ETAS ES5300.2-A User manual

ES5300.2-A Housing
ES5301.2-A Housing
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 - 11.2019

ES5300.2-A Housing, ES5301.2-A Housing - User’s Guide 3
Contents
ETAS Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Requirements for Users and Duties for Operators. . . . . . . . . . . . . . . 8
1.1.4 Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1.5 Transport and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1.6 Electrical Safety and Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1.7 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1.8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.1.9 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Identifications on the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.1 CE Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2 KC Mark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.3 RoHS Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Taking the Product Back and Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Materials Subject to Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.5.1 Using This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Features and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.2 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2.1 Connection Modules for the Breakout Box . . . . . . . . . . . . . . . . . . 25
2.2.2 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.3 Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3.1 Supported Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3.2 Backplane Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3.3 Connections between the Backplane and the Real-Time PC. . . . . . 28

ES5300.2-A Housing, ES5301.2-A Housing - User’s Guide4
Contents ETAS
2.4 Slots for I/O Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4.1 Supported PCI Express Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4.2 PCI Express Carrier Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.4.3 Integrating Housings with VMEbus Boards. . . . . . . . . . . . . . . . . . . 32
2.5 Real-Time PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.5.1 Mainboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.5.2 LAN Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.5.3 Hard Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.5.4 Expansion Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.5.5 CMOS Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.5.6 Power Supply Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.6 Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.7 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.7.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.7.2 Fuse Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.7.3 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3 Configuration and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1 Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.1.1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.2 Preparing the Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2.1 Installing Connection Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2.2 Opening the Cable Duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2.3 Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.3 Installing Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.3.1 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.3.2 Attaching the PCI Express Board on the ES5370.1 Carrier Board . . 48
3.3.3 Angle Clock Bus Connection between ES5370.1 Carrier Board and
ES5340.1 / ES5340.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.3.4 Gigabit Link between Master and Slave Board in an ES5370.1 . . . . 51
3.3.5 Inserting the ES5370.1 Carrier Board into a Slot . . . . . . . . . . . . . . 52
3.4 User PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.4.1 Connecting the User PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.4.2 Configuring RTIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.5 Powering on the ES5300.2-A / ES5301.2-A . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.6 Opening/Removing the Real-Time PC Drawer . . . . . . . . . . . . . . . . . . . . . . . 55
3.7 Removing and Cleaning the Filter Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4 Pin Assignment and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.1 Backplane Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.2 Power Supply Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.2.1 Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.2.2 Backplane Power Supply Connectors . . . . . . . . . . . . . . . . . . . . . . . 67
4.3 Real-Time PC Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
5.1 Fulfilled Standards and Norms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

ES5300.2-A Housing, ES5301.2-A Housing - User’s Guide 5
ETAS Contents
6 Ordering Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7 ETAS Contact Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

ES5300.2-A Housing, ES5301.2-A Housing - User’s Guide6
Contents ETAS

ES5300.2-A Housing, ES5301.2-A Housing - User’s Guide 7
ETAS Introduction
1 Introduction
This chapter contains information on the following topics:
• "Basic Safety Instructions" on page 7
• "Identifications on the Product" on page 15
• "CE Marking" on page 15
• "KC Mark" on page 16
• "RoHS Conformity" on page 16
• "Taking the Product Back and Recycling" on page 16
• "Materials Subject to Declaration" on page 16
• "About This Manual" on page 18
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 as well as the following safety instructions
to avoid injury to yourself and others as well as damage to the device.
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 (product safety
advice and this User’s Guide) carefully before using the product.

ES5300.2-A Housing, ES5301.2-A Housing - User’s Guide8
Introduction ETAS
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
Only install, operate and maintain the products if you have the required qualifi-
cations for and experience with them.
Incorrect operation or operation by users without sufficient qualifications may
lead to injuries, death or property damage.
General Safety at Work
The existing regulations for safety at work and accident prevention must be fol-
lowed. When using these products, all applicable regulations and laws concern-
ing their operation must be observed.
1.1.4 Intended Use
ES5300.2-A Housing / ES5301.2-A Housing
The ES5300.2-A Housing / ES5301.2-A Housing is a system housing for building
a hardware-in-the-loop (HiL) test system. The ES5300-based hardware-in-the-
loop test system consists of:
• A real-time PC which is part of the ES5300.2-A Housing / ES5301.2-A
Housing
• Digital and analog interfaces to the ECU which can be integrated into the
ES5300.2-A Housing / ES5301.2-A Housing as PCI Express, SPI or I2C-
based boards
• Load simulation for connecting to ECU output stages which can be inte-
grated into the ES5300.2-A Housing / ES5301.2-A Housing in the form of
SPI or I2C based boards
• Battery node simulation (e.g. K15, K30, …) for connecting to the ECU
which can be integrated into the ES5300.2-A Housing / ES5301.2-A Hous-
ing in the form of SPI or I2C based boards
– The simulation of the vehicle battery itself is not a component part of
the ES5300.2-A Housing / ES5301.2-A Housing and cannot be inte-
grated here.
The ES5300.2-A Housing / ES5301.2-A Housing must always be installed in the
ETAS housing (ES4015.2 Housing 9U) intended for this purpose or a 19" rack
system, and must not be operated as a stand-alone unit.
The whole ES5300-based HiL system consists of a real-time computer, which is
part of the ES5300.2-A Housing / ES5301.2-A Housing, and one or more plug-in
boards. The plug-in boards provide the connected ECU with analog and/or digital
interfaces, as well as the simulation of loads and battery nodes.
Note
The system integrator is responsible for the safety of systems that use the prod-
ucts.

