aes 5501 automotive emissions system - teseq€¦ · aes 5501 - automotive emissions system 7 the...

1

aes 5501 automotive emissions system

user manual

601-319B

AES 5501 - Automotive Emissions System

aes 5501 automotive emissions system

user manual

1. Explanation of symbols used in this manual 52. Warning symbols on the test system 73. Safety 8 4. Installation 104.1 Connecting the power cable 105. Introduction to emissions in ISO 7637-2 116. The AES 5501 - Automotive Emissions System 146.1 The system controller 156.2 Mechanical switch 156.3 Artificalnetwork&shuntresistor 166.4 Electronic switch 166.5 Timing 166.6 Triggersource 167. The MS 5501 178. The AN 5501 269. The ES 5501 Electronic switch 2910. Operation 3011. Specifications 3312. Technical data 3613. Maintenance 3713.1 Cleaning 3713.2 Calibration 3713.2.1 Calibrating the AN 5501 3713.2.2 Calibrating the ES 5501 3714 The package contents 3815 Declaration of conformitiy (CE) 3916 Addresses 40

contents

5

Pleasetakenoteofthefollowingexplanationsofthesymbolsusedinordertoachievetheoptimumbenefitfromthismanualandtoensuresafetyduringoperationoftheequipment.

Thefollowingsymboldrawsyourattentiontoacircumstancewherefailingtoobservethewarningcould lead inconvenienceor impairment inperfor-mance.

Example:

1 explanation of the symbols used in this manual

This connection must not be confused with the main power input.

Thefollowingsymboldrawsyourattentiontoacircumstancewherefailingtoobservethewarningcouldleadtocomponentdamageordangertotheoperating personnel.

Cautionsign:Asituationthatmaycausedamagetotheequipment

Example:

Connect the system only to rated mains power.

6


Dangersign:PossiblydangeroussituationthatmaycausedamagetopersonsorheavydamagetothetestequipmentorDUT.

Example:

It is dangerous to fail to observe safety warnings.

72 Warning symbols on the test system

CAUTION! Warning of a danger spot (refer to the docu-mentation).

8


3 safety

Potentially dangerous voltage may be present at the cables leading to and from the DUT. Take care and follow allapplicablesafetyguidelinesgivenforyourspecificDUT.

The AES 5501 system itself contains no dangerous voltages or currents,however,theapplicationrequiresanexternalpowersourceandcanuseupto100AforDUTpower.

Up to 100 A may be switched using the AES 5501. Care should be taken in connecting and operating the DUT.

TheAES5501systemisusedtomeasureemissionsfromtheDUT.Theseemis-sionsmaybehighvoltagescausedbyinductivekickbacks.CareshouldbeusedwhenpoweringtheDUTthroughtheAES5501system.RefertoengineeringorproductdocumentationforyourspecificDUT.

DANGER! It is imperative that you read the following safety instructions and all safety instructions in the manuals of the connected peripheral systems before installing and starting this test system for the firsttime.

General warnings.

9

Theoperatinginstructionsformanintegralpartoftheequipmentandmustbeavailabletotheoperatingpersonnelatalltimes.Allthesafetyinstructionsandadvicenotesaretobeobserved.

DANGER! The electrical and mechanical safety equip-ment must not be removed, put out of operation or bypassed. Handle all safety equipment with care. If a safety device should be broken or is not working, the system must be put out of operation until the safety device is repaired or exchanged and fully in working order again.

DANGER! HAZARDOUS AREA! Connectors on the test equipment should not be touched!

The equipment may only be operated within an area that is explicitly declared a “Test Floor” (with appropri-ate signs) and protected against improper acces.

It is important to power off the DUT before disconnec-ting the DUT or any parts of the AES 5501.

10


4 installation

4.1 Connecting the power cableThepowersupplyisanautorangingtype.Forexactspecifications,seethesectiontechnicalspecifications.

Pleaseonlyusepowercablesthatarecertifiedforusein your location.

Connecting the power cable

Forfurtherinformationoncabelingandsetuppleaseseethesection“Opera-tion”.

11

TheAES5501isdesignedinaccordancetoISO7637-2andmaybeusedwithconfidenceformanymanufacturerstandards.ThisguidegivesagoodoverviewofISO7637-2.

5 introduction to emissions in iso 7637-2

ISO7637-2:2004describesamethodofmeasuringtransientreturnsfromaDUTwhenthebatteryisswitchedonoroff.ThisstandardisanimportantpartofautomotiveEMCtesting.

ThisstandarddescribestwomethodsofswitchingtheDUT:withamechanicalswitch(recommendedtheactualswitchbuiltintothevehicle)orafastelectronicswitch.

Refer to the applicable annex of ISO 7637-2 for guidance in measuring the returned effects, and limits.

ISO7637-2recommendstwosetups.TheswitchcanbebeforeoraftertheANasseeninthefollowingdiagrams.RefertoISO7637-2formoreinformation.

Carefully consult the relevant manufacturer standard and ISO 7637-2 before operating the AES 5501 system.

Pay special attention to cable lengths. The standards have strict cable length requirements. The most common are provided with the AES 5501 system.

12


DUT

Oscilloscope

BatterySource

Artificial NetworkSimulates Wiring Harness

ImpedanceSwitch

Slowpulses(msrangeorslower)

Applicationfor“Slow”pulseshowingmostofthewiringharnessimpedancebetweentheswitchandDUT.

Wiring Harness

DUT

13

Applicationfor“Fast”pulseshowingmostofthewiringharnessimpedancebetweenthebatteryandswitch.

