ECUTS-16000 Reference Manual - National …The load-switching instrumentation in the ECUTS-16000 includes up to eight switch load signal conditioning (SLSC) fault insertion units that

ECUTS-16000

24U, 256 Test Point ECU Test System

Reference Manual

May 2020

ECUTS-16000 Reference Manual | 2

Before You Begin To ensure you have the most recent revision of the ECUTS-16000 Reference Manual, visit ni.com/manuals.

Know the ECU Test System (ECUTS) basics and safety requirements before you perform any maintenance, test, or repair procedures. Visit ni.com/manuals to review the ECUTS-16000 Safety, Environmental, and Regulatory Information document for safety information.

Regulatory Icons

Caution—take precautions to avoid injury. Cautions are localized into French for C-UL certification.

Notice—take precautions to avoid data loss, loss of signal integrity, degradation of model performance, and/or damage to the model.

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Table of Contents

ECUTS Overview 5 Hardware Overview 5 Software Overview 6 ECUTS-16000 Block Diagram 7 ECUTS-16000 Component Locator Images 8 Hardware Configuration 14 Ventilation Clearances 15 Power States 15

Basic Procedures 16 Powering On 16 Powering Off 16 Connecting the Interchangeable Test Adapter 16 Powering on After Thermal Shutdown 16

Mass Interconnect 17 Mass Interconnect Connector Types 18 Mass Interconnect Pin Maps 18 Recommended ITA Components 30 Installing and Removing Components on the Mass Interconnect 30

Maintenance 31 Cleaning the Test Rack Exterior 31

Cleaning Air Intake Filters 31

Calibration 31

Troubleshooting 32 ECUTS-1600 Does Not Power On 32 PXI Chassis Does Not Power On 32

Integrator Reference 33 Mechanical Stability and Loading 33 Maintaining Air Flow 33 Configuring Pneumatics 34


Contacting NI for Support 34 Return Materials Authorization, Repair, and Calibration 34 Technical Support 35


ECUTS Overview The ECUTS-16000 ECU Test System is a production-ready automotive test system for automated testing of DUTs such as engine control units, transmission control units, and body controller modules.

Hardware The ECUTS-16000 uses the NI PXI platform, SLSC, and modular instruments to enable the measurement and analysis capabilities required for your DUTs. Use the mass interconnect and an interchangeable test adapter (ITA) to connect the ECUTS-16000 to the DUT. Tables 1 and 2 list the required and optional hardware components for the ECUTS-16000. Table 1: Required Hardware Components

Component Type Part Description

Test Rack RMX-10011

Custom ATE Core Configurations assembly, low power, 24U with included: Power distribution unit (PDU) Power entry panel (PEP) Ethernet switch Fan panel

PXI Components PXIe-1084 18-slot (17 hybrid slots), up to 4 GB/s PXI Chassis PXIe-8861 2.8 GHz quad-core Intel Xeon PXI controller

Mass Interconnect 9025 or 9025TR Virginia Panel Corporation 25-slot receiver

Peripheral Components

Keyboard + Mouse USB keyboard and optical USB mouse

U2419H Dell UltraSharp 24” monitor

Table 2: Optional Hardware Components

Component Type Maximum Quantity Part Description

PXI Components

1 PXI-2520 80-channel, 2 A, SPST relay module 1 PXI-2564 16-channel, 5 A, SPST relay module

4 total PXIe-2737 4 × 64, 2-wire matrix switch module PXIe-2738 8 × 32, 2-wire matrix switch module PXIe-2739 16 × 16, 2-wire matrix switch module

4+ 1 per matrix switch

module PXIe-4081 7½-digit multimeter with 1.8 MS/s isolated digitizer

4 PXIe-4112 2-channel, 60 V, 1 A programmable power supply

4 PXIe-4139 ±60 V, 10 A, 40 W DC source power, 100 fA precision source measure unit

4 PXIe-4310 16-bit, 8-channel, 400 kS/s, Ch-Ch isolated analog input module

8+ 1 per matrix switch

module PXIe-4322 16-bit, 8-channel, 250 kS/s Ch-Ch isolated analog

output module

2 PXIe-5105 60 MHz, 8-channel, 12-bit oscilloscope 2 PXIe-5413 20 MHz, 2-channel, 16-bit waveform generator

4 PXIe-6386 8 AI (16-bit, 14 MS/s/ch), 2 AO, 24 DIO, PXI multifunction I/O module

2 PXIe-8510 6-port vehicle multiprotocol interface module, populated in pairs of CAN HS/FD or LIN transceivers

1 PXIe-8430/8 8-port, RS232 serial instrument control module.


SLSC

1 PXIe-6375 PXI MIO (for SLSC use only) 1 USB-6363 USB MIO (for SLSC use only) 1 SLSC-12001 12-slot chassis for SLSC (up to 8 modules total) 6 SLSC-12251 16-channel, 8 A, fault insertion unit 3 SLSC-12252 8-channel, 30 A, fault insertion unit

Power Supplies 8 total

RMX-4101, 20V 20 V, 10 A, programmable power supply device


RMX-4101, 60V 60 V, 3.5 A, programmable power supply device




Electronic Loads 1 RMX-4002 4-slot electronic load device mainframe

4 total RMX-4003 2-channel, 100 W, electronic load device RMX-4005 1-channel 350 W, electronic load device

Peripheral Components 1 USB hub 7-port USB 2.0 hub

Software The ECUTS Test System Suite is a pre-defined set of development environments, instrument drivers, and related toolkits commonly required for ECUTS-16000 test program development.

