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)

ES4440.2 Compact Failure Simulation Module - User’s Guide 11
ETAS Introduction
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.

ES4440.2 Compact Failure Simulation Module - User’s Guide12
Introduction ETAS
1.4 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 setup throughout the
EU for the collection, treating 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.
Fig. 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 55).
1.5 Materials Subject to Declaration
Some products from ETAS GmbH (e.g. modules, boards, cables) use components
with materials that are subject to declaration in accordance with the REACH reg-
ulation (EC) no.1907/2006. Detailed information is located in the ETAS down-
load center in the customer information "REACH Declaration" (www.etas.com/
Reach). This information is continuously being updated.

ES4440.2 Compact Failure Simulation Module - User’s Guide 13
ETAS Introduction
1.6 Applications
The ES4440.2 Compact Failure Simulation Module is used for real-time failure
simulation for ECUs. It is intended for use in a HiL system, but can also be used
as a stand-alone system, e.g. for
• tests on engine test beds
• tests on roller dynamometers
• failure simulation in a stationary vehicle.
The ES4440.2 Compact Failure Simulation Module is a 19” housing with 3 U
which can be assembled in a rack using the corresponding mounts. Fig. 1-2
shows the front panel (with mounts for rack assembly) and the rear of the
ES4440.2.
Fig. 1-2 Front View (Top) and Rear View (Bottom) of the ES4440.2 Compact
Failure Simulation Module
The ES4440.2 Compact Failure Simulation Module is addressed via the Ethernet
or CAN interface. The LABCAR-PINCONTROL software provided offers simple
and user-friendly interfaces for operating and configuring the ES4440.2 via
Ethernet.
The individual functions are described in detail in the following section.
WARNING!
The ES4440.2 Compact Failure Simulation Module is not intended for
operation in a traveling vehicle!
Rail 1/2
HV
+/- UBatt
ECU HVLOAD HV
ECU CH0-CH42ECU CH43-CH63 LOAD CH0-CH42LOAD CH43-CH63
A
D
C
B
GF
N
E
K
J
P
H
M
L
SR
T
A
K
L
M
GH
N
J
D
E
T
F
B
C
RS
P
AH
BIG
C
J
F
DE
D ECBA
G J KF H L
N R SM P T U
W Z aV Y b c
e g hd f j k
m p rl n s
w yvut
B ACDE
T R PU S N M
b Z Yc a W V
j g fk h e d
r n ms p l
u tvw
y
L K J H G F
B ACDE
T R PU S N M
b Z Yc a W V
j g fk h e d
r n ms p l
u tvw
y
L K J H G F
Fuse T1.6AH,250V
100-240VAC
50/60Hz
70W
D ECBA
G J KF H L
N R SM P T U
W Z aV Y b c
e g hd f j k
m p rl n s
w yvut
I
0
Ethernet
SYNC
CAN Current
Reset
System Error
+24V
+5V
+3.3V
Failure Active

ES4440.2 Compact Failure Simulation Module - User’s Guide14
Introduction ETAS
1.7 Functions and Features
This section provides a short overview of the functions and features of the
ES4440.2 Compact Failure Simulation Module. A detailed description can be
found in the chapter "Hardware Features" on page 19.
1.7.1 Failure Simulation
The ES4440.2 Compact Failure Simulation Module makes it possible to simulate
failures in real time for 80 ECU channels (per ES4440.2).
High-Current Channels
64 of these channels are for voltages up to 30 V and currents up to 20 A – the
following failures can be simulated for these 64 channels:
• Open load
• Short to +UBatt_A, -UBatt_A, +UBatt_B, -UBatt_B with or without con-
nected load
• Contacts between lines with and without resistance ("Pin-to-Pin") with or
without connected load
• Line resistance (”In-Line”)
• Pull-up resistance to +UBatt_A or +UBatt_B with or without connected
load
• Pull-down resistance to -UBatt_A or -UBatt_B with or without connected
load
High-Voltage Channels
A further 16 channels are for voltages up to 80 V RMS and currents up to 10 A
– the following failures can be simulated for these 16 channels:
• Open load
• Short to +UBatt_C and -UBatt_C with or without connected load
• Contacts between lines ("Pin-to-Pin") with or without connected load
Time Response
The difference between switching an failure via a relay or via MOSFET is particu-
larly seen in the time response. Whereas MOSFETs have negligible switch times
(approx. 50 μs), relays have high switch times (the time it takes from activating
Note
An failure can only be applied for a maximum of five minutes – after this time,
the overtemperature protection facility may be activated. When using the
resistor cascade, please ensure that the ratio "power-on time/cooling time" is
25% or less.
Note
The high-voltage channels are only suitable for connecting magnetic valves and
piezo injectors (pulsating direct current voltage)! The maximum permissible
voltage is 250 V with a maximum pulse duration of 100 ms.

