Pickering MBoS User manual

pickeringtest.com
Issue 6.3 July 2023
MBoS User Manual
Modular Breakout System -
Breakout Box & Fault Insertion Unit

MBoS, Modular Breakout System
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Page ii
© 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.
FM38792

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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 fulfil 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:
pickeringtest.com
Pickering Interfaces Headquarters
Stephenson Road, Clacton-on-Sea, CO15 4NL United Kingdom
Tel: [phone]
E-Mail: [email protected]
USA
Tel: (West) [phone]
Tel: (East) [phone]
E-mail: [e-mail]
France
Tel [phone]
E-mail: [email protected]
Germany
Tel: [phone]
E-mail: [email protected]
Sweden
Tel: [phone]
E-mail: [email protected]
Czech Republic
Tel: [phone]
E-mail: [email protected]
China
Tel: [phone]
E-mail: [email protected]
Technical Support

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Page iv
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
The following safety symbols may be used on the product and throughout the product documentation.
Product Safety

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Page v
Copyright Statement......................................................................................................................... ii
Technical Support and Warranty ..................................................................................................... iii
Product Safety.................................................................................................................................. iv
Contents (this page)........................................................................................................................... v
Warnings and Cautions................................................................................................................... vii
Section 1 - Technical Specification................................................................................................. 1.1
MBoS Chassis Mounting Frame.............................................................................. ................ 1.1
MBoS Breakout Modules ........................................... ............................................................. 1.4
Section 2 - Technical Description................................................................................................... 2.1
Introduction ............................................................................................................................. 2.1
MBoS Frame ............................................................................................................................ 2.2
Cabling..................................................................................................................................... 2.2
How to Use the Breakout System............................................................................................ 2.3
Section 3 - Connector Information................................................................................................. 3.1
Pinouts - 95-190B-003 Breakout Module for 40-190B............................................................ 3.2
Pinouts - 95-191-002 Breakout Module for 40-191................................................................. 3.3
Pinouts - 95-192-001 Breakout Module for 40-192................................................................. 3.4
Pinouts - 95-193-001 Breakout Module for 40-193................................................................. 3.5
Pinouts - 95-194-001 Breakout Module for 40-194................................................................. 3.6
Pinouts - 95-196-001 Breakout Module for 40-196................................................................. 3.7
Pinouts - 95-197A-001 Breakout Module for 40-197A ............................................................ 3.8
Pinouts - 95-198-001 Breakout Module for 40-198................................................................. 3.9
Pinouts - 95-199-004 Breakout Module for 40-199............................................................... 3.10
Pinouts - 95-200-001 Breakout Module for 40-200............................................................... 3.11
Pinouts - 95-201-001 Breakout Module for 40-201............................................................... 3.12
Pinouts - 95-293-001 Breakout Module for 40-293............................................................... 3.13
Pinouts - 95-294-001 Breakout Module for 40-294............................................................... 3.15
Pinouts - 95-295-001 Breakout Module for 40-295............................................................... 3.17
Pinouts - 95-296-001 Breakout Module for 40-296............................................................... 3.19
Pinouts - 95-525A-001 Breakout Module for 40-525A .......................................................... 3.21
Contents

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WARNING - Hazardous Environments Symbol
This product is not specifically 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 chassis may be populated with modules that contain hazardous voltages. Before removing any
module from the rack remove all supplies and disconnect user I/O signals.
Unused slots in this 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.
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:
• 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.
• 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.
• Outer clothing worn must be unable to generate static charges.
• Printed Circuit Boards (PCBs) fitted with these devices must be stored and transported in anti-
static bags.
CAUTION - Product Documentation Symbol
Suitably qualified & 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.
Warnings & Cautions

