ETAS ES4456.2 User manual

ES4456.2 Load Board for 8 RB CRI3-x Piezo Injectors
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 R03 EN - 10.2019

ES4456.2 Load Board for 8 RB CRI3-x Piezo Injectors - User’s Guide 3
Contents
ETAS Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Applications and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Basic Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.1 Labeling of Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.2 General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.3 Requirements for Users and Duties for Operators. . . . . . . . . . . . . . . 8
1.2.4 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Identifications on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3.1 CE Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.2 RoHS Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3.3 P007 Identification in Accordance with ISO 7010:2011 . . . . . . . . . 15
1.4 Product Return and Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Materials Subject to Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.6 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.6.1 Working with this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Connecting Loads and Measuring the Signals . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Overcurrent Protection of the Measure Outputs . . . . . . . . . . . . . . . . . . . . . 19
2.3 LED Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 Acoustic Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6 Settings in LABCAR-RTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Pin Assignment, Cables and Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.1 “Load 0..7” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2.1 “CBAV344.1-1” Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.2.2 “CBAV345.1-1” Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

ES4456.2 Load Board for 8 RB CRI3-x Piezo Injectors - User’s Guide4
Contents ETAS
3.3 LEDs for Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Standards Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5 Ordering Data and Scope of Delivery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6 ETAS Contact Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

ES4456.2 Load Board for 8 RB CRI3-x Piezo Injectors - User’s Guide 5
ETAS Introduction
1 Introduction
This User’s Guide describes the ES4456.2 Load Board for 8 RB CRI3-x Piezo Injec-
tors. It consists of the following chapters:
1.1 Applications and Features
Applications
The ES4456.2 Load Board for 8 RB CRI3-x Piezo Injectors is a load simulation for
eight Piezo Injectors.
The ES4456.2 can be directly built into the ES4408.1 Load Chassis. If the
ES4456.2 is built into the ES5372.1-B Carrier Board, it can also be used in the
ES5300.1-A Housing or in the ES5300.1-B Housing.
For fast project change, an ES4408.1 Load Chassis is usually equipped with two
ES4450.2 Load Boards for 4 RB CRS Injectors (or two ES4451.3 Load Boards for
4 RB GDI Injectors) for simulating eight injectors with solenoid valves for Com-
mon Rail systems or gasoline direct injection and one ES4456.2 Load Board for 8
RB CRI3-x Piezo Injectors for simulating eight Piezo Injectors.
Fig. 1-1 ES4408.1 Load Chassis with ES4456.2 Load Board for 8 RB CRI3-x
Piezo Injectors (Slot 3)
ETAS
ES4451.3
Threshold high Load 0
Threshold low Load 0
Threshold high Load 1
Threshold low Load 1
Threshold high Load 2
Threshold low Load 2
Threshold high Load 3
Threshold low Load 3
Threshold
calibration
connection
!
Load0
Load1
Load2
Load3
ETAS
ES4451.3
Threshold high Load 0
Threshold low Load 0
Threshold high Load 1
Threshold low Load 1
Threshold high Load 2
Threshold low Load 2
Threshold high Load 3
Threshold low Load 3
Threshold
calibration
connection
!
Load0
Load1
Load2
Load3
ES4434.1
1
ETAS
2
34
56
78
910
11 12
13 14
15 16
17 18
19 20
21 22
23 24
ES4434.1
1
ETAS
2
34
56
78
910
11 12
13 14
15 16
17 18
19 20
21 22
23 24
ES4434.1
1
ETAS
2
34
56
78
910
11 12
13 14
15 16
17 18
19 20
21 22
23 24
ES4435.1
ETAS
ES4435.1
ETAS
+ 5 V
+ 3.3 V
- 12 V
+ 12 V
+ 24 V
ETAS
Load 0..3
ES4456.2
Load 4..7
Load 0..7

ES4456.2 Load Board for 8 RB CRI3-x Piezo Injectors - User’s Guide6
Introduction ETAS
Features
The ES4456.2 Load Board for 8 RB CRI3-x Piezo Injectors has the following fea-
tures:
• 3 U plug-in board (14 HP, 340 mm x 100 mm)
• Eight channels for load simulations to 16 A/250 V
• Eight galvanically isolated analog channels for voltage measuring
Fig. 1-2 shows the block diagram of the ES4456.2 Load Board for 8 RB CRI3-x
Piezo Injectors.
Fig. 1-2 Block Diagram of the ES4456.2 Load Board for 8 RB CRI3-x Piezo
Injectors
PLD
EEPROM
Load 1
DAC
V_Out Output
Protection
Load 8
DAC
V_Out Output
Protection
...

