Mars Labs Titan CAI User manual

2
Titan CAI
Titan CAI Mini-Recorder
User Manual v1.2
MNL 1050
November 2017
This information is furnished for installation, operation, test and maintenance purposes.
The information is proprietary in nature and should be treated accordingly. The data shall
not be released or used, duplicated or disclosed, in whole or in part, for manufacture or
procurement without the written permission of Mars Labs.
Proprietary Notice
This Technical Manual is copyright © 2017. All rights reserved. Brief excerpts may be
made from this manual for technical purposes, as long as they are referenced.
Although this manual is believed to be correct at the time of publication, Mars Labs, its
employees, or agents involved in the preparation and publication of this manual do not
accept any form of liability for its contents or any consequences arising from its use. People
using the information contained in this manual should apply, and rely upon, their own skill
and judgement to a particular issue which they are considering.
Copyright
Only a qualified technician or representative of Mars Labs should attempt to service the
components of this system. There are no user-serviceable parts inside.
For safety and protection of the equipment, power must be turned off prior to connecting or
disconnecting cables and sensors.
Warning

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Titan CAI
Table of Contents
Furnished Accessories .......................................................................................
Support ............................................................................................................
General Guidelines and Warnings ...................................................................
Guidelines for Wiring Sensors .........................................................................
Introduction
Operation
Interface
Front Panel .......................................................................................................
Rear Panel ........................................................................................................
Signal Flow .....................................................................................................
Calibration Modes ............................................................................................
Formatting Memory Cards ................................................................................
Analog Input Connector ...................................................................................
COMM Port .....................................................................................................
GPS Port ..........................................................................................................
4
4
5
6
7
10
11
12
13
14
15
15
Features & Specifications
Key Features .....................................................................................................
Specifications ....................................................................................................
16
16
Troubleshooting ........................................................................................... 17
Warranty & Repair ........................................................................................ 19
Notes and Known Issues ........................................................................ 18

4
Titan CAI - Introduction
The Titan CAI Mini-Recorder is a fully integrated data acquisition system
that features a 16-channel interface with on-board signal conditioning,
programmable gain and filtering, A/D conversion, and built-in data storage via
an SD memory card data recorder. The Mini-Recorder can be powered by the
supplied USB ‘Y’ cable when connected to a PC, or by applying power to the
front panel auxiliary power connector when recording remotely.
This manual is intended to provide an overview of the Titan ICP Mini-
Recorder, with complete feature descriptions, specifications, setup procedures
and operational information. It contains important safety information as well.
Support for this product is available by contacting the factory during regular
business hours (9am – 6pm EST) at 301-470-3278. Additional information
can be found on our web site: http://www.marslabs.com
Introduction
Support
The Titan CAI Mini-Recorder is typically shipped with the following items:
1. Titan CAI Mini-Recorder
2. SD Memory Card
3. Breakout Cables (DB9 to multiple BNC)
A Titan Power Adapter or a mating connector for the Mini-Recorder Auxiliary
Power Connector may also be included.
Furnished Accessories

5
Titan CAI - Introduction
Electrostatic Discharge
Electrostatic Discharge (ESD) occurs when a static charge builds up on
either yourself or the Titan hardware, and then you touch the Titan hardware.
The static spark can be so small that you don’t feel it, however, it can flaw a
semiconductor. These flaws may generate an immediate failure, or, in most
cases, cause a slight reduction in performance which will continue to degrade,
eventually leading to failure of the hardware. When you feel a static shock,
you are experiencing a minimum of 3,000 volts of electricity.
Even though the input connectors have protection to prevent ESD damage,
it is good practice to always ground yourself and the Titan hardware while
connecting and removing sensors.
Always use approved ESD handling procedures to prevent ESD damage.
Grounding Titans
In general, grounding the Titan hardware to the test vehicle or test structure
will usually reduce noise pickup.
All of the analog inputs of the Titan hardware have a return path to ground.
However, it is very important that each senor have only one return path to
avoid ground loops. When testing a vehicle, often the vehicle chassis and
Titan can have very large ground imbalances of one or two volts. In such
situations, ground the senors to Titan and use differential inputs across the
sensor. A totally floating input (like a 9-Volt battery) must have one side
grounded at the point where used, either grounded to Titan or connected to the
vehicle chassis ground via a resistor (e.g. 10K ohm).
If there is a possibility that a floating sensor may be occasionally grounded,
install a 10K ohm resistor from the minus input to Titan ground. When the
sensor is floating, the 10K ohm resistance will reference it to Titan ground,
and when it is grounded, the resistor will allow the direct minus input wire to
reference the remote chassis ground.
Specific Warnings
1. When using a power adapter with the Titan, always connect the adapter
to the Titan before applying power. Never hot plug a Titan device under any
circumstances - hot plugging may damage the device!
2. Under no conditions should the 12V and 5V lines on the Titan hardware be
shorted together or connected directly to ground.
General Guidelines and Warnings