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Page 1.1
Section 1 - Technical Specification
MBoS Chassis Mounting Frame - 95-901
yChassis Mounting Frame for Modular
Breakout System
ySupports Modular Patch Panels
Optimised for Fault Insertion
yDesigned for Pickering PXI, Hybrid
Chassis & LXI Modular Chassis
ySupports Breakouts for Specific
Pickering FIU & Resistor Modules
yMany Breakout Options for Different
Current and/or Voltage Requirements
yCustomized Breakout Versions Available
to Match Specific Requirements
y3 Year Warranty
Designed to Simplify HILS Applications
Traditional HILS (Hardware In the Loop Simulation) features
signal switching for the purpose of injecting faults into a UUT
(Unit Under Test). In addition, a Breakout Box (BoB) is used to
make manual measurements as well as induce faults manually
prior to writing test code. The majority of the BoBs and FIU
systems available today are not modular and are fixed in
configuration, creating test solutions that are limited in scope.
In addition, they have cable configurations that are cumbersome
and in many cases expensive.
Modular in a Single Unit
The low-cost Modular Breakout System combines a BoB
feature set with the added flexibility of an FIU. By mating
the FIU chassis directly to the BoB, cabling is minimized,
creating a more compact reliable design and improving signal
integrity. In addition, all cables to the simulation system and
the UUT are located behind the front panel of the BoB. This
creates a simpler front panel that is less prone to damage.
MBoS System Definition
The MBoS system is based on two common mechanical
frameworks that, with an adaptor plate, can be configured
to suit different chassis types. To aid with selection, part
numbers are defined that include both the framework and
adapter plate. Once the framework has been selected (based
on the required chassis) the user selects the number and
type of breakout module(s) required. To ensure suitability
of the MBoS configuration it is recommended that the local
Pickering sales office is contacted to review the requirements.
Note, due to the physical size of the 18/19-slot chassis the
final right hand side slot in each chassis is not accessible
when used with the MBoS frame. This limitation is not
present on the 7, 8 or 14-slot chassis.
Breakout Modules
allow an easy
connection between
the FIU, Simulator
and UUT
To
Simulation
To UUT
To PXI
Module
The breakout modules are designed for all versions of the
associated module irrespective, for example, of the number
of channels. This commonality reduces spares inventory
and assists with product selection.
Choices for FIU and Breakout System Requirements
As the modular design uses PXI, users can take advantage
of Pickering’s large range of FIU modules - the largest in the
industry. This range of FIU modules is available in different
choices for channel count, fault buses, voltage and current.
Multiple FIU module types can be installed in a chassis. Go to:
pickeringtest.com/products/pxi-switching/fault-signal-insertion
to see the broad range of choices.
In addition, the Breakout modules are optimized for each FIU
module, so it is as customizable as the FIU system.
Modular
Breakout
System: MBoS
Chassis fitted with
an 18-Slot PXI Chassis
and Breakout Modules

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Page 1.2
Section 1 - Technical Specification
Specification
MBoS Frame
Dimensions:
Full width 19 inch rack, 6 U high,
638 mm depth (95-901-00x versions),
838 mm depth (95-901-10x versions).
Chassis
Compatibility:
PXI Chassis: 40-908-x01, 40-914-x01,
40-924-001 & 40-923A-001,
LXI Modular Chassis: 60-102C-001
& 60-103D-001.
Hybrid chassis: 42-924-001,
42-925-001, 42-926-001,
NI PXIe-1084 & NI PXIe-1092
PXI Module
Compatibility:
Breakout modules are available for
specific 1 or 2 slot fault insertion
switch modules and selected
programmable resistor modules.
Breakout Module
Front Panel
Connectors:
2 mm female terminals rated at
30 VAC, 60 VDC, 10 A.
4 mm female terminals rated at
1000 V, 32 A.
See individual Breakout Module data
sheets for more information.
484mm
267mm
672mm (95-901-00x versions)
872mm (95-901-10x versions)
638mm (95-901-00x versions)
838mm (95-901-10x versions)
MBoS Chassis Mounting Frame Dimensions
Breakout Modules are available for specific PXI Fault
Insertion Switches & Programmable Resistors - see
individual Breakout data sheets for details

