Zodiac PRO User manual

Prototyping / Extension Modules
User’s Manual
Document No.: MUT300082E1R1
02 – 2017
PRO/EXT

THIS DOCUMENT IS THE PROPERTY OF ZODIAC DATA SYSTEMS UNDER THE COPYRIGHT LAWS,
IT MUST NOT BE REPRODUCED OR TRANSMITTED IN ANY FORM, ELECTRONIC OR MECHANICAL,
INCLUDING PHOTOCOPYING, RECORDING, STORING IN AN INFORMATION RETRIEVAL SYSTEM, OR
TRANSLATING, IN WHOLE OR IN PART WITHOUT PRIOR WRITTEN APPROVAL OF ZODIAC DATA SYSTEMS
ZODIAC DATA SYSTEMS RESERVES THE RIGHT TO AMEND THIS USER’S MANUAL WITHOUT NOTICE

MUT300082E1R1 — 02 – 2017 i
TABLE OF CONTENT
TABLE OF CONTENT
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 About this User’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2.1 PRO module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2.2 EXT module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Transportation, storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. OVERVIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Physical overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1 PRO module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.2 EXT module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Power capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 User defined electronic board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2.1 PRO Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2.2 PRO / EXT Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2.3 Filling material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Potting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.1 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.2 Mezzanine board preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.3 Mount the mezzanine board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.4 EXT module (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.5 Preliminary clean-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.6 PRO and EXT assembly (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3.7 Potting tool installation (PRO only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.8 Potting tool installation (PRO+EXT only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3.9 Potting material preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3.10 Expected result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 eZ software installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Physical layer configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Configuration using eZ software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Troubleshooting and status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5. CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

ii PRO/EXT — User’s Manual
TABLE OF CONTENT
5.2 Input/Output connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6. MAINTENANCE AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7. GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

MUT300082E1R1 — 02 – 2017 1
INTRODUCTION
1. INTRODUCTION
1.1 About this User’s Manual
This User’s Manual includes the information necessary for the installation and operation of the PRO/EXT modules.
This document describes external interfaces and how to configure these modules with eZ Software.
Read this document completely before using these module.
1.2 General information
PRO/EXT modules allow hardware customization of the DAU embedding user defined electronics.
Traditionally, these features were embedded in the harness or in additional external boxes leading to complex me-
chanical integration and non-flexible costly solutions.
The user can implement a specific board or a wire based solution. Its electronics can be either passive or active,
the PRO module provides power supply from the DAU stack to the user defined electronics.
1.2.1 PRO module
The PRO module is installed as a standard module.
1.2.2 EXT module
The EXT module must be associated with a PRO module to provide more component height and I/O capabilities for
the user electronics. It avoids having Y cables in an application where inputs are coming from an A/C cabling sys-
tem, being adapted in the PRO / EXT modules before going to another module (e.g. the ANA module).
1.3 Reference Documents
RD1 MUT300107 XMA/CMA System Reference
RD2 MUT300059 XMA Series Assembly/Disassembly instructions
RD3 MUT300049 eZ Software User’s Manual
RD4 MUT300053 XMA/CMA Series Status Reference Manual
RD5 FTP300057 XMA PRO/EXT Datasheet
RD6 FTP300110 CMA PRO/EXT Datasheet

2PRO/EXT — User’s Manual
Safety
1.4 Safety
Observing the safety instructions will help prevent personal injury or damage to the device. Therefore, carefully
read through and adhere to safety instructions before using this equipment. It is also absolutely essential to
observe the additional safety instructions on personal safety that appear in first chapter of [RD1].
1.5 Transportation, storage
For unpacking, inspection and storage of the PRO/EXT modules, refer to the related chapter of [RD1].

MUT300082E1R1 — 02 – 2017 3
OVERVIEWS
2. OVERVIEWS
2.1 Physical overview
2.1.1 PRO module
1. I/O Connectors
2. Holes (x4) for stack mounting
3. Identification label
4. Internal connector (P2P)
5. Available power (PCB lands)
6. XMA internal connector area (filled)
7. User Electronics board mounting holes (4x M2x4)