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Titan CAI - Operation
Guidelines for Wiring Sensors
Observe the following guidelines when wiring and connecting sensors to the
Titan hardware:
1. Observe polarity of sensor wires
2. Strain relieve all connections
3. Secure cables with wire ties and bundle cables where possible.
4. Secure DB9 connectors by fastening to the Titan chassis
5. For Thermocouples, apply heat shrink to exposed wires
6. Double check all connections prior to connecting the cables to
the Titan.
7. Use only heavy gauge CAT-6 cables with locking tabs when
connecting to the Titan CPU.
8. When routing cables, be aware of sharp edges and pinch points
where cables can bind, or be cut, introducing shorts in the wiring

7
Titan CAI - Operation
Operation
Front Panel
The Titan CAI front panel incorporates an SD Memory card slot, a
CONTROL toggle switch to initiate remote recording and select calibration
modes, connections for USB, GPS, and Auxiliary Power.
The Auxiliary Power Connector is used to power the Titan CAI in remote
applications. The connector pinout is shown below. The voltage applied to Pin
2 is the operating voltage of the CAI (the operating voltage depends on the
model).
Auxiliary Power Connector
WARNING: When using a power adapter with a Titan device, always connect the
adapter to the device before applying power. Never hot plug a device under any
circumstances - hot plugging may damage the device!
NOTE: The mating connector for 4-pin Auxiliary Power input is available from the
following sources:
Mars Labs - P/N MLCON10227
Description: 4-Pin Female CB and HAM Radio Microphone Plug
Radio Shack - P/N 274-001
Description: 4-Pin Female CB and HAM Radio Microphone Plug
Westlake Electrical Supply - P/N T609B
Description: 4-Pin Inline Female Mobile Connector

8
Titan CAI - Operation
The Titan CAI accepts Ultra II, Extreme III, or Class 10 SD cards. Make
sure to have an SD memory card inserted prior to initiating recording or
configuring tests in the Titan Control Software (TCS) application. In order
to create a test header file on the SD card, you must configure a test in TCS
prior to recording. This is done by creating a new test in TCS, connecting to
the CAI, configuring the sensors, and initiating a Scan. For more information,
consult the TCS User Manual.
SD Card Slot
The CONTROL switch is a multi-function toggle switch that is used to initiate
manual recording and select calibration modes. LEDs to the left and right of the
switch indicate the current status of the CONTROL modes.
Stop Mode – The red STOP LED indicates that the CAI is not in record (REC)
mode. It remains illuminated when scanning, but goes off when recording begins.
Record (REC) Mode – The green REC LED is illuminated when the CAI is
recording. To enter record mode manually, move the toggle switch to the ‘REC’
position and release. To exit record mode, move the toggle switch to the ‘REC’
position a second time and release.
Calibration (CAL) Modes – The CAI offers three calibration modes: ‘CAL-’,
‘CAL+’ and ‘CAL 0’. ‘CAL-’ is indicated by a red LED, ‘CAL+’ is indicated by
a green LED, and ‘CAL 0’ is indicated by both red and green LEDs. When any
of these LEDs are lit, the CAI is in CAL mode. To engage CAL mode, move the
toggle switch to the ‘CAL’ position and release. Successively toggling the switch
will cycle through the three CAL modes as follows:
CAL- →CAL+ →CAL 0 →CAL OFF
CONTROL Switch
NOTE: If you are using memory cards other than the one supplied, those cards must
be formatted prior to use. See page 13 for the procedure on formatting memory cards.

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Titan CAI - Operation
USB Port
A USB Type B port that provides communication between the CAI and the
Titan Control Software (TCS). The port also supplies power to the device.
GPS Port (Auxiliary Digital Input)
A multi-function port that accepts either a GPS sensor (Garmin 18X-5Hz)or
serial data from digital sensors. GPS sensor support is an optional feature on
the Titan CAI.
NOTE: The Titan CAI requires only a single USB connection for power when no
sensors are driven. When sensor excitation is enabled, however, the USB connection
alone may not be able to supply sufficient power to the device and to all connected
sensors. To insure proper operation under these conditions, external power should
be provided through the Auxiliary Power connector.