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Page 1.3
Section 1 - Technical Specification
Product Order Codes - MBoS Support Frame
Small for 40-908-x01, 8-slot chassis
or 40-914-x01, 14-slot chassis
Small for 42-924-001, 8-slot chassis
Small for 40-924-001, 8-slot
or 60-102C-001, 7-slot chassis
95-901-001
95-901-004
95-901-005
Large for 40-923A-001, 19-slot
or 60-103D-001, 18-slot chassis
Large for NI PXIe-1084, 18-slot chassis
Large for 42-925-001, 18-slot chassis
or 42-926-001, 18-slot chassis
Large for NI PXIe-1092, 10-slot chassis
95-901-101
95-901-103
95-901-104
95-901-105
Obsolete:
Small for 40-922-001, 8-slot
or 60-102B-001, 7-slot chassis 95-901-003
Operating/Storage Conditions
Operating Conditions
Operating Temperature:
Humidity:
Altitude:
0 °C to +55 °C
Up to 90 % non-condensing
5000 m
Storage and Transport Conditions
Storage Temperature:
Humidity:
Altitude:
-20 °C to +75°C
Up to 90 % non-condensing
15000 m
Safety & CE Compliance
All modules are fully CE compliant and meet applicable
EU directives: Low-voltage safety EN61010-1:2010,
EMC Immunity EN61326-1:2013,
Emissions EN55011:2009+A1:2010.
Programmable Resistance
Traditional BoB designs feature a manual potentiometer for
creating resistive faults. Pickering can automate this process
using one of our programmable resistance modules for
which a Breakout System module is available. The module
can be controlled manually through a soft front panel as well
as programmatically. This can speed up a test process and
ensure repeatability.
Field Upgradable
If testing needs to change, both Breakout System modules and
FIU modules can be added and/or replaced by the user. The
software driver from Pickering supports our entire FIU range,
so no new software is needed to integrate the new modules.
New Designs
Pickering is always looking to expand our catalog of FIU and
Breakout System options. If you don’t see what you need,
contact us and we will see if we can accommodate your test
requirements.
Breakout Module Capability
The voltage and current specifications of the Breakout System
module’s UUT and simulation ports are matched to the FIU
module for which they are designed, but the front panel 2 mm
terminals are for low voltage (30 VAC/60 VDC) monitoring
purposes only.

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Page 1.4
MBoS Breakout Modules
Section 1 - Technical Specification
yPlugin Module for Modular Breakout System
(MBoS)
yDesigned for Use With Each Family Of
Module
yAllows Separate Cable Harnesses for
Simulator and UUT Signals
ySignal Monitoring Via Individual Front Panel
Terminals
ySuitable for Hardware-in-the-Loop
Simulation Applications
y3 Year Warranty
Breakout modules are designed for use with specific PXI
modules hosted in a Pickering PXI, hybrid or LXI Modular
Chassis which in turn is fitted into a Pickering MBoS frame.
The MBoS system is primarily designed for Hardware-in-
the-Loop simulation applications and combines a Breakout
Box with the Fault Insertion Unit. This minimizes cabling
and creates a compact reliable system with improved
signal integrity. Additionally, all cabling to the UUT and
Simulation system is behind the front of the MBoS creating
a tidier front panel that is less prone to damage.
Example Simplified Application Diagram of an MBoS Breakout Module
(95-190B Breakout Module for use with 40-190B PXI Fault Insertion Switch)
40-190B PXI
Fault Insertion
Switch Module
PXI, Hybrid or LXI Modular Chassis
95-190B-003
MBoS Plugin
Module
Front
Panel
Signal
Monitoring
Terminals
78-Pin D-type Cable
78-Pin D-type Cable
160-Pin
Connection
To Unit
Under Test
From
Simulator
MBoS Frame
U1 to U74
& F5 to F8
Signals
M1 to M74
& F1 to F4
Signals
The breakout module plugs directly onto the front panel
connector of the PXI module, and signals for the UUT and
Simulation system are accessible via separate connectors
(same connector family as PXI module front panel) located
toward the rear face of the breakout module. Signals
are also routed to front panel 2mm or 4mm (current
dependent) terminals for monitoring purposes. For more
information on the MBoS system and to see other products
in the range, go to:
pickeringtest.com/products/connectivity-cables/modular-breakout-system