ECU Test System Maintenance Software ECU Test System Maintenance software allows you to monitor system and hardware components of the ECUTS-16000. Use ECU Test System Maintenance Software to verify your system configuration, run self-test, self-calibrate hardware components, and execute continuity-checking to the master interconnect.

TestStand ECU Toolkit Test program development for the ECUTS-16000 occurs in NI TestStand™, allowing you to quickly develop, debug, and deploy characterization and production test programs. TestStand allows you to integrate code modules written in multiple programming languages and offers tools such as test program templates for different development environments.

TestStand ECU Toolkit adds automotive industry-specific features to TestStand, helping you to configure, control, and debug supported ECUTS-16000 instruments based on configurations defined in InstrumentStudio. InstrumentStudio is a software-based front panel application that allows you to perform interactive measurements on several different device types in a single program. InstrumentStudio is automatically installed when you install TestStand ECU Toolkit. For more information on using InstrumentStudio, refer to the InstrumentStudio Manual online at ni.com/manuals.

Example test sequences are located in the <TestStand Public>\Examples\NI_ECU_Toolkit directory.

Code Modules Code modules are program modules, such as a LabVIEW VI or a Microsoft Windows DLL, that contain one or more functions that perform a specific test or other action. Use LabVIEW or .NET applications

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to create, edit, and debug code modules that control the instruments in the ECUTS-16000, take measurements from the DUT, and publish test results. NI provides instrument drivers to configure, customize, and implement instrument control applications.

Debugging NI provides several options for debugging instruments, DUTs, test applications, and code modules.

Use the soft front panels (SFPs) included with most NI modular instruments to troubleshoot and debug your instrument or DUTs.

Use InstrumentStudio to debug instruments while controlling them from test sequences in TestStand.

Use the built-in tools in TestStand to debug sequences and related components in TestStand.

ECUTS-16000 Block Diagram Figure 1: ECUTS-16000 Block Diagram

ECUTS-16000 Block Diagram Key

Hardware Block Power

Hardware Populated as Required Signal

Optional Hardware Block


ECUTS-16000 Component Locator Images Refer to the following images to locate internal and external ECUTS-16000 components. Image 1: ECUTS-16000 Front Exterior

Emergency Power Off (EPO) Panel Mass Interconnect

Cable Brush Panel Exhaust Panel for Electronic Loads (Optional)


Image 2: ECUTS-16000 Front Interior (Monitor Not Shown)

PXI Instrumentation Power Distribution Unit (PDU)

PXI Controller SLSC-12001

RMX Power Supplies (RMX-410x) RMX Load Mainframe (RMX-4002)


Image 3: ECUTS-16000 Left Side Interior (Monitor Not Shown)

PXI-4112 Power Supplies (Optional) USB-6363


Image 4: ECUTS-16000 Right Side Interior (Monitor Not Shown)

NI-XNET Transceiver Cables PXI-4112 Power Supplies (Optional)


Image 5: ECUTS-16000 Rear Exterior

Monitor Panel Pneumatic Air Port

Monitor Arm and Keyboard Tray Power Entry Panel (PEP)

Removable Rear Panel Door Air Intake and Filter

Rear Cable Entry Brush Panel


Image 6: ECUTS-16000 Rear Interior (Monitor Not Shown)

USB Hub PS-16

Ethernet Switch Multioutlet

PXI Chassis RMX Power Supplies

RMX-10050 PDU RMX-4002 Mainframe

SLSC Chassis RMX-400x Electronic Loads


Hardware Configuration

PXI The PXI instrumentation in the ECUTS-16000 includes a PXIe-1084 Chassis, a PXIe-8861 Controller, and user-configured PXI modular instruments.

Programmable Power Supplies The ECUTS-16000 includes up to eight rack-mount RMX-410x programmable power supplies. Power supplies can be powered by a secondary PDU. The following figure displays the IP address assigned to each power supply according to location in the test rack. Figure 2: Power Supply IP Address Assignments

Rack Mount Electronic Loads The ECUTS-16000 includes one electronic load mainframe and up to four RMX-4003 or RMX-40005 electronic load devices. The IP address assigned to the electronic load instrumentation is 169.254.160.30.

Switch Load Signal Conditioning The load-switching instrumentation in the ECUTS-16000 includes up to eight switch load signal conditioning (SLSC) fault insertion units that provide high-current switching and current measurement. The ECUTS-16000 supports up to six SLSC-12251 8 A fault insertion units and up to three SLSC-12252 30 A fault insertion units. Use a PXIe-6375 to take current measurements from the fault insertion units. If you are using an ECUTS-16000 configuration that contains six SLSC-12251 and two SLSC-12252 modules, use a USB-6363 to take current measurements from SLSC-12252 channels. The IP address assigned to the SLSC chassis is 169.254.160.10.

Power Distribution Unit The power distribution unit (PDU) takes input power and distributes AC and DC power to the ECUTS-16000 components.

The ECUTS-16000 uses a single-phase PDU that supports global voltages (200 V to 240 V; 50 Hz to 60 Hz) and has a 20 A (IEC C19) input connector that cables directly to the PEP. The eight standard AC sockets on the PDU are allocated in a specific configuration to power the internal components of the ECUTS-16000 and balance the power loads.


Ventilation Clearances The following clearances are required to ensure proper airflow to the ECUTS-16000. Clearances are measured from the ECUTS-16000 test rack exterior and do not include the 9025TR platform or monitor arm. Ensure obstructions do not violate the following clearance requirements: Top: 760 mm (30 in.) Front and Back: 300 mm (12 in.)