ES4440.2 Compact Failure Simulation Module - User’s Guide 15
ETAS Introduction
the failure in the software to switching: MOSFET 200 μs, relay 5 ms). The disad-
vantage when using MOSFETs is to do with the leakage currents which occur;
these do not occur with relays.
If conventional relays are used for a failure mode, the delay between setting the
failure 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
failure actually occurs and also, for example, the duration of the failure 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 14-bit cascade with resistors from 2 to 16384 , with which resis-
tances from 2 to approx. 32 kcan be displayed in 2 intervals. For more
information on the resistor cascade, refer to the section "Resistor Cascade"
on page 24.
1.7.2 Connectors, Displays and Fuses
Connectors on the Front Panel and Rear
The ES4440.2 Compact Failure Simulation Module has several connectors on the
front and rear for connecting the ECU and loads, addressing the ES4440.2 and
for master/slave operation.
The following connectors are on the front panel:
• Connector for synchronization signals when using several ES4440.2s in
master/slave operation ("”SYNC” Connector" on page 31)
• Connector for CAN bus ("”CAN” Connector" on page 32)
• Connector for Ethernet ("”Ethernet” Connector" on page 32)
• Connector for measuring currents between the two failure rails with the
failure modes ”Pin-to-Pin Resistance”, ”Inline Resistance” and ”Leakage
Current” ("”Current” Connector" on page 33)
The following connectors are on the rear:
• Connector for connecting the failure rails when using several ES4440.2s in
master/slave operation ("”Rail 1/2” Connector" on page 33)
• Connector for the 16 high-voltage ECU signals ("”ECU HV” Connector"
on page 33)
• Connector for the load to the channels above ("”LOAD HV” Connector"
on page 35)
• Connector for the 64 high-current ECU signals ("”ECU CH0-CH42” /
”ECU CH43-CH63” Connector" on page 36)
• Connector for the load to the channels above ("”LOAD CH0-CH42” /
”LOAD CH43-CH63” Connector" on page 40)
• Mains connection with integrated fuse

ES4440.2 Compact Failure Simulation Module - User’s Guide16
Introduction ETAS
Status Displays via LEDs on the Front Panel
There are several LEDs on the front panel of the ES4440.2 Compact Failure Sim-
ulation Module which provide information on operating states of the ES4440.2
and the communication interfaces. For more details on the LEDs, refer to the
section "Status Displays via LEDs on the Front Panel" on page 24.
Fuses
The ES4440.2 Compact Failure Simulation Module is protected against overcur-
rents with fuses. When a reset1takes place, the fuse state is queried and trans-
ferred to the control software. The fuse monitor is designed so that there are no
disturbing influences on the ECU signals.
For more details on the fuses used and how to change them, refer to the section
"Safety Concept" on page 27.
1.7.3 Application Environment
Master/Slave Operation of Several ES4440.2 Systems
If greater demands are made of the number of channels than can be catered for
with one ES4440.2 Compact Failure Simulation Module (64 + 16), you can use
several ES4440.2s. A dedicated master synchronizes failure simulation on the
connected slave systems.
This takes place by connecting the failure rails and the synchronization lines of
the ES4440.2s involved and assigning corresponding IP addresses in the operat-
ing software LABCAR-PINCONTROL.
Communication Interfaces
The ES4440.2 Compact Failure Simulation Module has interfaces for communi-
cation via the Ethernet and CAN protocol. The relevant APIs are described in the
LABCAR-PINCONTROL User's Guide.
When using the LABCAR-PINCONTROL software on a host system, communica-
tion takes place by Ethernet – otherwise the ES4440.2 can also be controlled
using a CANbus.
In addition, it is also possible to realize complex hardware configurations in a HiL
system with a real-time PC as simulation target and an ES600 Network Module
(see the chapter "Accessories" on page 45).
LABCAR-PINCONTROL
LABCAR-PINCONTROL (Version 2.0 and higher) provides an easy-to-use user
interface in which all failures can be activated and reset.
LABCAR-PINCONTROL has, in particular, the following features:
• Creating and managing failure sets. A failure set is a group of ECU signals
(e.g. all signals of the oxygen sensor)
1. When a reset takes place, all relays are set to a state in which no failures are
switched any more.
Note
Using the LABCAR-PINCONTROL software requires communication by Ethernet
between the host and the ES4440.2.