ES4456.2 Load Board for 8 RB CRI3-x Piezo Injectors - User’s Guide 7
ETAS Introduction
The following figure shows the front panel of the ES4456.2 Load Board for 8 RB
CRI3-x Piezo Injectors.
Fig. 1-3 Front Panel of the ES4456.2 Load Board for 8 RB CRI3-x Piezo Injec-
tors
The elements of the front panel are:
• The LEDs “Load n” that light up when the currents exceed the thresholds
set in the software
• The “Load 0..7” port to which the eight loads of the board can be con-
nected (e.g. to a LABCAR).
ETAS
Load 0..3
ES4456.2
Load 4..7
Load 0..7

ES4456.2 Load Board for 8 RB CRI3-x Piezo Injectors - User’s Guide8
Introduction ETAS
1.2 Basic Safety Instructions
Please adhere to the safety instructions in this manual to avoid injury to yourself.
1.2.1 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.
1.2.2 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.
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.
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
The User's Guide and the Product Safety Advice must be read carefully prior to
the startup of the product!

ES4456.2 Load Board for 8 RB CRI3-x Piezo Injectors - User’s Guide 9
ETAS Introduction
1.2.4 Intended Use
The ES4456.2 Load Board for 8 RB CRI3-x Piezo Injectors is for load emulation of
eight piezo injectors.
The ES4456.2 is a plug-in board for the ES4408.1 Load Chassis. When built into
the ES5372.1-B, it can also be used in the ES5300.1-A Housing and the
ES5300.1-B Housing.
The ES4456.2 consists of the following:
• Load emulation for 8 RB CRI13-x piezo injectors 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, the ES5300.1-A Housing or
ES5300.1-B Housing
The ES4456.2 may be installed and operated only in the ES4408.1 Load Chassis,
the ES5300.1-A Housing or in the ES5300.1-B Housing.
The intended use of the ES4456.2 in an ES4408.1 Load Chassis, an ES5300.1-A
Housing or ES5300.1-B Housing is:
• Use as a component in industrial lab facilities or at industrial workplaces
• Use as hardware interface for ECUs in a hardware-in-the-loop test system
• Use in conjunction with ETAS software that supports the ES4408.1 Load
Chassis, th ES5300.1-A Housing and the ES5300.1-B Housing
• Use as interface in cooperation with software programs that operate the
standardized, documented and open APIs of ETAS software products
The ES4456.2 is not intended for the following:
• Use within a vehicle on the road.
• Use as part of a life support system.
• Use as part of a medical application
• In applications where misuse can lead to injuries or damages.
• Use in environments in which conditions prevail that fall outside the spec-
ified ranges (see "Environmental Conditions" on page 29).
• Use with signal conditioning that falls outside the specified ranges (see
voltages, currents and power consumption in the chapter "Technical
Data" on page 29)
Requirements for the Technical State of the Product
The product is designed in accordance with state-of-the-art technology and rec-
ognized safety rules. The product may be operated only in a technically flawless
condition and according to the intended purpose and with regard to safety and
dangers as stated in the respective product documentation. If the product is not
used according to its intended purpose, the protection of the product may be
impaired.
Requirements for Operation
The following requirements are necessary for safe operation:

ES4456.2 Load Board for 8 RB CRI3-x Piezo Injectors - User’s Guide10
Introduction ETAS
• Use the product only according to the specifications in the corresponding
User's Guide. With any deviating operation, the product safety is no lon-
ger ensured.
• Do not use the product in a wet or damp environment.
• 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!
DANGER!
Risk of electric shock!
At the plug Load 0...7 high voltages may still be present even after
disconnecting the counter plug.
After disconnecting the cable, wait one minute before touching the
connections or the circuit board. Parallel to the capacitors are resis-
tors that allow a safe discharging.
Nonobservance may lead to fatal injury or death.
WARNING!
Danger of high voltages!
The components, plug connectors, conductor paths of the ES4456.2
may have dangerous voltages. These voltages can also be present
when the ES4456.2 is not installed in the ES4408.1 Load Chassis, the
ES5300.1-A Housing or in the ES5300.1-B Housing or if the ES4408.1
Load Chassis, the ES5300.1-A Housing and the ES5300.1-B Housing
are switched off.
Ensure that the ES4456.2 is protected against touching it during
operation. Switch off the ES4408.1 Load Chassis, the ES5300.1-A
Housing or the ES5300.1-B Housing and pull the power plug. Wait at
least three minutes before removing the ES4456.2.
Nonobservance may lead to fatal injury or death.
WARNING!
Danger trough electromagnetic radiation!
The ES4456.2 and loads connected to it, can emit electromagnetic
radiation during operation which can cause interference with the
operation or damage pacemakers or implanted defibrillators.
The ES4456.2 may be operated only in areas where persons with
pacemakers are prohibited from entering. At the entrances to these
areas, the P007 identification, "No access for persons with pacemak-
ers or implanted defibrillators" in accordance with ISO 7010:2011
"Registered Safety Signs", must be attached and clearly legible.
Failure to observe it can lead to health hazards and even death for
persons with pacemakers and implanted defibrillators.