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Titan CAI - Operation
Rear Panel
The Titan CAI Mini-Recorder rear panel incorporates two LED status
indicators, a communications (COMM) port and DB9 input connectors:
Status Indicators
COMM (currently not implemented)
P (Power) – A green LED indicating that the CAI is ON.
E (Error) – A red LED indicating that a sensor output has meet or exceeded
the range for the configured sensor channel as displayed on the
TCS ‘Tags & Channels’ screen. If the input exceeds this amount,
either positive or negative, the Error LED will be lit for as long
as the input exceeds the maximum range. When the input signal
falls back into the acceptable range the Error LED will go out.
Note that the Error LED will be lit for any channel that exceeds
the maximum range. If you are viewing signals in the Runtime
screen in TCS, the signals will be clipped when they exceed the
maximum allowable input.
An RJ-45 port to interface the CAI with the Titan CPU Channel Multiplexer
and other connectivity options. Integrated LEDs in the connector (RX & TX)
indicate when the Mini-Recorder is receiving or transmitting data through this
port.
CH1-8 / CH9-16
Two DB9 female connectors provide analog input (see pinout diagram, page 14).

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Titan CAI - Operation
Signal Flow
The diagram below shows the signal flow of the Titan CAI Mini-Recorder for a
single input channel. The Titan ICP Mini-Recorder supports up to 16 channels
at 2400 samples per second (Low Speed operation), or up to 60,000 samples per
second (High Speed operation).
The Titan CAI features on-board signal conditioning, programmable gain
and filtering, and A/D conversion. Each channel features sensor Balance*
and Calibration loopback functions (VCal ) to facilitate ease of setup and
ensure data integrity. All channels have individual input amplifiers to achieve
high accuracy, high inter-channel isolation, and low temperature drifts. Data
recording options include recording directly to a PC (via USB), to a Titan CPU
Channel Multiplexer, or internally to an SD memory card.
* Balance is a function that removes channel offsets. It is configured and
controlled via TCS. For more on the Balance function, consult the
TCS User Manual.

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Titan CAI - Interface
Calibration Modes
Calibration modes CAL+ and CAL- places a fixed voltage into the input (if the
calibration type for the channel is set to ‘VCal’). The input is switched over to
the CAL voltage (either positive or negative), and Balance values (if any) are
removed.
CAL+ and CAL-
CAL0 mode activates a common mode short on the input of all channels,
providing an indication of the system offset. Like the CAL+ and CAL- modes,
the balance value for VCal sensors is removed.
CAL0
Calibration for the Titan CAI Mini-Recorder can either be activated from the
panel switch or under control from TCS.

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Titan CAI - Interface
Formatting Memory Cards
New SD memory cards must be formatted for the CAI Mini-Recorder prior to use.
New memory cards should always be formatted in the CAI Mini-Recorder using the
following procedure:
1. If a memory card is inserted, eject the card and power cycle the CAI.
2. In TCS, connect [F1] to the CAI.
3. Insert the SD memory card.
4. In TCS, select ‘Format SD Card (Mini-Recorder)’ from the Device menu:
5. A warning message will be displayed:
6. Click ‘YES’ to proceed and the card will be formatted. When finished,
a “Format Complete’ message will be displayed:
7. Close the message window and disconnect in TCS, or proceed with test
configurations.
NOTES:
1. Memory cards up to 32GB (Ultra II, Extreme III, or Class 10) supported.
2. The maximum file size that a Pod can handle is 2GB. If your anticipated acquisition
approaches or exceeds this amount, enable File Partitioning under “Recording Options” in
TCS and adjust the partition size to ‘1000M’ (1GB). File Partitioning breaks up large test files
into small chunks; when the chunk size limit is reached, the file is closed out and stored, and
a new file is opened. For more on File Partitioning, refer to the TCS User Manual.

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Titan CAI - Interface
Interface
Pinouts for the analog input connector, communications (COMM) port and
GPS port are shown below.
Titan CAI Mini-Recorder provides up to 16 analog inputs on DB9F
connectors. The connector pinouts are shown below.
Analog Input Connector:
Channels 1 - 8
Channels 9 - 16

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Titan CAI - Interface
COMM Port (currently not implemented):
GPS Port:
The pinout of the COMM port appears below. The POWER IN pin is
internally configured at the factory for +5V, +12V or 0V. A label on the side
nearest the COMM connector displays the POWER IN configuration.
The pinout of the GPS port appears below. The labels identify the signal lines
coming from the GPS device.
NOTE: For information on configuring
the COMM port for communication with
TCS instead of using the USB port, refer
to ‘Running with RS-422’ in the TCS
User Manual

