B Housing.
Fig. 1-2 Block diagram of the ES4455.2 Load Carrier Board with loads,
installed in the ES5300.1-A Housing or the ES5300.1-B Housing.
Back-
plane
SPI, I²C, JTAG ES4455.2_E
Control
Interface
Control
Interface
Ribbon
cable
ES4408.1
Load
Chassis
Control, Feedback
I
U
Load 1
I
U
Load 2
I
U
Load 3
I
U
Load 4
Speaker
Control
DAC
ADC ADC ADC ADC ADC ADC ADC ADC
Multiplexer 8:1
Register; Logic FPGA
I_Dig_Out_1
...4
Online_Probe
Piggyback Load
Load 7, Load 8-1, Load 8-2 Meas 7, - 8-1, - 8-2
VG48 CO200

ES4455.2 Load Carrier Board - User’s Guide 9
ETAS Introduction
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 identified with the danger symbol
shown below:
The safety notices shown below are used for this purpose. They provide notes to
extremely important information. Please read this information carefully.
1.2.2 General Safety Information
Observe 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.
1.2.3 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 prod-
uct.
CAUTION!
identifies a hazard with low risk that could result in minor or medium
physical injuries or property damages if not avoided.
WARNING!
indicates a possible danger with moderate risk of death or (serious)
injury, if not avoided.
DANGER!
indicates an immediate danger with a high risk of death or serious
injury, if not avoided.
Note
All product related documentation (product Safety Advice and this User’s
Guide) must be read prior to the startup of the product!

ES4455.2 Load Carrier Board - User’s Guide10
Introduction ETAS
General Safety at Work
Follow the existing regulations for work safety and accident prevention. All appli-
cable regulations and laws regarding operation must be strictly adhered to when
using this product.
1.2.4 Intended Use
The ES4455.2 Load Carrier Board, the ES4450.3, ES4451.4, ES4452.1,
ES4453.1, ES4457.1 and ES4458.1 are plug-in cards for the ES4408.1 Load
Chassis. With the help of ES5372.1 Carrier for ES4455 Load Boards, the plug-in
cards can also be used in the ES5300.1-A Housing or in the ES5300.1-B Housing.
The ES4455.2 Load Carrier Board consists of the following:
• Slot for a load emulation for simulating injection valves with connections
to ECU output stages
• Digital and analog output interfaces for the ES4408.1 or ES5300.1-A-
based hardware-in-the-loop system or for connecting oscilloscopes or
other measurement devices
• SPI Interface to the ES4408.1 Load Chassis or the ES5300.1-A Housing or
the ES5300.1-B Housing
The ES4450.3, ES4451.4, ES4452.1, ES4453.1, ES4457.1 and ES4458.1 plug-in
cards consist of the following:
• Load emulation for simulating injection valves with connections to ECU
output stages
• Digital and analog output interfaces for the ES4408.1 or ES5300.1-A
based hardware-in-the-loop system or for connecting oscilloscopes or
other measurement devices
• SPI Interface to the ES4408.1 Load Chassis or the ES5300.1-A Housing
and to the ES5300.1-B Housing
The ES4455.2 and its variants ES4450.3, ES4451.4, ES4452.1, ES4453.1,
ES4457.1 and ES4458.1 mounted with load modules may be operated only in
the ES4408.1 Load Chassis, ES5300.1-A Housing and in the ES5300.1-B Hous-
ing.
The intended use of the ES4455.2 and its variants ES4450.3, ES4451.4,
ES4452.1, ES4453.1, ES4457.1 and ES4458.1 mounted with load modules is as
follows:
• Use in industrial lab facilities or workplaces
• Hardware interface for ECUs in a hardware-in-the-loop test system
• Cooperation with ETAS software which supports the ES4408.1 Load
Chassis or ES5300.1-A Housing or the ES5300.1-B Housing
• Interface in cooperation with software programs that operate the stan-
dardized, documented and open APIs of ETAS software products
The ES4455.2 and its variants ES4450.3, ES4451.4, ES4452.1, ES4453.1,
ES4457.1 and ES4458.1 mounted with load modules are not intended to be
used as follows:
• Within a vehicle on the road
• As part of a life support system