Pickering 40-191B User manual

pickeringtest.com
Issue 2.1 August 2023
40-191B User Manual
PXI 30 A Fault Insertion Switch Module

Page (II) 30A FAULT INSERTION SWITCH MODULE 40-191B
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Page (II) REED RELAY MODULE 40-110/115/120/125
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© COPYRIGHT (2023) PICKERING INTERFACES. ALL RIGHTS RESERVED.
No part of this publication may be reproduced, transmitted, transcribed, translated or stored in any form, or by
any means without the written permission of Pickering Interfaces.
Technical details contained within this publication are subject to change without notice.
ISO 9001
Reg No. FM38792

Page (III)
30A FAULT INSERTION SWITCH MODULE 40-191B
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Page (III)
REED RELAY MODULE 40-110/115/120/125
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TECHNICAL SUPPORT
For Technical Support please contact Pickering Interfaces either by phone, the website or via e-mail.
WARRANTY
All products manufactured by Pickering Interfaces are warranted against defective materials and workmanship for a period of
three years, excluding programmable power supplies, from the date of delivery to the original purchaser. Any product found to be
defective within this period will, at the discretion of Pickering Interfaces be repaired or replaced.
Products serviced and repaired outside of the warranty period are warranted for ninety days.
Extended warranty and service are available. Please contact Pickering Interfaces by phone, the website or via e-mail.
ENVIRONMENTAL POLICY
Pickering Interfaces operates under an environmental management system similar to ISO 14001.
Pickering Interfaces strives to full all relevant environmental laws and regulations and reduce wastes and releases to the
environment. Pickering Interfaces aims to design and operate products in a way that protects the environment and the health and
safety of its employees, customers and the public. Pickering Interfaces endeavours to develop and manufacture products that can
be produced, distributed, used and recycled, or disposed of, in a safe and environmentally friendly manner.
Worldwide Technical Support and Product Information
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Germany
Tel: [phone]
E-mail: [email protected]
Sweden
Tel: [phone]
E-mail: [email protected]
USA
Tel: (West) [phone]
Tel: (East) [phone]
E-mail: [email protected]
Czech Republic
Tel: [phone]
E-mail: [email protected]
France
Tel [phone]
E-mail [email protected]
Pickering Interfaces Headquarters
Stephenson Road Clacton-on-Sea CO15 4NL United Kingdom
Tel: [phone]
E-Mail: [email protected]
China
Tel: [phone]
E-mail: [email protected]

Page (IV) 30A FAULT INSERTION SWITCH MODULE 40-191B
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Page (IV) REED RELAY MODULE 40-110/115/120/125
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MEANING / DESCRIPTION SYMBOL
PROTECTIVE EARTH (GROUND)
To identify any terminal which is intended for connection to an external conductor for
protection against electric shock in case of a fault, or the terminal of a protective earth
(ground) electrode.
DANGEROUS VOLTAGE
To indicate hazards arising from dangerous voltages.
WARNING / CAUTION
An appropriate safety instruction should be followed or caution to a potential hazard
exists.
Refer to the relevant instructions detailed within the product manual.
HEAVY
If this product is heavy reference should be made to the safety instructions for
provisions of lifting and moving.
STATIC SENSITIVE
To indicate that static sensitive devices are present and handling precautions should
be followed.
!
kg
SAFETY SYMBOLS
PRODUCT SAFETY
The following safety symbols may be used on the product and throughout the product documentation.

Page (V)
30A FAULT INSERTION SWITCH MODULE 40-191B
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Copyright Statement ...................................................................II
Technical Support and Warranty................................................III
Product Safety .............................................................................IV
Contents (this page)....................................................................V
Warnings and Cautions ..............................................................VII
Section 1
Technical Specication...............................................................1.1
Section 2
Technical Description .................................................................2.1
Functional Description..........................................................2.1
Hardware Interlock ................................................................2.2
Section 3
Installation....................................................................................3.1
Pre Operation Checks...........................................................3.1
Hardware Installation ............................................................3.2
Software Installation .............................................................3.2
Testing Operation ..................................................................3.3
Section 4
Programming Guide....................................................................4.1
Programming Options For Pickering PXI Modules ............4.1
Module Architecture..............................................................4.2
Programming The Module ....................................................4.3
Section 5
Connector Information................................................................5.1
Section 6
Trouble Shooting .........................................................................6.1
Section 7
Maintenance Information............................................................7.1
Switching System Test Tools ...............................................7.1
Relay Lookup Tables.............................................................7.1
Appendix A
Interlock Connector Wiring ........................................................A.1
CONTENTS