CAUTION You must follow the ECUTS-16000 power dissipation and ventilation requirements to avoid thermal hazards. ATTENTION Vous devez suivre les exigences de ventilation et de dissipation de puissance du ECUTS-16000 pour éviter tout risque thermique.

Power States Table 6: Power States

Power State PEP PDU Temperature Controller On On On On Off Off Off Off Standby On Off On EPO DC Power Only Off On

On – A change to this state begins the ECUTS-16000 main power on sequence. All PDUs receive AC power and enable outlets to other instruments.

Off – The ECUTS-16000 is entirely disabled with no power passing through the line filter or any internal test rack components.

Standby – AC and DC power is passing out of the PEP and into the thermostat on the EPO panel and the PDU. AC power is not passing out of the PDU.

When the ECUTS-16000 is in standby, MAINs power is connected to the PEP and the main breaker on the PEP is in the on position, but the main power switch on the EPO panel is off.

Emergency power off (EPO) – Pressing the EPO button immediately cuts AC power from the PEP and PDU(s). The ECUTS-16000 will power back on once the EPO button is released unless the main power switch or main breaker are turned off. The ECUTS-16000 enters the emergency power off state automatically if the following conditions occur:

– The temperature controller on the EPO panel is reading a higher temperature than the programmed shutoff value. The system will power back on when the over-temperature condition clears.

– The safety shutoff thermostats have detected unsafe air exit temperature. Refer to Powering on After Thermal Shutdown for more information.


Basic Procedures

Powering On

To avoid damage to the system, verify that an ITA or field diagnostic tester (FDT) is not connected to the ECUTS-16000 before powering on the system.

Procedure 1. Verify that the main circuit breaker is in the On position on the PEP. 2. Confirm that the primary EPO button is not engaged. 3. Confirm that the programmed temperature shutoff value on the EPO panel thermostat is below the

programmed temperature shutoff value. 4. Flip the main power switch to the right to turn on the ECUTS-16000.

Powering Off

To completely interrupt power to a single-phase system, you must disconnect the AC power cable. Do not position equipment so that it is difficult to disconnect the cable.

Procedure 1. Close any open applications. 2. Shut down Windows. 3. Flip the main power switch to the left. 4. Switch the main breaker on the PEP to the off position or disconnect MAINs power from the PEP.

Powering On After Thermal Shutdown The ECUTS-16000 has two safety shutoff thermostats on the interior of the test rack. Thermostats are located near the hot air exhaust vent in the front and back of the test rack. When triggered by a thermal event, the thermostats shut down the ECUTS-16000 by cutting power to the power entry AC outlet(s). To reset the thermostats after they have tripped, complete the following steps:

CAUTION Allow the ECUTS-16000 surface to cool to 65 °C before performing any maintenance or service procedures. ATTENTION Attendez que la température de surface de l'ECUTS-16000 descende sous 65 °C avant d'effectuer toute procédure de maintenance ou de réparation.

1. Disconnect MAINs power from the PEP. 2. Open the rear cabinet door. 3. Press the red button on the bottom of each thermostat.

Thermostats must cool to 65° C before resetting.

4. Restart the ECUTS-16000 using the Powering On procedure. 5. Close and lock the rear cabinet door.


Mass Interconnect The ECUTS-16000 uses the 9025 and 9025TR mass interconnect as the interface between the ECUTS-16000 and the DUT. Refer to the Virginia Panel Corporation 9025 User Manual for additional information about using the mass interconnect. Refer to the following figure for the arrangement of the mass interconnect receiver.

Use only original 9025 and 9025TR mating parts for all interface modules, pins, and frames.

Figure 3: Mass Interconnect Receiver Arrangement


Mass Interconnect Connector Types Table 9: Mass Interconnect Connector Types

Connector Connector Type J1 VPC QuadraPaddle (192 pins) J2 VPC Micro Power (50 pins) J3 J4 VPC QuadraPaddle (192 pins) J5 VPC QuadraPaddle (192 pins) J6 VPC QuadraPaddle (192 pins) J7 VPC QuadraPaddle (192 pins) J8 VPC QuadraPaddle (192 pins) J9 VPC Mini Power (19 pins)

J10 VPC Mini Power (19 pins) J11 J12 VPC TriPaddle (96 pins) J13 J14 VPC TriPaddle (96 pins) J15 J16 VPC Mini Power (19 pins) J17 J18 VPC QuadraPaddle (192 pins) J19 VPC QuadraPaddle (192 pins) J20 VPC QuadraPaddle (192 pins) J21 VPC QuadraPaddle (192 pins) J22 VPC Micro Power (50 pins) J23 VPC QuadraPaddle (192 pins) J24 VPC Micro Power (50 pins) J25

Mass Interconnect Pin Maps The following tables show the pin definitions for each slot type on the mass interconnect.


Table 10: J1 Pin Map A B C D Function

1 DIO1# DIO2# GND ATN#

GPIB

2 DIO3# DIO4# GND SRQ# 3 DIO5# DIO6# GND IFC# 4 DIO7# DIO8# GND NDAC# 5 SHIELD LOGIC GND GND NRFD# 6 GND DAV# 7 GND EOI# 8 REN# 9