ES4440.2 Compact Failure Simulation Module - User’s Guide 17
ETAS Introduction
• Signal lists with all signals of a selected failure set. This is where the signal
is selected for which an failure is to be simulated.
• Display of all available failures for a selected signal in one window
• Failures are selected in this window by mouse click
• Settings of the desired failure duration
• Triggering the failure by mouse click
• Configuration of the Ethernet and CAN interface
• Configuration for master/slave operation
• Self-test and fuse test
• Automated control (with the LABCAR-PINCONTROL controller)
1.7.4 Block Diagram
Fig. 1-3 Block Diagram of the ES4440.2 Compact Failure Simulation Module
The core of the ES4440.2 Compact Failure Simulation Module is a micro-
controller (μC) with an integrated Ethernet controller – the μC is connected
directly to Ethernet-PHY. A CAN transceiver acts as a second interface to control
the ES4440.2.
A serial, non-volatile EEPROM saves a range of specific parameters such as MAC
address, IP address, CAN baud rate. Three PLDs with subsequent relay drivers
address the relays and MOSFETs.
A further feature is the fuse monitoring by the μC.
Relays for
Resistor
Cascade
20 A Relays
(64 Channels)
80 V Relays
(16 Channels) MOSFET
EEPROM
Ethernet
PHY
µC
MOSFET
Driver
Relay DriverRelay Driver Relay Driver
Fuse Monitor
SYNC
CAN
Transceiver

ES4440.2 Compact Failure Simulation Module - User’s Guide18
Introduction ETAS

ES4440.2 Compact Failure Simulation Module - User’s Guide 19
ETAS Hardware Features
2 Hardware Features
This chapter contains detailed information on the features of the ES4440.2 Com-
pact Failure Simulation Module.
These are:
• "Failure Simulation for 80 Channels" on page 19
• "Failure modes" on page 20
• "Time Response" on page 23
• "Resistor Cascade" on page 24
• "Status Displays via LEDs on the Front Panel" on page 24
• "Master/Slave Operation of Several ES4440.2 Systems" on page 25
• "Safety Concept" on page 27
2.1 Failure Simulation for 80 Channels
The ES4440.2 Compact Failure Simulation Module has 64 channels which are
equipped for a continuous current of 20 A (at 30 V) and 16 channels for a volt-
age of 80 V RMS at 10 A current rating.
This number of ECU channels is sufficient if only outputs of engine ECUs (gaso-
line or diesel) have to be tested. If, however, inputs are to be tested simultane-
ously, two or more ES4440.2s are used in master/slave operation (see section 2.6
on page 25).
The text that follows describes which types of failure can be simulated for which
channels.

ES4440.2 Compact Failure Simulation Module - User’s Guide20
Hardware Features ETAS
2.2 Failure modes
In the following description of all available failures, the failures are shown sepa-
rately according to the type of channel (high-voltage or high-current channels).
2.2.1 Failures for High-Voltage Channels
The following figure shows
• the failures which can be realized on the 16 high-voltage channels,
• whether several failures can be activated simultaneously,
• the settable duration of the failure state and
• whether this failure can also be realized in PWM control as a loose con-
tact.
Fig. 2-1 Failures for High-Voltage Channels
High-Voltage Channel
Error Type
Switched by
(Single/Multiple
Error)
Duration
(fixed or PWM)
Open Load
Relay
(single)
20 ms - 60 s
or 
Short Circuit
to
±UBatt_C
Relay
(single)
Short Circuit
Relay
(single)
20 ms - 60 s
or 
20 ms - 60 s
or 