4PRO/EXT — User’s Manual
Power capability
2.1.2 EXT module
1. I/O Connectors
2. Holes (x4) for stack mounting
3. Identification label
4. Internal connector (P2P)
2.2 Power capability
The PRO module can deliver the following power supply lines to the user defined electronics:
■5V3 ±5%, 500mA max.
■+15V ±5%, 100mA max.
■-15V ±5%, 100mA max.
■Vaux: 15V to 30V ±5% (One programmable value per DAU power supply PSI or PSS, based on PRO/EXT modules
min/max range requirement, and ANA modules excitation constraints), 500mA max.
The power supply lines are accessible in the PRO module via PCB lands to be fitted with soldered wires and are
protected against overcharge (current limitation). The EXT module does not deliver power.
Note:
◆Vaux always starts at 30V at start-up. The programmed Vaux(e.g. 15V) is available only after a few
seconds, after configuration by the CPU.
◆The power consumption of a complete DAU shall remain compliant with the maximum power deliv-
ered by the power supply modules (PSI and PSS).
◆Contact ZODIAC DATA SYSTEMS to verify the power capacity of your DAU configuration.
◆The user electronics shall not dissipate more than 5W in a PRO or EXT module.
◆When using power from the DAU, the user shall implement proper filtering to avoid DAU perfor-
mance degradation.
◆The PCB lands of the power supply lines allow a maximum of 3 soldering/unsoldering operations.





Power connections
MUT300082E1R1 — 02 – 2017 5
OVERVIEWS
2.3 Power connections
The power assignments are as follows:
The power is available from 3mm x 1mm rectangular exposed copper lands, designed to support up to three
soldering/unsoldering operations using standard soldering precautions. Pitch: 2.54mm.
2.4 User defined electronic board
Detailed information can be found in ZODIAC DATA SYSTEMS document SP01056012.
Permissible component height on high side (PRO only): 5.97mm
Permissible component height on high side (PRO/EXT): 15.8mm
Permissible component height on low side: 1.8mm
Note:
For information only, do not design with this drawing.
Contact ZODIAC DATA SYSTEMS for definition data and CAD files.
+5V3
GND
+15V
GND
VAUX
GND
-15V

6PRO/EXT — User’s Manual
User defined electronic board
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MUT300082E1R1 — 02 – 2017 7
INSTALLATION
3. INSTALLATION
3.1 Introduction
This section provides information for installation of the PRO/EXT module.
3.2 Mechanical installation
3.2.1 PRO Assembly
Follow these instructions to assemble a mezzanine board in a PRO module:
1. Prepare your mezzanine board by soldering the power and I/O wires
2. Install your mezzanine board in the PRO module
3. Solder the power wires (if needed).
4. Fit the I/O connector with contacts and wires
5. If waterproofness is required for your electronics, consider using filling material.
Refer to ⇨ Potting procedure – page 9 for more details.
Notes:
◆If waterproofness is required, you must equip each of the 51 pins with a contact
◆The I/O connector can be unscrewed from the module to ease operation.
◆The I/O connector locks must be screwed using a proper torque limiting tool (45cm.N).

8PRO/EXT — User’s Manual
Mechanical installation
3.2.2 PRO / EXT Assembly
Follow these instructions to assemble an EXT module on top of a PRO module:
1. Assemble the PRO module as explained above
2. Assemble PRO and EXT module, using the two M2x12 screws to maintain them (recommended torque:
30cm.N).
3. Fit the EXT I/O connector with contacts and wires
4. Screw the EXT I/O connector locks using a proper torque limiting tool (45cm.N).
Note:
You may need to prepare the mezzanine board with EXT I/O wires.
Note:
If waterproofness is required, you must equip each of the 51 pins with a contact.

Potting procedure
MUT300082E1R1 — 02 – 2017 9
INSTALLATION
5. If waterproofness is required for your electronics, consider using filling material.
Refer to ⇨ Potting procedure – page 9 for more details.
3.2.3 Filling material
The user area of the PRO and EXT modules are not filled to allow user operation. Precautions must be taken if
waterproofness of the user area is a requirement for the application.
Refer to ⇨ Potting procedure – page 9 for more details.
3.3 Potting procedure
This procedure is a recommendation from ZODIAC DATA SYSTEMS for potting the customer area of:
■The PRO module when used alone
■The PRO+EXT modules when used together (for higher component clearance, or double connector capacity)
3.3.1 Precautions
Wear appropriate ESD protection (wrist band and gowns) and gloves (for chemicals preparation and handling)
After boards are cleaned, always wear gloves to manipulate the module.
This procedure requires specific tools to be manufactured.
Check chemicals validity date.
Please comply to the steps order hereafter.
3.3.2 Mezzanine board preparation
1. The MicroComp external connector should be wired and soldered. It is highly recommended to place all 51
contacts in the connector (or both connectors for PRO+EXT).
a) Use the appropriate tool and procedure to insert contacts
Note:
◆The DAU stack waterproofness is ensured by the filling material at the DAU internal connector area.
◆Power lands are protected and short circuits transients on these lands will not affect DAU operation.