10 P0.0 P0.1 P0.2 P0.3

J1_DIO

11 P0.COM P0.COM P0.COM P0.COM 12 P0.4 P0.5 P0.6 P0.7 13 P1.0 P1.1 P1.2 P1.3 14 P1.COM P1.COM P1.COM P1.COM 15 P1.4 P1.5 P1.6 P1.7 16 P2.0 P2.1 P2.2 P2.3 17 P2.COM P2.COM P2.COM P2.COM 18 P2.4 P2.5 P2.6 P2.7 19 P3.0 P3.1 P3.2 P3.3 20 P3.COM P3.COM P3.COM P3.COM 21 P3.4 P3.5 P3.6 P3.7 22 P4.0 P4.1 P4.2 P4.3 23 P4.COM (P4.VCC) P4.GND P4.GND P4.GND 24 P4.4 P4.5 P4.6 P4.7 25 P5.0 P5.1 P5.2 P5.3 26 P5.COM (P5.VCC) P5.GND P5.GND P5.GND 27 P5.4 P5.5 P5.6 P5.7 28 P6.0 P6.1 P6.2 P6.3 29 P6.COM (P6.VCC) P6.GND P6.GND P6.GND 30 P6.4 P6.5 P6.6 P6.7 31 P7.0 P7.1 P7.2 P7.3 32 P7.COM (P7.VCC) P7.GND P7.GND P7.GND 33 P7.4 P7.5 P7.6 P7.7 34 P6 +5V P7 +5V 35 SHIELD

J1_NET_1 36 Reserved Reserved RX+ TX+ 37 Reserved Reserved RX- TX- 38 SHIELD

J1_NET_2 39 Reserved Reserved RX+ TX+ 40 Reserved Reserved RX- TX- 41 42 43 12 V Interlock 24 V Interlock PPS Interlock User Interlock

Interlock 1 44 12 V Interlock Return 24 V Interlock Return PPS Interlock Return User Interlock Return 45 46 47 48

1 Connect the interlock pins through dry contacts to their associated return pin to enable the respective subsystem.


Table 11: J2 Pin Map

1 LOAD0+ 34 18 SENSE0+

2 LOAD0- 35 19 SENSE0-








10 LOAD4- 43 27 SENSE4-

11 LOAD5+ 44 28 SENSE5+

12 LOAD5- 45 29 SENSE5-

13 LOAD6+ 46 30 SENSE6+

14 LOAD6- 47 31 SENSE6-

15 LOAD7+ 48 32 SENSE7+

16 LOAD7- 49 33 SENSE7-

17 50



1 2 3 4 5 COM0 COM2 COM5 COM7

J4_RELAY

6 CH0 CH2 CH5 CH7 7 COM1 COM3 COM6 COM8 8 CH1 CH3 CH6 CH8 9 COM4 CH4 COM9 CH9

10 COM10 COM12 COM15 COM17 11 CH10 CH12 CH15 CH17 12 COM11 COM13 COM16 COM18 13 CH11 CH13 CH16 CH18 14 COM14 CH14 COM19 CH19 15 COM20 COM22 COM25 COM27 16 CH20 CH22 CH25 CH27 17 COM21 COM23 COM26 COM28 18 CH21 CH23 CH26 CH28 19 COM24 CH24 COM29 CH29 20 COM30 COM32 COM35 COM37 21 CH30 CH32 CH35 CH37 22 COM31 COM33 COM36 COM38 23 CH31 CH33 CH36 CH38 24 COM34 CH34 COM39 CH39 25 COM40 COM42 COM45 COM47 26 CH40 CH42 CH45 CH47 27 COM41 COM43 COM46 COM48 28 CH41 CH43 CH46 CH48 29 COM44 CH44 COM49 CH49 30 COM50 COM52 COM55 COM57 31 CH50 CH52 CH55 CH57 32 COM51 COM53 COM56 COM58 33 CH51 CH53 CH56 CH58 34 COM54 CH54 COM59 CH59 35 COM60 COM62 COM65 COM67 36 CH60 CH62 CH65 CH67 37 COM61 COM63 COM66 COM68 38 CH61 CH63 CH66 CH68 39 COM64 CH64 COM69 CH69 40 COM70 COM72 COM75 COM77 41 CH70 CH72 CH75 CH77 42 COM71 COM73 COM76 COM78 43 CH71 CH73 CH76 CH78 44 COM74 CH74 COM79 CH79 45 46 47 48


Table 13: J5, J6, J7, and J8 Pin Map A B C D Function

1 HI RESERVED HI SENSE

DMM 2 RESERVED RESERVED RESERVED RESERVED 3 LO LO SENSE 4 5 C0+ C2+ C4+ C6+

MATRIX 2

6 C0- C2- C4- C6- 7 C1+ C3+ C5+ C7+ 8 C1- C3- C5- C7- 9 R0+ R0- R1+ R1-

10 C8+ C10+ C12+ C14+ 11 C8- C10- C12- C14- 12 C9+ C11+ C13+ C15+ 13 C9- C11- C13- C15- 14 R2+ R2- R3+ R3- 15 C16+ C18+ C20+ C22+ 16 C16- C18- C20- C22- 17 C17+ C19+ C21+ C23+ 18 C17- C19- C21- C23- 19 R4+ R4- R5+ R5- 20 C24+ C26+ C28+ C30+ 21 C24- C26- C28- C30- 22 C25+ C27+ C29+ C31+ 23 C25- C27- C29- C31- 24 R6+ R6- R7+ R7- 25 C32+ C34+ C36+ C38+ 26 C32- C34- C36- C38- 27 C33+ C35+ C37+ C39+ 28 C33- C35- C37- C39- 29 R8+ R8- R9+ R9- 30 C40+ C42+ C44+ C46+ 31 C40- C42- C44- C46- 32 C41+ C43+ C45+ C47+ 33 C41- C43- C45- C47- 34 R10+ R10- R11+ R11- 35 C48+ C50+ C52+ C54+ 36 C48- C50- C52- C54- 37 C49+ C51+ C53+ C55+ 38 C49- C51- C53- C55- 39 R12+ R12- R13+ R13- 40 C56+ C58+ C60+ C62+ 41 C56- C58- C60- C62- 42 C57+ C59+ C61+ C63+ 43 C57- C59- C61- C63- 44 R14+ R14- R15+ R15- 45 AO0+ AO1+ AO2+ AO3+

AO 46 AO0- AO1- AO2- AO3- 47 AO4+ AO5+ AO6+ AO7+ 48 AO4- AO5- AO6- AO7-

2 Where a populated matrix dimension is less than 16x64, rows and columns are replicated on integer multiples. For example, rows 0-3 of a 4x64 matrix will be replicated on rows 4-7, 8-11, and 12-15. Similarly, columns 0-31 of an 8x32 matrix will be replicated on columns 32-63.