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Page 1.5
Section 1 - Technical Specification
Specification - 95-190B-003
PXI Module Compatibility: 40-190B series of PXI 2 A
Fault Insertion Switches.
Breakout Module Size 2 slot width
PXI Module Connector: 160-pin female DIN 41612
UUT Connector: 78-pin female D-type
Simulator Connector: 78-pin male D-type
Front Panel Connectors: 2 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 2 A
Front Panel Connector
Rating: 30 VAC, 60 VDC, 10 A
Specification - 95-191-002
PXI Module Compatibility: 40-191 30 A PXI Fault
Insertion Switch module.
Breakout Module Size 2 slot width
PXI Module Connectors: 2x 8-pin female power D-type
UUT Connector: 8-pin female power D-type
Simulator Connector: 8-pin female power D-type
Front Panel Connectors: 4 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 30 A
Front Panel Connector
Rating: 1000 V, 32 A
Specification - 95-192-001
PXI Module Compatibility: 40-192 PXI 10 A Fault
Insertion Switch module.
Breakout Module Size 2 slot width
PXI Module Connectors: 2x 8-pin female power D-type
UUT Connector: 8-pin female power D-type
Simulator Connector: 8-pin female power D-type
Front Panel Connectors: 2 mm female terminals for
U & M signals.
4 mm female terminals for
COM signals.
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 30 A
Front Panel Connector
Rating: 30 VAC/60 VDC, 10 A (2 mm
terminals)
1000 V, 32 A (4 mm terminals)
Specification - 95-193-001
PXI Module Compatibility: 40-193 PXI 20 A Fault
Insertion Switch modules.
Breakout Module Size 2 slot width
PXI Module Connectors: 2x 8-pin female power D-type
UUT Connector: 8-pin female power D-type
Simulator Connector: 8-pin female power D-type
Front Panel Connectors: 4 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 30 A
Front Panel Connector
Rating: 1000 V, 32 A
Specification - 95-194-001
PXI Module Compatibility: 40-194 PXI 20 A Fault
Insertion Switch modules.
Breakout Module Size 2 slot width
PXI Module Connectors: 2x 8-pin female power D-type
UUT Connector: 8-pin female power D-type
Simulator Connector: 8-pin female power D-type
Front Panel Connectors: 4 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 30 A
Front Panel Connector
Rating: 1000 V, 32 A
Available Breakout Modules
The currently available Breakout modules are listed below
and the following tables outline their specifications.
• 95-190B-003 for 40-190B 2 A Fault Insertion Switch
• 95-191-002 for 40-191 30 A Fault Insertion Switch
• 95-192-001 for 40-192 10 A Fault Insertion Switch
• 95-193-001 for 40-193 20 A Fault Insertion Switch
• 95-194-001 for 40-194 20 A Fault Insertion Switch
• 95-196-001 for 40-196 5 A Fault Insertion Switch
• 95-197A-001 for 40-197A 2 A Fault Insertion Switch
• 95-198-001 for 40-198 5 A Fault Insertion Switch
• 95-199-004 for 40-199 10 A Fault Insertion Switch
• 95-200-001 for 40-200 Differential Bus Fault Switch
• 95-201-001 for 40-201 Ethernet Fault Insertion Switch
• 95-293-001 for 40-293 Programmable Resistor & Relay
• 95-294-001 for 40-294 Programmable Resistor & Relay
• 95-295-001 for 40-295 Programmable Resistor Module
• 95-296-001 for 40-296 Programmable Potentiometer
• 95-525A-001 for 40-525A Signal Insertion & Monitor

