ETAS ES4440.2 User manual

ES4440.2 Compact Failure Simulation Module
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 2011 - 2019 ETAS GmbH, Stuttgart
The names and designations used in this document are trademarks or brands
belonging to the respective owners.
V1.2.0 R10 EN 11.2019

ES4440.2 Compact Failure Simulation Module - User’s Guide 3
Contents
ETAS Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Basic Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 Identification of Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2 General Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.3 Requirements for Users and Duties for Operators. . . . . . . . . . . . . . . 6
1.1.4 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 General Instructions on Operating the ES4440.2 . . . . . . . . . . . . . . . . . . . . . . 8
1.3 Identifications on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.1 CE Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.2 KC Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.3 RoHS Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Taking the Product Back and Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Materials Subject to Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.6 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7 Functions and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7.1 Failure Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7.2 Connectors, Displays and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.7.3 Application Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.7.4 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.1 Failure Simulation for 80 Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 Failure modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.1 Failures for High-Voltage Channels . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2.2 Failures for High-Current Channels . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2.3 Relay or MOSFET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2.4 Duration of the Failure State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2.5 Simulating Loose Contacts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2.6 Number of Possible Active Failure States . . . . . . . . . . . . . . . . . . . . 22

ES4440.2 Compact Failure Simulation Module - User’s Guide4
Contents ETAS
2.2.7 Decoupling the Load before Failure Activation . . . . . . . . . . . . . . . . 23
2.2.8 Measuring the Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3 Time Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4 Resistor Cascade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5 Status Displays via LEDs on the Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.6 Master/Slave Operation of Several ES4440.2 Systems . . . . . . . . . . . . . . . . . 25
2.6.1 IP Addresses and CAN Identifiers . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7 Safety Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7.1 Resetting on Overtemperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7.2 Protecting the Rails/Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7.3 Automatic Monitoring of the Fuses . . . . . . . . . . . . . . . . . . . . . . . . 27
2.7.4 Changing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.7.5 Changing the Mains Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3 Pin Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 ”SYNC” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 ”CAN” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3 ”Ethernet” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4 ”Current” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.5 ”Rail 1/2” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.6 ”ECU HV” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.7 ”LOAD HV” Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.8 ”ECU CH0-CH42” / ”ECU CH43-CH63” Connector . . . . . . . . . . . . . . . . . . 36
3.9 ”LOAD CH0-CH42” / ”LOAD CH43-CH63” Connector . . . . . . . . . . . . . . . . 40
4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Power Supply Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 ES600 Network Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.3 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.3.1 Ethernet Cable (RJ-45 Connector – Lemo Connector) . . . . . . . . . . 47
4.3.2 Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6 Ordering Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7 ETAS Contact Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

ES4440.2 Compact Failure Simulation Module - User’s Guide 5
ETAS Introduction
1 Introduction
This User’s Guide contains a description of the ES4440.2 Compact Failure Simu-
lation Module.
It consists of the following chapters:
• Introduction
This chapter
• "Hardware Features" on page 19
This chapter contains a detailed description of the features of the
ES4440.2 Compact Failure Simulation Module.
• "Pin Assignment" on page 31
This chapter contains a description and assignment of all connectors on
the front panel and on the rear of the housing.
• "Technical Data" on page 49
This contains details of the technical data of the ES4440.2 Compact Fail-
ure Simulation Module.
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 Identification of Safety Information
The safety instructions contained in this manual are identified by the general
danger symbol shown below:
The safety instructions shown below are used for this purpose. They provide
notes about extremely important information. Please read this information very
carefully.
DANGER!
Identifies an immediate danger with high risk, which could result in
death or severe bodily injury if it is not avoided.
WARNING!
Identifies a possible danger with medium risk, which could result in
death or (severe) bodily injury if it is not avoided.
CAUTION!
Identifies a danger with low risk that could result in slight or moder-
ate bodily injuries or property damage if it is not avoided.

ES4440.2 Compact Failure Simulation Module - User’s Guide6
Introduction ETAS
1.1.2 General Safety Information
Please read the product safety advice ("ETAS Safety Advice") as well as the fol-
lowing safety instructions to avoid injury to yourself and others as well as dam-
age 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.
1.1.3 Requirements for Users and Duties for Operators
The product may be assembled, operated and maintained only if you have the
necessary qualifications and experience for this product. Improper use or use by
a user without sufficient qualifications can put life at risk or cause damage to
health or property.
General Safety at Work
The existing regulations for safety at work and accident prevention must be fol-
lowed.
1.1.4 Intended Use
The ES4440.2 Compact Failure Simulation Module is a standalone unit which
electrically simulates faults in automotive ECUs in real time. The unit can also be
installed as part of a hardware-in-the-loop test system.
The ES4440.2 Compact Failure Simulation Module consists of:
• A microcontroller which is part of the ES4440.2
– The microcontroller is programmed with ETAS software
• An Ethernet and a CAN interface for the configuration and control of the
ES4440.2
• Interfaces to feed in ECU signals
• An interface to synchronize several ES4440.2
• An interface for the connection of different voltages (e.g. T15, T30,
T31,…)
– The ES4440.2 can not generate these voltages
• A resistor cascade which is part of the ES4440.2
The ES4440.2 Compact Failure Simulation Module can be installed in a 19" rack
system or can be used as a standalone unit.
Note
Please read the documentation accompanying the product ("ETAS Safety
Advice Housing" and this User’s Guide) carefully before using the product.
Note
The safety of the system in which the ES4440.2 Compact Failure Simulation
Module was installed is the responsibility of the person who assembled the
system!