Table 14: J9, J10, J16 Pin Map 1 Pneumatic Pneumatic 2 DUT0

FIU

3 DUT1 4 DUT2 5 DUT3 6 DUT4 7 DUT5 8 DUT6 9 DUT7

10 LOAD0 11 LOAD1 12 LOAD2 13 LOAD3 14 LOAD4 15 LOAD5 16 LOAD6 17 LOAD7 18 ABA 19 ABB


Table 15: J12, J14 Pin Map

1 FIU-1 DUT0 33 FIU-2 DUT0 65 FIU-3 DUT0 2 FIU-1 DUT1 34 FIU-2 DUT1 66 FIU-3 DUT1 3 FIU-1 DUT2 35 FIU-2 DUT2 67 FIU-3 DUT2 4 FIU-1 DUT3 36 FIU-2 DUT3 68 FIU-3 DUT3 5 FIU-1 DUT4 37 FIU-2 DUT4 69 FIU-3 DUT4 6 FIU-1 DUT5 38 FIU-2 DUT5 70 FIU-3 DUT5 7 FIU-1 DUT6 39 FIU-2 DUT6 71 FIU-3 DUT6 8 FIU-1 DUT7 40 FIU-2 DUT7 72 FIU-3 DUT7 9 FIU-1 DUT8 41 FIU-2 DUT8 73 FIU-3 DUT8

10 FIU-1 DUT9 42 FIU-2 DUT9 74 FIU-3 DUT9 11 FIU-1 DUT10 43 FIU-2 DUT10 75 FIU-3 DUT10 12 FIU-1 DUT11 44 FIU-2 DUT11 76 FIU-3 DUT11 13 FIU-1 DUT12 45 FIU-2 DUT12 77 FIU-3 DUT12 14 FIU-1 DUT13 46 FIU-2 DUT13 78 FIU-3 DUT13 15 FIU-1 DUT14 47 FIU-2 DUT14 79 FIU-3 DUT14 16 FIU-1 DUT15 48 FIU-2 DUT15 80 FIU-3 DUT15 17 FIU-1 LOAD0 49 FIU-2 LOAD0 81 FIU-3 LOAD0 18 FIU-1 LOAD1 50 FIU-2 LOAD1 82 FIU-3 LOAD1 19 FIU-1 LOAD2 51 FIU-2 LOAD2 83 FIU-3 LOAD2 20 FIU-1 LOAD3 52 FIU-2 LOAD3 84 FIU-3 LOAD3 21 FIU-1 LOAD4 53 FIU-2 LOAD4 85 FIU-3 LOAD4 22 FIU-1 LOAD5 54 FIU-2 LOAD5 86 FIU-3 LOAD5 23 FIU-1 LOAD6 55 FIU-2 LOAD6 87 FIU-3 LOAD6 24 FIU-1 LOAD7 56 FIU-2 LOAD7 88 FIU-3 LOAD7 25 FIU-1 LOAD8 57 FIU-2 LOAD8 89 FIU-3 LOAD8 26 FIU-1 LOAD9 58 FIU-2 LOAD9 90 FIU-3 LOAD9 27 FIU-1 LOAD10 59 FIU-2 LOAD10 91 FIU-3 LOAD10 28 FIU-1 LOAD11 60 FIU-2 LOAD11 92 FIU-3 LOAD11 29 FIU-1 LOAD12 61 FIU-2 LOAD12 93 FIU-3 LOAD12 30 FIU-1 LOAD13 62 FIU-2 LOAD13 94 FIU-3 LOAD13 31 FIU-1 LOAD14 63 FIU-2 LOAD14 95 FIU-3 LOAD14 32 FIU-1 LOAD15 64 FIU-2 LOAD15 96 FIU-3 LOAD15


Table 16: J18, J19, J20, and J21 Pin Map

A B C D Function 1 HI HI SENSE

DMM 2

3 LO LO SENSE 4 5 6 GUARD

SMU 7 HI GUARD LO CHSGND 8 GUARD GUARD LO SENSE

9 HI SENSE

10 11 AO0+ AO1+ AO2+ AO3+

AO_1 12 AO0- AO1- AO2- AO3- 13 AO4+ AO5+ AO6+ AO7+ 14 AO4- AO5- AO6- AO7- 15 16 AO0+ AO1+ AO2+ AO3+

AO_2 17 AO0- AO1- AO2- AO3- 18 AO4+ AO5+ AO6+ AO7+ 19 AO4- AO5- AO6- AO7- 20 21 AI0+ AI1+ AI2+ AI3+

AI

22 AI0- AI1- AI2- AI3- 23 COM0 COM1 COM2 COM3 24 AI4+ AI5+ AI6+ AI7+ 25 AI4- AI5- AI6- AI7- 26 COM4 COM5 COM6 COM7 27 PFI0 PFI1 28 CHSGND CHSGND