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Page 1.6
Section 1 - Technical Specification
Specification - 95-197A-001
PXI Module Compatibility: 40-197A PXI 2 A Fault
Insertion Switch modules.
Breakout Module Size 2 slot width
PXI Module Connector: 78-pin female D-type
UUT Connector: 78-pin female D-type
Simulator Connector: 78-pin male D-type
Front Panel Connectors: 2 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 2 A
Front Panel Connector
Rating: 30 VAC, 60 VDC, 10 A
Specification - 95-198-001
PXI Module Compatibility: 40-198 PXI 5 A Fault Insertion
Switch modules.
Breakout Module Size 1 slot width
PXI Module Connector: 50-pin female D-type
UUT Connector: 50-pin female D-type
Simulator Connector: 50-pin male D-type
Front Panel Connectors: 2 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 2 A
Front Panel Connector
Rating: 30 VAC, 60 VDC, 10 A
Specification - 95-199-001
PXI Module Compatibility: 40-199 PXI 10 A Fault
Insertion Switch modules.
Breakout Module Size 1 slot width
PXI Module Connectors: 20-pin female GMCT
& 3-pin female power D-type
UUT Connector: 20-pin female GMCT
Simulator Connectors: 20-pin male GMCT
& 3-pin male power D-type
Front Panel Connectors: 2 mm female terminals for
U & M signals.
4 mm female terminals for
F1 & F2 signals.
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 30 A
Front Panel Connector
Rating: 30 VAC/60 VDC, 10 A (2 mm
terminals)
1000 V, 32 A (4 mm terminals)
Specification - 95-200-001
PXI Module Compatibility: 40-200 PXI Differential Bus
Fault Insertion Switches.
Breakout Module Size 1 slot width
PXI Module Connector: 78-pin female D-type
UUT Connector: 78-pin female D-type
Simulator Connector: 78-pin male D-type
Front Panel Connectors: 2 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 2 A
Front Panel Connector
Rating: 30 VAC, 60 VDC, 10 A
Specification - 95-201-001
PXI Module Compatibility: 40-201 PXI Ethernet Fault
Insertion Switch modules.
Breakout Module Size 1 slot width
PXI Module Connector: 78-pin female D-type
UUT Connector: 78-pin female D-type
Simulator Connector: 78-pin male D-type
Front Panel Connectors: 2 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 2 A
Front Panel Connector
Rating: 30 VAC, 60 VDC, 10 A
Specification - 95-196-001
PXI Module Compatibility: 40-196 PXI 5 A Fault Insertion
Switch modules.
Breakout Module Size 1 slot width
PXI Module Connector: 50-pin female D-type
UUT Connector: 50-pin female D-type
Simulator Connector: 50-pin male D-type
Front Panel Connectors: 2 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 2 A
Front Panel Connector
Rating: 30 VAC, 60 VDC, 10 A

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Page 1.7
Section 1 - Technical Specification
Operating/Storage Conditions
Operating Conditions
Operating Temperature:
Humidity:
Altitude:
0 °C to +55 °C
Up to 90 % non-condensing
5000 m
Storage and Transport Conditions
Storage Temperature:
Humidity:
Altitude:
-20 °C to +75 °C
Up to 90 % non-condensing
15000 m
Safety & CE Compliance
All modules are fully CE compliant and meet applicable
EU directives: Low-voltage safety EN61010-1:2010,
EMC Immunity EN61326-1:2013,
Emissions EN55011:2009+A1:2010.
Specification - 95-294-001
PXI Module Compatibility: 40-294 series of PXI
Programmable Resistor &
Relay modules.
Breakout Module Size 1 slot width
PXI Module Connector: 37-pin female D-type
UUT Connector: 78-pin female D-type
Simulator Connector: 78-pin male D-type
Front Panel Connectors: 2 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 2 A
Front Panel Connector
Rating: 30 VAC, 60 VDC, 10 A
Specification - 95-295-001
PXI Module Compatibility: 40-295 series of PXI
Programmable Resistor
modules.
Breakout Module Size 1 slot width
PXI Module Connector: 37-pin female D-type
UUT Connector: 37-pin female D-type
Simulator Connector: 37-pin male D-type
Front Panel Connectors: 2 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 2 A
Front Panel Connector
Rating: 30 VAC, 60 VDC, 10 A
Specification - 95-296-001
PXI Module Compatibility: 40-296 series of PXI
Programmable
Potentiometer modules.
Breakout Module Size 1 slot width
PXI Module Connector: 37-pin female D-type
UUT Connector: 37-pin female D-type
Simulator Connector: 37-pin male D-type
Front Panel Connectors: 2 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 2 A
Front Panel Connector
Rating: 30 VAC, 60 VDC, 10 A
Specification - 95-525A-001
PXI Module Compatibility: 40-525A PXI Signal Insertion
& Monitor Matrix modules.
Breakout Module Size 2 slot width
PXI Module Connector: 78-pin female D-type
UUT Connector: 78-pin female D-type
Simulator Connectors: 78-pin male D-type
Front Panel Connectors: 2 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 2 A
Front Panel Connector
Rating: 30 VAC, 60 VDC, 10 A
Specification - 95-293-001
PXI Module Compatibility: 40-293 series of PXI
Programmable Resistor &
Relay modules.
Breakout Module Size 1 slot width
PXI Module Connector: 37-pin female D-type
UUT Connector: 37-pin female D-type
Simulator Connector: 37-pin male D-type
Front Panel Connectors: 2 mm female terminals
UUT/Simulator Connector
Voltage Rating: 300 VDC
UUT/Simulator Connector
Current Rating: Up to 2 A
Front Panel Connector
Rating: 30 VAC, 60 VDC, 10 A