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Titan CAI - Specifications
• Supports multiple modes of operation:
- Standalone recording up to 16 channels
- Connected to a PC recording up to 16 channels
• 24 bit analog conversion
• ICP sensor support
• Compact size, light weight and low power make the device suitable for in-vehicle
applications
• Slim form factor permits device stacking to create compact large channel-count systems
• Available in a top-mount 16 channel configuration or rear-mout dual DB9 (8 + 8 channel)
configurations
Features and Specifications
Number of Channels 16 fault tolerant channels on BNC (-23 version) or DB9 (-53 version)
connectors
Sample Rate High Speed Operation: up to 60,00 samples per second per channel
Low Speed Operation: up to 2400 samples per second per channel
Resolution Utilizes 24-bit A/D conversion; 16-bit exported
Programmable Gain From ±1 to ± 8; ±8V full scale input maximum
Programmable Filter 10 pole Linear Phase (High Speed operation)
8 pole Butterworth (Low Speed operation)
Calibration Modes Voltage (VCal): Precision positive and negative calibration voltages
Analog Sensor Support Techometer/Totalizer: Frequencies up to 7KHz
ICP Sensors: 2.5mA current @ 20V compliance
Recorder Records data to Secure Digital memory card.
Supports SD cards up to 32 GB.
PC Operation Remote recording and control via USB
Stand-alone operation Via on-board switches
Power Requirements 11-32VDC, 3W for base unit
Dimensions 13.5cm x 10.6 cm x 3.7 cm (L x W x H)
Breakout Cables DB9 to multiple BNC (included)
Key Features
Specifications

Titan CAI - Troubleshooting
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Troubleshooting
If you are having difficulties configuring, connecting or using your Titan
device, refer to the troubleshooting section below. This section addresses
common issues with the operation of Titan devices. If your specific issue is
not addressed, please contact the factory for additional assistance.
This section under development

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Titan CAI - Notes and Known Issues
Notes and Known Issues
This section offers additional operational information about the Titan CAI Mini-Recorder not
covered elsewhere.
Frequency Measurements
1. The Titan CAI supports a single frequency sensor on channel 8 only.
2. The frequency sensor input requires an input of 2Vpp or greater to function correctly. If
there is a negative offset on the input signal, the signal may need to be boosted to register
correctly.
3. With a timebase setting of 50,000, the lowest value that the frequency input can read is
800 mHz (0.8 Hz). Lower values will be rounded down to zero.
DC Inputs
1. Channels configured for a DC input have an offset of -2.048V. To create a balanced
signal, you must add an offset of 2.048V.
Input Dividers
1. Unlike other Titan Input Modules, the CAI does not have input divider circuitry,
therefore enabling input dividers in TCS will have no effect.

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Titan CAI - Warranty & Repair
Mars Labs warrants all their manufactured equipment to be free from defects in material and
workmanship. Mars Labs liability under this warranty is limited to servicing or adjusting any
equipment returned to the factory for that purpose, and to replace any defective parts thereof.
The warranty remains effective for 365 days following delivery to the original purchaser.
During this time, equipment will only receive repair when the original purchaser prepays all
return transportation charges, and Mars Labs finds to its satisfaction that the equipment is
indeed defective.
If the fault has been caused been misuse or abnormal conditions of operation, normal service
charges will prevail. In this case, an estimate will be submitted before work is started. Mars
Labs must authorize any warranty returns.
Mars Labs reserves the right to make changes in the design of its instruments without
incurring any obligation to make the same changes on equipment previously purchased.
This warranty will be void if unauthorized alterations or modifications are found which
impede the repair or testing of the equipment.
Warranty
The equipment should be tested as soon as it is received. If the equipment is damaged in any
way, a claim should be obtained by the claim agent, and this report should be forwarded to
Mars Labs.
Mars Labs will then advise the customer of the disposition to be made of the equipment and
arrange for repair or replacement. When referring to this equipment for any reason, the model
number, serial number and purchase order number should be included.
Receipt of Equipment
If the unit fails to operate, or any fault develops, Mars Labs should be notified, giving full
details of the difficulty, including model number and serial number. Upon receipt of this
information, Mars Labs will provide service data and shipping instructions.
This warranty is expressly in lieu of all other obligations or liabilities on the part of Mars
Labs, which neither assumes nor authorizes any person to assume for it any other liability in
connection with the sale of its equipment. Contact:
Mars Labs
29 C Street
Laurel, MD
20707
[phone]
email: [email protected]
Malfunction