Page (VI) 30A FAULT INSERTION SWITCH MODULE 40-191B
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THIS PAGE INTENTIONALLY BLANK

Page (VII)
30A FAULT INSERTION SWITCH MODULE 40-191B
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Page (VII)
2 AMP 1-POLE UHD MATRIX MODULES 40-575 / 576 / 577 / 578 / 579
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WARNINGS AND CAUTIONS
WARNING - HAZARDOUS ENVIRONMENTS SYMBOL
This product is not specically designed for use in hazardous environments, for example in explosive
atmospheres. If the product is to be used in hazardous environments we recommend that the user
ensures suitable protective measures are taken.
!
WARNING - DANGER OF ELECTRIC SHOCK SYMBOL
This module may contain hazardous voltages. Before removing the module from the rack remove all
supplies and disconnect user I/O signals.
Unused slots in the host chassis are populated with blanking plates to prevent access to user I/O
signals that may be present. Blanking panels are available to order from Pickering in a variety of
slot widths. If the product is not used in this manner for example by using an extender card then
additional care must be taken to avoid contact with exposed signals.
Not to be used in safety critical circuits, refer to the Pickering Interfaces’ terms & conditions of sale.
This module must not be used for the switching of Mains Circuits. For the switching of voltages up
to the module’s full specication, Secondary Circuit power supplies and the Device Under Test must
be fully isolated from the Mains Circuit and the safety earth.
The host chassis must be correctly installed and be connected to mains or factory safety ground,
please refer to your chassis installation manual.
Diagram Showing Separation Between The Mains Circuit and Secondary Circuit / DUT
For the purposes of this document, a Mains Circuit is an installation classied as Overvoltage
Category II up to 300V. Separation between the Secondary Circuit and Mains Circuit is achieved
by a transformer in which the primary windings are separated from the secondary windings by
reinforced insulation, double insulation, or a screen connected to the protective conductor terminal.
CAUTION - HANDLING OF ELECTROSTATIC-SENSITIVE DEVICES SYMBOL
Certain semiconductor devices used in this equipment are liable to damage due to static voltage.
Observe the following precautions when handling these devices in their unterminated state, or
sub-assemblies containing these devices:
1. Persons removing sub-assemblies from equipment using these devices must be earthed by a
wrist strap and a resistor at the point provided on the equipment.
2. Soldering irons used during the repair operations must be low voltage types with earthed tips and
isolated from the mains voltage by a double insulated transformer.
3. Outer clothing worn must be unable to generate static charges.
4. Printed Circuit Boards (PCBs) tted with these devices must be stored and transported in
anti-static bags.
PXI Switching
Module
Device
Under Test
Power
Supply
Power
Supply
Host Chassis
Secondary Circuit
Mains
Circuit
Mains
Circuit
Mains/Factory
Safety Ground

Page (VIII) 30A FAULT INSERTION SWITCH MODULE 40-191B
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Page (VIII) 2 AMP 1-POLE UHD MATRIX MODULES 40-575 / 576 / 577 / 578 / 579
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CAUTION - PRODUCT DOCUMENTATION SYMBOL
Suitably qualied & trained users should ensure that the accompanying documentation is fully read
and understood before attempting to install or operate the product.
!
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
All cleaning and servicing requires the equipment to be isolated and disconnected from the power source and user I/O
signals (refer to the Maintenance Section).
• Appropriate manual handling procedures should be followed as dictated by the weight of the individual module or
the combined weight of the modules & chassis.
• Should a fault occur with the module or chassis, immediately isolate and disconnect the incoming power to the
chassis and the user I/O signals.
• Ensure the equipment is installed, operated and maintained by trained and authorised personnel.
• For suitably equipped products in the event of an emergency press the red “emergency stop” button situated on
the front of the unit.