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Page 1.8
Section 1 - Technical Specification
Mating Connectors & Cabling
For connection accessories for the 95 series of breakout
module, please refer to the Connector Accessories data
sheets for the connector type used. A complete list of
available connector types and supporting documentation
can be found on the connectivity page of out website.
Product Order Codes
MBoS Breakout Module for:
40-190B 2A Fault Insertion Switch
40-191 30A Fault Insertion Switch
40-192 10A Fault Insertion Switch
40-193 20A Fault Insertion Switch
40-194 20A Fault Insertion Switch
40-196 5A Fault Insertion Switch
40-197A 2A Fault Insertion Switch
40-198 2A Fault Insertion Switch
40-199 10A Fault Insertion Switch
40-200 Differential Fault Insertion Switch
40-201 Ethernet Fault Insertion Switch
40-293 Programmable Resistor & Relay
40-294 Programmable Resistor & Relay
40-295 Programmable Resistor
40-296 Programmable Potentiometer
40-525A Signal Insertion & Monitor Matrix
95-190B-003
95-191-002
95-192-001
95-193-001
95-194-001
95-196-001
95-197A-001
95-198-001
95-199-004
95-200-001
95-201-001
95-193-001
95-194-001
95-195-001
95-196-001
95-525A-001
Product Customization
Pickering modules are designed and manufactured on our
own flexible manufacturing lines, giving complete product
control and enabling simple customization to meet very
specific requirements.
All customized products are given a unique part number,
fully documented and may be ordered at any time in the
future. Please contact your local sales office to discuss.

MBoS, Modular Breakout System
pickeringtest.com
Page 2.1
Section 2 - Technical Description
Breakout
Module
PXI Module
PXI, Hybrid or LXI Modular Chassis
MBoS Frame
Cabling to Unit Under Test
(routed from back of MBoS frame)Cable Assembly
Cable Assembly Cabling from Simulator
(routed from back of MBoS frame)
Introduction
The MBoS is a system specifically designed for HILS (Hardware In the Loop Simulation) applications. It integrates a
Pickering chassis (PXI, Hybrid or LXI Modular) and Pickering PXI fault insertion switch and selected programmable resistor
modules into a specially designed rack mounted unit. Connection to the user’s unit under test and simulation system is
simplified by the use of breakout modules that mate with the front panel connector of the PXI modules and route the signals
to dedicated connectors for UUT and simulation signals. The breakout module also routes the PXI module’s signals to
individual front panel terminals allowing the user to connect measurement equipment, manually route signals or introduce
fault conditions.
In addition to the PXI, Hybrid or LXI Modular chassis and PXI modules required for a particular application, the system
consists of an MBoS frame, breakout modules for the PXI modules and cabling to the unit under test and simulation system.
This is outlined in Figure 2.1 below.
Figure 2.1 - Components of the MBoS
MBoS Frame
The MBoS frame is a 19 inch full rack width mounting frame for a PXI, Hybrid or LXI chassis. Breakout modules mount on
the front of the frame and mate with the front panels of the PXI modules installed in the chassis. The frame has sufficient
clearance above and below the chassis to allow cabling to be routed in a way best suited to the application - this would
usually be out of the rear of the frame.
The MBoS frame is available in two sizes: The small size is compatible with Pickering’s 7-slot LXI, 8-slot PXI, 14-slot PXI and
8-slot hybrid chassis (40-908, 40-914, 40-924, 42-924 and 60-102C), the large size is compatible with Pickering's 18-slot LXI,
19-slot PXI and 18-slot hybrid chassis (40-923A, 42-925, 42-926, 60-103D) as well as hybrid chassis from NI (NI PXIe 1084
and NI PXIe 1092). See page 1.3 for part numbers for the MBoS frames for a specific chassis.
Each chassis type has an adapter plate that is used to secure the chassis to one of the two standard MBoS frames.
Note: Cable routing may be dictated by chassis type. The chassis mentioned above allow access for cables both under and
over the chassis.
Warning: Due to the physical size of the 40-923A, 42-925, 42-926 and 60-103D chassis the final PXI slot in each chassis
is not accessible when used with the MBoS frame. This limitation is not present on the 40-908, 40-914, 40-924, 42-924
or 60-102C chassis.