PPS 29 OUT0+ SENSE0+ OUT1+ SENSE1+ 30 OUT0- SENSE0- OUT1- SENSE1- 31 32 6386 AI0+ 6386 AI1+ 6386 AI2+ 6386 AI3+

SMIO

33 6386 AI0- 6386 AI1- 6386 AI2- 6386 AI3- 34 6386 AIGND 6386 AIGND 6386 AIGND 6386 AIGND 35 6386 AI4+ 6386 AI5+ 6386 AI6+ 6386 AI7+ 36 6386 AI4- 6386 AI5- 6386 AI6- 6386 AI7- 37 6386 AIGND 6386 AIGND 6386 AIGND 6386 AIGND 38 6361 AISENSE 6386 APFI0 6386 AO0 6386 AO1 39 6386 +5V 6386 Shield 6386 AOGND 6386 AOGND 40 6386 P0.0 6386 P0.1 6386 P0.2 6386 P0.3 41 6386 DGND 6386 DGND 6386 DGND 6386 DGND 42 6386 P0.4 6386 P0.5 6386 P0.6 6386 P0.7 43 6386 P1.0 6386 P1.1 6386 P1.2 6386 P1.3 44 6386 DGND 6386 DGND 6386 DGND 6386 DGND 45 6386 P1.4 6386 P1.5 6386 P1.6 6386 P1.7 46 6386 P2.0 6386 P2.1 6386 P2.2 6386 P2.3 47 6386 DGND 6386 DGND 6386 DGND 6386 DGND 48 6386 P2.4 6386 P2.5 6386 P2.6 6386 P2.7


Table 17: J22 Pin Map Function Function Function

1 12 V 34 24 V 18 CHSGND

DC Supplies 2 12 V COM 35 24 V COM 19 CH0

J22_SCOPE_2

3 CH0

J22_SCOPE_2

36 CH0

J22_FGEN_1

20 CH1

4 CH1 37 CH1 21 CH2

5 CH2 38 PFI0 22 CH3

6 CH3 39 PFI1 23 CH4

7 CH4 40 CH0

J22_FGEN_2

24 CH5

8 CH5 41 PFI0 25 CH6

9 CH6 42 PFI1 26 CH7

10 CH7 43 CH0 27 PFI 11 PFI 44 28

J12-FIU1 12 ABA 45 ABB 29





J14-FIU3 17 ABA 50 ABB


Table 18: J23 Pin Map CAN Port Pair A B C D CAN(x) LO CAN(x) SHIELD CAN(x+1)

SHIELD CAN(x+1) LO

CAN(x) HI CAN(x) VSUP CAN(x+1) VSUP CAN(x+1) HI CAN(x) COM CAN(x) COM CAN(x+1) COM CAN(x+1)

COM

Table 19: J23 Pin Map LIN Port Pair A B C D No connect LIN(x) SHIELD LIN(x+1)

SHIELD No connect

LIN(x) LIN(x) VSUP LIN(x+1) VSUP LIN(x+1) LIN(x) COM LIN(x) COM LIN(x+1) COM LIN(x+1) COM


1 CAN or LIN Ports 1 and 2

CAN/LIN

2 3 4 CAN or LIN

Ports 3 and 4 5 6 7 CAN or LIN

Ports 5 and 6 8 9

10 11 CAN or LIN

Ports 7 and 8

CAN/LIN

12 13 14 CAN or LIN

Ports 9 and 10 15 16 17 CAN or LIN

Ports 11 and 12 18 19

20


(Continued) Table 20: J23 Pin Map A B C D Function

21 COM2 RXD COM2 DTR COM3 DTR COM3 RXD

RS-232

22 COM2 RI COM2 DSR COM3 DSR COM3 RI 23 COM2 DCD COM2 RTS COM3 RTS COM3 DCD 24 COM2 TXD COM2 CTS COM3 CTS COM3 TXD 25 GND GND 26 COM4 RXD COM4 DTR COM5 DTR COM5 RXD 27 COM4 RI COM4 DSR COM5 DSR COM5 RI 28 COM4 DCD COM4 RTS COM5 RTS COM5 DCD 29 COM4 TXD COM4 CTS COM5 CTS COM5 TXD 30 31 COM6 RXD COM6 DTR COM7 DTR COM7 RXD 32 COM6 RI COM6 DSR COM7 DSR COM7 RI 33 COM6 DCD COM6 RTS COM7 RTS COM7 DCD 34 COM6 TXD COM6 CTS COM7 CTS COM7 TXD 35 GND GND 36 COM8 RXD COM8 DTR COM9 DTR COM9 RXD 37 COM8 RI COM8 DSR COM9 DSR COM9 RI 38 COM8 DCD COM8 RTS COM9 RTS COM9 DCD 39 COM8 TXD COM8 CTS COM9 CTS COM9 TXD 40 41 CH0 CH1 CH2 CH3

J4_RELAY

42 COM0 COM1 COM2 COM3 43 CH4 CH5 CH6 CH7 44 COM4 COM5 COM6 COM7 45 CH8 CH9 CH10 CH11 46 COM8 COM9 COM10 COM11 47 CH12 CH13 CH14 CH15 48 COM12 COM13 COM14 COM15