ES4440.2 Compact Failure Simulation Module - User’s Guide 7
ETAS Introduction
The intended purpose of the ES4440.2 Compact Failure Simulation Module is for
it to be used:
• To electrically simulate faults in ECUs.
• In industrial lab facilities or workplaces.
• For tests on engine test benches.
• For tests on chassis dynamometers.
• In stationary vehicles.
– On private land.
• As an electric fault simulation unit for ECUs in a hardware-in-the-loop test
system.
• In conjunction with ETAS software that supports the ES4440.2.
• As an interface together with software programs that operate the stan-
dardized, documented and open APIs of ETAS software products.
The ES4440.2 Compact Failure Simulation Module is not to be used:
• Within a vehicle on public roads.
• As part of a life support system.
• As part of a medical application.
• In applications in where misuse can lead to injuries or property damage.
• In environments in which conditions prevail that fall outside the specified
ranges (see "Ambient Conditions" on page 52)
Requirements for Operation
The following requirements are made to ensure safe operation:
• Only use the product according to the specifications in the corresponding
user manual. If the product is used in any other way, product safety is no
longer ensured.
• Observe the regulations applicable at the operating location concerning
electrical safety as well as the laws and regulations concerning occupa-
tional safety.
• Do not use the product in a wet or damp environment.
• Do not use the product in potentially explosive atmospheres.
• Keep the surfaces of the product clean and dry.
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.
In order to operate the ES4440.2 Compact Failure Simulation Module safely, you
must observe the section "General Instructions on Operating the ES4440.2"
on page 8.

ES4440.2 Compact Failure Simulation Module - User’s Guide8
Introduction ETAS
1.2 General Instructions on Operating the ES4440.2
Please note the following when operating the device:
Transport/Installation
The ES4440.2 Compact Failure Simulation Module weighs 14 kg. Only lift or
carry the housing with two people.
Power Supply Cord
The respective requirements for the power supply cord, which vary according to
regional differences in the power supply, and the ETAS order number can be
found in the user manual. To avoid injuries and damage to hardware, please only
use the power supply cord specified here.
Use only primary power cables in accordance with IEC 60320 with a C13 plug at
one end and a non-locking plug approved according to national safety standards
at the other end. Plug and cable must be rated for at least 250 VAC/10 A or
125 VAC/15 A.
Insulation requirements for lab power supplies to circuits connected to the HIL
system:
• The power supply to connected circuitry must be safely separated from
the supply voltage. For example, use a car battery or a suitable lab power
supply.
• Only use lab power supplies with dual protection for the supply network
(with double/reinforced insulation (DI/RI)). This requirement is met by lab
power supplies which comply with IEC/EN 60950 or IEC/EN 61010.
• The lab power supply must be approved for use at a height of 2000 m and
in ambient temperatures of up to 40 °C.
Connecting Cables
Use only approved cables for creating cable assemblies (e.g. for connecting the
ECU and external loads).
Grounding/Grounding Contact
The ES4440.2 is grounded by the protective conductor of the power supply cord.
Avoid the danger of electric shock when touching housing components by
ensuring that the power connection used has properly connected grounding
contacts.
Note
The cables used must be suitable particularly for the occurring currents, volt-
ages and temperatures and flame-retardant in accordance with one of the fol-
lowing standards IEC60332-1-2, IEC60332-2-2, UL2556/UL1581VW-1.
DANGER!
Risk of electric shock!
If no proper grounding via the PE conductor is available, housing
components that can be touched could be live. This can cause serious
or fatal injuries! For this reason, it must be ensured that the power
cable features correctly connected grounding contacts!

ES4440.2 Compact Failure Simulation Module - User’s Guide 9
ETAS Introduction
Supply Voltage Disconnect Device
The power cord serves as a supply voltage disconnect device.
Opening the Housing
Fuses
The module must not be operated when the fuse box lid is open. To avoid injuries
and damage, only fuses specified in the user manual may be used. The corre-
sponding requirements and the ETAS order numbers can be found in the section
"Safety Concept" on page 27.
Air Supply
Do not cover the ventilation slots of the device under any circumstances! If
required, forced cooling must be implemented when the device is installed in a
19" rack. The ventilation openings must have a distance of at least 15 cm to
walls or objects in the environment. Keep a distance of at least 1 RU to the next
module at the top and bottom.
Cleaning
Clean the device only with a dry cloth. Do not use any cleaning agents or sol-
vents.
Maintenance
The device does not require any separate maintenance from the user.
Repairs
In the case of a malfunction, the device needs to be shut down, secured against
being switched on again and sent to ETAS to be repaired.
Note
The power cord must be easy to access! It must not be longer than 3 m.
DANGER!
Risk of electric shock!
There could be extremely dangerous high voltages at the individual
pins of the "ECU HV" and "LOAD HV" connections. Therefore you
should only open the housing when the device has been discon-
nected from the mains power and all other connections have been
removed.

ES4440.2 Compact Failure Simulation Module - User’s Guide10
Introduction ETAS
1.3 Identifications on the Product
The following symbols are used for identifying the product:
Observe the information in chapter "Technical Data" on page 49.
1.3.1 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.
1.3.2 KC Mark
With the KC mark attached to the product and its packaging, ETAS confirms that
the product has been registered in accordance with the product-specific KCC
guidelines of the Republic of Korea.
1.3.3 RoHS Conformity
European Union
The EU Directive 2011/65/EU limits the use of certain dangerous materials for
electrical and electronic devices (RoHS conformity).
ETAS confirms that the product corresponds to this directive which is applicable
in the European Union.
Symbol Description
Before using the product, carefully read the user’s guide!
Identification for CE (see "CE Marking" on page 10)
Marking for KCC conformity
(see "KC Mark" on page 10)
Identification for China RoHS (see "RoHS Conformity"
on page 10)
Identification for WEEE directive
(see "Taking the Product Back and Recycling" on page 12)