10 PRO/EXT — User’s Manual
Potting procedure
2. Wires to the power supplies should be shaped so as to be easily soldered to the power supply tab of the PRO
module.
3. High components should be glued:
a) Clean PCB
b) Glue high components to the PCB (epoxy paste adhesive, e.g. Araldite AW106)
c) Oven-dry the glue if necessary (Four hours at 60°C for AW106)
d) Cover high components with RTV Coating (RTV 3140) and let dry 24 hours at ambient temperature

Potting procedure
MUT300082E1R1 — 02 – 2017 11
INSTALLATION
4. Waterproofness of MicroComp connector (both connectors in case of PRO+EXT)
a) Apply silicon Sealant (e.g. RTV 162) to completely cover the connector grommet. Be careful not to damage
the wires or contacts. Make sure cover is complete (binoculars or magnifying glass are recommended)
b) If no contact is used: cover the whole connector with Silicon Sealant (e.g. RTV 162)
c) Dry the sealant appropriately (One hour at 60°C for RTV 162)
3.3.3 Mount the mezzanine board
Mezzanine board should be mounted in the XMA-PRO module, with four CZX M2x4 screws (supplied in kit), without
thread-lock, at 30cm.N torque.
1. Mount supplied connector jackpots, without thread-lock, at 45cm.N torque.
2. Solder the power supplies wires according to datasheet schematics.

12 PRO/EXT — User’s Manual
Potting procedure
3.3.4 EXT module (if applicable)
1. If EXT module connector is not used, mount the sealed connector using the supplied jackpots, without thread-
lock, at 45cm.N torque.
2. If EXT module connector is wired, then PRO and EXT modules need to be assembled (see procedure below)
before assembling the EXT connector jackpots.
3.3.5 Preliminary clean-up
Clean-up board and module (or modules) with ethanol and oven-dry one hour at 60°C.
3.3.6 PRO and EXT assembly (if applicable)
1. Connect the two modules using the internal connector.
2. Place at least two rods in the guide holes and assemble the module with the two supplied M2x12 screws, with-
out thread-lock, at 30cm.N torque.

Potting procedure
MUT300082E1R1 — 02 – 2017 13
INSTALLATION
3. Remove the guides, and make sure they come out without resistance, otherwise check alignment of the two
modules before tightening the two screws.
3.3.7 Potting tool installation (PRO only)
▶Place the PRO module on the tool’s rods and tighten the four screws at 75cm.N torque.
3.3.8 Potting tool installation (PRO+EXT only)
▶Place the PRO+EXT modules on the tool’s rods and tighten the four screws at 75cm.N torque

14 PRO/EXT — User’s Manual
Potting procedure
3.3.9 Potting material preparation
Zodiac Data Systems recommends using XE14-B7892 elastomer compound:
1. Mix in equal proportions the two components :
□PRO: 15g of A and 15g of B
□PRO+EXT: 30g of A and 30g of B
2. Stir for three minutes
3. It is recommended to degas the compound at this point
4. Fill a syringe (35cc for example) with the compound
5. Use a plastic nozzle, and place in caulking gun
6. Hold vertical (nozzle upward) and chase the air out
7. Inject compound in the tool’s feeding hole, while holding the modules at a 45° angle. Inject slowly and regularly
until fluid overflows:
8. Place cap on feeding hole.
9. Let rest for five minutes
10. Oven-dry for 15 minutes at 100°C
11. Let it cool
CAUTION!
Once mixed, compound must be used within one hour.

Electrical installation
MUT300082E1R1 — 02 – 2017 15
INSTALLATION
12. With a wooden spatula (to avoid scratching the housing and connectors), remove the excess compound:
3.3.10 Expected result
3.4 Electrical installation
▶Connect your cable to plugs.
▶Use a specific tool as a torque screwdriver, to clamp the plug (Recommended coupling torque: 28 N.cm).
▶Power on your DAU.
3.5 eZ software installation
eZ software is the mission configuration & control software intended to configure, monitor and control PRO/EXT
modules.
Refer to RD3 to install and setup this software.
Note:
Use the recommended connector SOURIAU 8MC.N.E.H51.P.011.B.002.
Choose a cable with a wire gauge between 24 et 28 AWG

16 PRO/EXT — User’s Manual
eZ software installation
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