Table 21: J24 Pin Map 1 OUT+ 34 Function

18 SENSE+

J24_PPS_1 2 OUT- 35 19 SENSE-

3 OUT+ 36

J24_PPS_2 20 SENSE+

4 OUT- 37 21 SENSE-

5 OUT+ 38

J24_PPS_3 22 SENSE+

6 OUT- 39 23 SENSE-

7 OUT+ 40

J24_PPS_4 24 SENSE+

8 OUT- 41 25 SENSE-

9 OUT+ 42

J24_PPS_5 26 SENSE+

10 OUT- 43 27 SENSE-

11 OUT+ 44

J24_PPS_6 28 SENSE+


13 OUT+ 46

J24_PPS_7 30 SENSE+


15 OUT+ 48

J24_PPS_8 32 SENSE+


17 50


Recommended ITA Components NI recommends the following ITA components for the ECUTS-16000. Table 22: Recommended ITA Components

Vendor Part Number Description VPC 410 104 111 ITA, 9025, 25 module, single tier VPC 410 112 198 Enclosure, 25 module, hinged cover plate, 4" deep VPC 410 112 273 Enclosure, 25 module, hinged cover plate, 8" deep VPC 410 112 823 Enclosure, 25 module, hinged cover plate, for 9025TR VPC 410 114 004 Enclosure, 25 module, front mount, sloped, for 9025TR VPC 410 112 578 Protective cover, 9025, 9025VXI & 9025TR, ITA VPC 510 109 296 Strain relief plate for ITA modules VPC 510 104 118 Blank module, receiver/ITA, 1 module position, 90 series modules VPC 510 104 144 Blank module, receiver/ITA, 5 module positions VPC 510 151 105 Signal module, ITA, QuadraPaddle, 192 position, unloaded VPC 510 151 121 Signal module, ITA, QuadraPaddle, 192 position, right angle contacts for

custom PCB mounting (510 151 107 and 510 109 316) VPC 510 108 126 TriPaddle signal, module, ITA, 96 position VPC 510 108 125 Signal module, ITA, TriPaddle, 96 position with right angle contacts for

custom PCB mounting VPC 510 108 262 Micro Power & Micro Coax, module, ITA, 90 series, 50 position VPC 510 108 115 Mini Power module, ITA, 19 position

Installing and Removing Components on the Mass Interconnect Installing and removing ITA modules or receiver modules on the master interconnect requires a 3/32” ball-end hex bit that is at least 75 mm (3.0 in) long. NI recommends a Bondhus 0105 or a McMaster-Carr 6972A16. Because 3/32” sockets or nut drivers are not widely available, adapting this tool to common hand or power tools may require a chuck adapter. NI recommends a Jacobs 30248 or McMaster-Carr 28055A71 chuck adapter. Refer to the Virginia Panel Corporation 9025 User Manual for torque values.


Maintenance

Cleaning the Test Rack Exterior Clean ECUTS-16000 exterior surfaces with a dry lint-free cloth or a soft-bristle brush. If any dirt remains, wipe with a cloth moistened in a mild soap solution. Remove any soap residue by wiping with a cloth moistened with clear water. Do not use abrasive compounds on any part of the test rack.

Use the following guidelines to avoid damaging the ECUTS-16000 when cleaning the test rack exterior: Avoid getting moisture inside the system during exterior cleaning. Use only enough

moisture to dampen the cloth. Do not wash the front- or rear-panel connectors or switches. Cover these

components when cleaning the test rack. Do not use harsh chemical cleaning agents; they may damage the ECUTS-16000.

Avoid chemicals that contain benzene, toluene, xylene, acetone, or similar solvents.

Cleaning Air Intake Filter Complete the following steps to clean the air intake filter:

1. Remove the four screws securing the 4U air inlet panel to the test rack. 2. Remove the filter media from the inlet panel. 3. Clean the air intake filter using warm water with a mild soap solution, then air dry the filter to

remove moisture. 4. After verifying that the filter is dry, replace the filter in the test rack. 5. Replace the 4U air inlet panel.

Calibration NI provides the following options for instrument-level calibration support for the ECUTS-16000:

Factory calibration—Performed using the same sequence and procedure used when the instrument was originally manufactured. The assurance given by the NI Factory Calibration Certificate is that the instrument met specifications at date of manufacture with sufficient margin to likely remain in spec for the initial calibration interval.

Traceable calibration—Performed using NI-developed calibration procedures and measurement standards traceable to SI units. NI recommends traceable calibration for most applications.

Compliant calibration—Performed at an ISO-17025 accredited laboratory that complies with ANSI/NCSL Z540-1-1994 and includes a measurement uncertainty evaluation.

Accredited calibration—Performed at an ISO-17025 accredited laboratory and includes detailed measurement uncertainty and the official logo of the accreditation body.

Use the following table to determine the level of calibration support available for ECUTS-16000 instruments. For additional information, consult the documentation for each instrument or visit ni.com/r/nical.

https://www.ni.com/en-us/support/documentation/supplemental/17/calibration-service-levels-and-product-information.html


Table 23: Instrument Calibration Support

Instrument Function Recommended

Calibration Interval

Calibration Support

PXIe-4081 DMM 2 years Accredited PXIe-4112 Programmable Power Supply 2 years Traceable PXIe-4139 SMU 1 year Accredited PXIe-4310 Analog Input 2 years Accredited PXIe-4322 Analog Output 1 year Accredited PXIe-5105 Oscilloscope 2 years Accredited PXIe-5413 Waveform Generator 2 years Accredited PXIe-6386 Multifunction I/O module 2 years Traceable PXIe-6375 Current measurement for SLSC 2 years Accredited USB-6363 Current measurement for SLSC 2 years Accredited SLSC-12251 Current Measurement for SLSC 2 years Factory SLSC-12252 Current Measurement for SLSC 2 years Factory RMX-4003 Electronic Load 1 year Traceable RMX-4005 Electronic Load 1 year Traceable

Troubleshooting ECUTS-16000 Does Not Power On Check the power source connection and voltage supply. Verify that the main power switch is turned to the On position. Confirm that the EPO button is not engaged. Verify that the main breaker is in the On position on the PEP. Verify that the temperature controller on the EPO panel has not detected a temperature higher than

the programmed shutoff value. Checking the incoming power lights on the rear side of the PDU. Verify that the PDU main breaker is on and that the control breaker is depressed. Check that the cables in and out of the PDU are connected. Verify the shutoff thermostats have been reset if the ECUTS-16000 shut down due to thermal

overload.