MBoS, Modular Breakout System
pickeringtest.com
Page 2.2
Breakout Modules
These are available or a wide variety of single and dual slot PXI Fault Insertion switch modules made by Pickering as well as
selected Programmable Resistor modules. A Breakout Module is designed to mate with the front panel connector(s) of a specific
PXI module fitted into a PXI, Hybrid or LXI chassis which is in turn fitted into the MBoS frame. The user signals from the PXI
module are routed to the front panel of the Breakout Module where they are accessible via individual terminals. It should be noted
that in some cases, not all signals are routed due to limited space and pin count restrictions. The user signals are grouped within
the Breakout Module according to function and routed to a male connector to the Measurement/Simulation system and a female
connector to the Unit Under Test. These connectors are mounted on the rear of the Breakout Module and allow easy attachment
and routing of cabling to the rest of the test system.
Breakout Modules are available for the following PXI modules.:
• 40-190B - 32, 64 or 74-Channel, 2 A Fault Insertion Switches
• 40-191 - 6-Channel, 30 A Fault Insertion Switch
• 40-192 - 6-Channel, 10 A Fault Insertion Switch
• 40-193 - 7-Channel, 20 A Fault Insertion Switch
• 40-194 - 7-Channel, 20 A Fault Insertion Switch
• 40-196 - 10 or 5-Channel, 5 A Fault Insertion Switches
• 40-197A - 34 or 16-Channel, 2 A Fault Insertion Switches
• 40-198 - 20-Channel, 5 A Fault Insertion Switch
• 40-199 - 10-Channel, 10 A Fault Insertion Switch
• 40-200 - 4 or 8-Channel, CAN/FlexRay/Differential Bus Fault Insertion Switches
• 40-201 - 4 or 8-Channel, Ethernet/AFDX/BroadR-Reach Fault Insertion Switches
• 40-293 - Programmable Resistor & Relay Modules
• 40-294 - Programmable Resistor & Relay Modules
• 40-295 - Programmable Resistor Modules
• 40-296 - Programmable Potentiometer Modules
• 40-525A - 32x4 or 16x4 Signal Insertion & Monitor Matrices
It should be noted that in some cases, not all signals are routed due to limited space and pin count restrictions. In addition, the
individual front panel terminals may be a limiting factor for the applied signals due to the specification of 2mm (maximum voltage
of 30 VAC/60VDC) & 4mm (maximum current of 32 A) terminals.
Currently Breakout Modules are available for a sub-set of the available product ranges of programmable resistor modules.
Contact us for Breakout Module support for alternative resistor modules or for any other PXI module.
The signal terminals on the front panel of the Breakout Module are grouped according to function and color coded to aid easy
identification. Pickering can manufacture Breakout Modules color coded to suit the customer’s application. Also, front panel
labelling can be customized on request with specific text or symbols.
Cabling
All connections to the UUT are via female connectors and exit at the top of the MBoS frame, all Simulator connections are via male
connectors exit at the bottom. This helps to differentiate between wiring harnesses which can be routed via the back of the frame
to the rest of the test system.
Pickering can supply cabling solutions for wiring the MBoS unit to the customer's unit under test and simulation system. Cables
with custom lengths and a choice of terminating connectors can be manufactured to exactly meet the customer’s requirements.
Section 2 - Technical Description