Page 1.1
30A FAULT INSERTION SWITCH MODULE 40-191B
pickering SECTION 1 - TECHNICAL SPECIFICATION
SECTION 1 - TECHNICAL SPECIFICATION
Supported by eBIRST
eBIRST switching system test tools simplify switching
system fault-finding by quickly testing the system and
graphically identifying the faulty relay.
For more information go to: pickeringtest.com/ebirst
y6 Fault Insertion Channels
yAvailable With Optional Hardware Interlock
y40 A Single Channel
y30 A Continuous, All Channels
ySimulation of Various Types of Electrical Fault,
Enabling Rigorous Fault Testing
y2 Fault Insertion Buses
yHigh Inrush Current Rating
ySwitch ±40 V Signals (AC or DC)
yDrivers Supplied for Windows and Linux, Plus
Support for Real-time Systems
ySupported by PXI or LXI Chassis
ySupported by
eBIRST ™
y3 Year Warranty
U2
U3
U4
M2
M3
M4
U5
U6
M5
M6
Stimulus/Measurement Connections
UUT Connections
Fault Insertion Bus 2 Fault Insertion Bus 1
Fault Connections
COM1
COM2
U1
M1
40-191B 6-Channel Fault Insertion Switch
Schematic Diagram
The 40-191B is a 6 Channel Fault Insertion switch for fault
simulation in automotive systems. It can carrying 40 A on
single channel or 30 A on all channels at the same time and
provides a robust solution to high current fault insertion.
It is is able to insert 3 different fault conditions between the
test fixture and the equipment under test:
• Open-Circuit
• Short-Circuit between UUT connections
• Short-Circuit to external signals
Through relays allow signals to the UUT to be set open-
circuit. Two fault insertion buses can be used for shorting
channels together or connecting to an external signal such as
power, ignition or ground to simulate fault conditions.
The 40-191B uses solid state switching capable of handling
inrush current of greater than 120 A and peak voltage of 40 V.
With an indefinite number of switching operations the 40-191B
can hot switch AC or DC with no life degradation.
pickeringtest.com
40-191B
PXI 30 A Fault Insertion Switch Modules
Issue 2.0 June 2023

Page 1.2 30A FAULT INSERTION SWITCH MODULE 40-191B
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SECTION 1 - TECHNICAL SPECIFICATION
Model No. Signal Channels Fault Buses Fault Inputs Max Voltage Max Current or Bus Type
40-190B 74, 64 or 32 1 or 2 4 or 8 165 V 2 A
40-191B 6 2 2 40 V 30 A
40-192A 6 2 2 200 V 10 A
40-193A 7 1 or 2 1 or 2 16 V 20 A, 1 A min
40-194A 7 1 or 2 1 or 2 16 V 20 A, no min
40-195 22 or 11 pairs — 8 or 4 150 V 1 A
40-196 10 or 5 pairs — 10 or 5 110 V 5 A
40-197A 34 or 16 4 8 300 V 2 A
40-198 20 1 or 2 3 or 6 250 V 5 A
40-199 10 1 or 2 2 250 V 10 A
40-200 4 or 8 differential 4 8 100 V CAN, FlexRay
40-201 4 or 8 differential 2 4 100 V Ethernet/AFDX/
BroadR-Reach
40-202 22 or 11 pairs — 22 or 11 150 V 1 A
Hardware Interlock
The 40-191B modules are available with an optional
hardware interlock. The interlock, when activated,
will return all relays to their default unpowered state
(assuming the relays are fully functional) and also
provide error notification via the software interface.
The interlock feature can be daisy-chained between
additional hardware interlock enabled modules for
example to allow one signal to disable multiple cards.
For further details please refer to the Hardware
Interlock section within the user manual.
100 Ω
+3.3 V
GND
External
Wire Link
Front Panel
Connector
Interlock
Daisy-chain
Interlock
Detection
Circiuitry
Processor Relay Driver(s)
SPI Serial
Comms
Output Enable
SPI Serial
Comms
Output Enable
Drive
Outputs
To
Relays
Interlock Signal Routing Diagram for 40-191B
Versions With Hardware Interlock Option
Interlock Connector
Pickering’s Range of PXI Fault Insertion Switches
40-191B
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PXI 30 A Fault Insertion Switch Modules