PXI Chassis Does Not Power On Confirm that the EPO button is not engaged. Check if the PXI controller is properly seated inside the PXI chassis. Check the PXI chassis LED indicators. Check if the chassis power supply cable is connected.


Integrator Reference

Mechanical Stability and Loading Each ECUTS-16000 configuration is designed to ensure physical stability of the test rack and to prevent overbalancing or tipping. When adding additional instruments or components to the ECUTS-16000, it is important to preserve stability. Use the following guidelines to maintain mechanical stability when adding additional components to the ECUTS-16000: For IEC 61010-1 compliance, the ECUTS-16000 and all included components must weigh less than

453.5 kg (1,000 lbs), evenly distributed across all caster wheels. Any component over 4.5 kg (10 lbs) that hangs permanently outside of the ECUTS-16000 must

have external support such as legs. Tether the ECUTS-16000 to the floor or wall for additional stability. Tethering should be done

according to facility practices and follow the ECUTS-16000 ventilation clearance guidelines.

Maintaining Air Flow To prevent the ECUTS-16000 from overheating, adhere to the following cool air intake and hot air exhaust requirements when adding additional instruments or components to the ECUTS-16000.

Figure 4: ECUTS-16000 Air Distribution


Configuring Pneumatics The ECUTS-16000 does not ship ready for use with facility compressed air. To configure the ECUTS-16000 pneumatics to route compressed air, use the following guidelines: Use 6 mm outer diameter tubing to connect to the pneumatic air port on the back of the test rack. Mount pneumatic components such as regulators and valves on the bottom of the test or in empty

test rack space. If installed, do not remove the ECUTS-16000 ballast plates from the bottom of the test rack.

Removing the ballast plates may cause the ECUTS-16000 to become unstable. Connect to the pneumatic output ports using 6 mm outer diameter tubing.

Available pneumatic output ports on the mass interconnect are J9, J10, or J16 (if populated), in the pin 1 location.

The mass interconnect receiver has a contact switch that closes when an ITA mates to the receiver. You can use the contact switch to control a valve to stop the flow of air when removing a fixture from the mass interconnect. The mating connection on the ITA is a VPC Pneumatic Contact 610132106, 610132110, 610132111, or 610132112 in the VPC Mini Power Module 510108115.

Contacting NI for Support When you submit a support request, providing as much information as possible enables NI service representatives to fully understand the issue you are experiencing. NI can work with you to gather all the necessary information but preparing it ahead of time can reduce the amount of time it takes to process the support request.

NI cannot ensure support for any items added to the original shipping configuration, such as from a during a second-tier integrator, because they were not provided by NI. Please contact the responsible party first if you suspect the issue involves any of these items.

Return Materials Authorization, Repair, and Calibration To submit a request for return materials authorization, repair, or calibration, use the ECU Test System Maintenance Software to generate a report that includes the information listed below, then contact your assigned Hardware Services Program Manager to discuss service options. Information required for an ECUTS-16000 return materials authorization, repair, or calibration request:

ECUTS-16000 System Information Serial number Part number Model name Configuration Name System Tag

System Component Information System component part number


System component serial number Gather the serial number, part number, and system tag information from the ECUTS-16000 system sticker or from the ECU Test System Maintenance Software. Refer to the ECU Test System Maintenance Software Help for additional information about generating reports for the ECUTS-16000.

Technical Support To open a technical support request, use the ECU Test System Maintenance Software to generate a report that includes the information listed below, then email [email protected]. Information required for an ECUTS-16000 technical support request:

ECUTS System Information Serial number Part number Model name Configuration Name System Tag

Short Description of the Issue Gather the serial number, part number, and system tag information from the ECUTS-16000 system sticker or from the ECU Test System Maintenance Software. Refer to the ECU Test System Maintenance Software Help for additional information about generating reports for the ECUTS-16000.

Information is subject to change without notice. Refer to the NI Trademarks and Logo Guidelines at ni.com/trademarks for information on National Instruments trademarks. Other product and company names mentioned herein are trademarks or trade names of their respective companies. For patents covering National Instruments products/technology, refer to the appropriate location: Help»Patents in your software, the patents.txt file on your media, or the National Instruments Patent Notice at ni.com/patents. You can find information about end-user license agreements (EULAs) and third-party legal notices in the readme file for your NI product. Refer to the Export Compliance Information at ni.com/legal/export-compliance for the National Instruments global trade compliance policy and how to obtain relevant HTS codes, ECCNs, and other import/export data. NI MAKES NO EXPRESS OR IMPLIED WARRANTIES AS TO THE ACCURACY OF THE INFORMATION CONTAINED HEREIN AND SHALL NOT BE LIABLE FOR ANY ERRORS. U.S. Government Customers: The data contained in this manual was developed at private expense and is subject to the applicable limited rights and restricted data rights as set forth in FAR 52.227-14, DFAR 252.227-7014, and DFAR 252.227-7015.

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Documents

ECUTS-16000 Reference Manual - National …The load-switching instrumentation in the ECUTS-16000 includes up to eight switch load signal conditioning (SLSC) fault insertion units that