MBoS, Modular Breakout System
pickeringtest.com
Page 2.3
Section 2 - Technical Description
How to Use The Breakout System
Once the MBoS has been integrated into a test system, the terminals on the front panel of the Breakout Modules can be used in a
number of ways:
• Manually simulate short and open circuit conditions between signals to confirm a test process before it is automated using the
fault insertion module.
• Manually short signals together without the use of the fault insertion module's fault bus.
• Inject low level signals (limited to 30 VAC/60 VDC for signals using 2 mm front panel terminals) or fault conditions without the
use of the module's fault bus.
• Monitor applied signals (provided that they are within 30 VAC/60 VDC for signals using 2 mm front panel terminals).
An example MBoS system is shown in Figure 2.2 which includes 40-190B and 40-199 PXI Fault Insertion Switch modules as well
as a 40-294 PXI Programmable Resistor module. Figures 2.3 to 2.18 give detailed diagrams of the individual PXI modules and how
their signals interface with the corresponding Breakout Module.
Please contact your local Pickering sales office to discuss your own MBoS system requirements. In order to reduce integration
time, Pickering can supply the MBoS fully assembled with a chassis and PXI modules of the customer's choice, fitted into an MBoS
frame with the required Breakout Modules and all wiring ready for connecting to the customer's test system.

MBoS, Modular Breakout System
pickeringtest.com
Page 2.4
Section 2 - Technical Description
40-199 10A Fault
Insertion Switch
PXI, Hybrid or LXI Host Chassis
40-190B 2A Fault
Insertion Switch
40-294 Programmable
Resistor & Relay
Module
PXI Controller
Module
To Unit
Under
Test
From
Simulator
Front
Panel
Breakout
Terminals
95-199-004
Breakout
Module
Front
Panel
Breakout
Terminals
95-190B-003
Breakout
Module
Front
Panel
Breakout
Terminals
95-294-001
Breakout
Module
PXI Backplane
Control
Computer
(PXI or Hybrid
Chassis)
or Ethernet
(LXI Chassis)
MBoS Frame
For more
details on
the 40-190B
and its
breakout
module see
Figure 2.3
For more
details on
the 40-199
and its
breakout
module see
Figure 2.11
For more
details on
the 40-294
and its
breakout
module see
Figure 2.15
Figure 2.2 - System Diagram For Typical Application of the MBoS With 40-190B & 40-199 PXI Fault Insertion Switch
Modules and a 40-294 PXI Programmable Resistor Module

MBoS, Modular Breakout System
pickeringtest.com
Page 2.5
Section 2 - Technical Description
Front
Panel
Breakout
Terminals
40-190B PXI 2A Fault Insertion
Switch Module
95-190B-003
Breakout
Module
PXI
Backplane
Interface
PXI, Hybrid
or LXI Host
Chassis
Connections to Unit Under Test
(78-Pin Female D-Type)
Connections From Simulator
(78-Pin Male D-Type)
U1
U2
U3
U73
U74
M1
M2
M3
M73
M74
F1
F2
F3
F4
MON1
F5
F6
F7
F8
MON2
PXI Module’s Connector
(160-Pin Male DIN 41612)
NOTE: The 40-190B terminals
“MON1” and “MON2” are not connected
within the Breakout Module
For pinout
details of the
95-190B-003
breakout
module see
Figure 3.1
Figure 2.3 - Schematic For 40-190B 2A Fault Insertion Switch and 95-190B-003 Breakout Module
(see Figure 3.1 for pinout information)

MBoS, Modular Breakout System
pickeringtest.com
Page 2.6
Section 2 - Technical Description
Figure 2.4 - Schematic For 40-191 30A Fault Insertion Switch and 95-191-002 Breakout Module
(see Figure 3.2 for pinout information)
Front
Panel
Breakout
Terminals
40-191 PXI 30A Fault Insertion Switch Module 95-191-002
Breakout
Module
PXI
Backplane
Interface
PXI, Hybrid
or LXI Host
Chassis
Connections to Unit Under Test
(8-Pin Female Power D-Type)
Connections From Simulator
(8-Pin Male Power D-Type)
COM2
U1
U2
U3
U4
U5
U6
M1
M2
M3
M4
M5
M6
COM1
PXI Module’s Connectors
(2x 8-Pin Male Power D-types)
For pinout
details of the
95-191-002
breakout
module see
Figure 3.2