ES5300.2-A Housing, ES5301.2-A Housing - User’s Guide 9
ETAS Introduction
ES5370.1 Carrier Board PCI Express x16 socket, GEN1/2 x1 Link
The ES5370.1 is a plug-in board for the ES5300 system housing. The ES5370.1
must only ever be used in the ETAS ES5300 system housing intended for this
purpose and must not be operated as a stand-alone unit.
The ES5370.1 is a carrier board that is designed for accommodating the
ES5340.1, ES5340.2 and ES5335.1 PCI Express boards and third party hardware
that has been approved by ETAS for the ES5370.1.
The intended use of the products is as follows:
• Use as a component in industrial lab equipment or at industrial work-
places
• Use as a hardware interface for ECUs in a hardware-in-the-loop test sys-
tem
• Use in conjunction with ETAS software that supports the ES5300.2-A
Housing / ES5301.2-A Housing and the ES5300.1-B Housing
• Use as an interface in conjunction with software programs that operate
the standardized, documented and open APIs from ETAS software prod-
ucts
The products are not intended for the following:
• Use within on-road vehicles
• Use as part of a life support system
• Use as part of a medical application
• Applications in which misuse may result in injury or damage
• Use in environments in which conditions prevail that fall outside the spec-
ified ranges (see "Environmental Conditions" on page 71)
• Use with signal conditioning that falls outside the specified ranges
Requirements for the Technical State of the Products
The products reflect the state of the art and comply with recognized safety rules.
The products must only be operated in a technically flawless state, in accordance
with their intended purpose and in a safety-conscious and hazard-aware manner
under consideration of the documentation regarding each product. If the prod-
ucts are not used in accordance with their intended purpose, their product safety
may be impaired.
In order to operate the ES5300.2-A Housing / ES5301.2-A Housing and the
ES5300.1-B Housing safely, you must observe the section "Safety Instructions"
on page 41.
Requirements for Operation
• Only use the products in accordance with the specifications in the corre-
sponding User's Guides. If the products are used in any other way, product
safety is no longer ensured.
• Do not use the products in a wet or damp environment.
• Do not use the products in potentially explosive atmospheres.
• Keep the surfaces of the products clean and dry.

ES5300.2-A Housing, ES5301.2-A Housing - User’s Guide10
Introduction ETAS
1.1.5 Transport and Installation
Transport
Installation
Requirements for the Installation Location
CAUTION!
The ES5300.2-A Housing / ES5301.2-A Housing weighs at least
20.5 kg. Only lift or carry the transport box or the housing with two
people.
CAUTION!
The ES5300.2-A Housing / ES5301.2-A Housing and the ES5300.1-B
Housing together weigh at least 30 kg. Only lift and carry the trans-
port box or the housing with two persons or using a lifting device.
CAUTION!
Danger of falling parts!
The rail guides on the 19" rack system must be specified for double
the total weight (A Housing or B Housing + fitted plug-in boards).
Only use rail guides that are designed to hold at least 100 kg per pair.
If the rail guides are designed for too light a weight, they could bend
or break.
CAUTION!
In order to prevent damage to the plug-in boards and the LABCAR
housing, and thereby also avoid damage to property or health,
observe the installation instructions and information contained in the
relevant User's Guides.
CAUTION!
Some components of the ES5370.1 Carrier Board may be damaged
or destroyed by electrostatic discharges. Leave the plug-in board in its
transport packaging until it is installed. Only remove, configure and
install the product at a workplace that is protected against electro-
static discharges.
WARNING!
This is class A equipment. This equipment can cause radio interfer-
ence in residential areas. Should that be the case, the operator may
be requested to institute reasonable measures.