Wiring Harness

DUT

DUT

Oscilloscope

BatterySource

Artificial NetworkSimulates Wiring Harness

Impedance Switch

Fastpulses(nstoμsrange)

14


6 the aes 5501 - automotive emis-sions system

TheAES5501isasystemofelectronicandmechanicalswitches,anartificialnetwork,andauniquecontrolstationdesignedforemissionstestingtoISO7637-2.Consistingofafour-partsolution,theuserhascompletecontroloverwhere,whenandhowtheswitchescanbeplacedandcontrolled, includingthenecessarydrivevoltagesfortherelays.The100Aconnectorsarecarefullyplacedandcountersunktoallowprecisecablingbetweentheswitches,theartificialnetworkandtestbenchandallowsfortheelectronicormechanicswitchestobeplacedatanypointbeforeoraftertheartificialnetwork.Thiscarefulattentiontoswitchplacementandcablelengthmeansthatthenumer-ousmanufacturerstandardscanalsobemet.TheAES5501featuresaruggedconstructionwithunpaintedundersideforgoodearthcontact,preciseswitch-ingcontrolandmonitoringfunctions.AcounterfortherelayandLEDindica-torsforbothelectronicandmechanicalelectronicswitchesareprovided.The ES5501hastemperaturecontrolledfansforquietoperationandathermalshutdownfeature.

The AES 5501

156.1 The system controllerThesystemcontrollerSC5501isusedtocontroltimingandprovidetheneces-saryvoltagesfortheAES5501system,andprovideaconvenientmethodofselectingthevariousfunctions..

The SC 5501

TheSC5501isbrokenintoseveralfieldsdependingontheirfunctions:Mechani-calswitch,artificialnetwork&shuntresistor,electronicswitch,triggersourceandtimings.

Thefollowingsectionswillprovidedetailsabout thesevariouscontrolele-ments.

6.2 Mechanical switchThemechanicalswitchfieldisusedtocontroltheMS5501andcontainsthreeinput elements: buttons named triggered, Off and On. In “Off” mode, theswitch isturnedcompletelyoff, thusblockinganyDCvoltagetotheDUT. In“On”mode,theswitchisturnedon,thusprovidinganyDCvoltageavailableattheinputofthemechanicalswitchtotheDUT.Triggermodeisthemodebywhichtheuserhastheabilitytocontrolthetimingoftheswitchusingthefieldstimingand triggersource.ThisfieldalsohasanLEDdisplay thatshows thestatusoftheswitch.Theswitchwillindicategreenwhenitison(conducting),andunlitwhenoff.redindicatesanerrorcondition.Pressingtheunlitindicatorwillselectthemode.Refertothedescriptionsofthetimingfieldandtriggersourcefieldsbelow.

16


6.3 Artifical network & shunt resistorThis field allows the user to select the impedance of the artificial network.Selectingtheresistanceherewillsettheresistorontheleft(input)sideoftheartificialnetworktotheselectedvalue,asshownontheAN5501.SelectingtheOff/Exernaloption,willconnecttheresistortothebananajacksontheleft(input)sideoftheAN5501.Formoredetails,consultsection8.

6.4 Electronic switchTheelectronicswitchfieldisusedtocontroltheES5501andcontainsthreeinput elements: buttons named Triggered, Off and On. In “Off”mode, theswitchisturnedcompletelyoff,thusblockinganyDCvoltagetotheDUT.In“On”mode,theswitchisturnedon,thusprovidinganyDCvoltageavailableattheinputofthemechanicalswitchtotheDUT.Triggermodeisthemodebywhichtheuserhastheabilitytocontrolthetimingoftheswitchusingthefieldstimingandtriggersource.ThisfieldalsohasanLEDdisplaythatshowsthestatusoftheswitch.TheLEDwillindicategreenwhenitison,andunlitwhenoff,andred indicatinganerrorcondition.Pressing theunlit indicatorwillselectthemode.Refertothedescriptionsofthetimingfieldandtriggersourcefieldsbelow.

6.5 TimingThetimingfield isusedtoselectthebatteryoff,andbatteryontimes.Thebatteryon time isonlyvalidwhenthe triggersource isset to Internal.Thebatteryofftimeisusedonlywhentriggersourcemodeisinternalorsingle.Boththebatteryoffandbatteryontimesmaybesetusingtheincludeddialsbetweenapproximately10msand10s(seespecificationsforexacttimings.)

6.6 Trigger sourceThe triggersource isused toselect thesourceandmodeof theswitchingtiming.

In“internal”mode,thetimingofbothrepetitionanddisconnectionisselectedwiththedialsprovidedinthetimingfieldoftheSC5501.

17In“singlemode”, thetimingof thepulsewillbeselectedbythebatteryoff(TOFF)dialinthetimingfieldoftheSC5501.Therewillbenorepetitioninsinglemode.Toactivateapulse,pressthetriggerbuttonunderthe“single”buttonwhenselected.

In “manual”mode, the timing is dependant on how long the trigger is de-pressed.Tostartapulse(batteryvoltageoff),depressthetriggerbutton(un-derthemanualbutton)withmanualselected.Toendthepulse(allowbatteryvoltagetotheDUT),releasethetriggerbutton.

In“external”mode,theusersuppliesaTTLsignalontheBNClocatedattheback side of the SC 5501. Thebattery outputwill follow the signal: A highinputtothetriggerinBNCwillresultinbatteryvoltageavailabletotheDUT(selectedswitchON).Theinputsignalmaybebetween~4.5and12Vandisadifferentialinput.

Connectors on the SC 5501

Controlcables(Interchangeable)

Trigger inTriggerout

18


7 The MS 5501TheMS5501isthecontainerofthemechanicalswitch(relay).

125 mm

50 m

m

The MS 5501

TheMS5501isdeliveredwitha100Arelay.Refertosection6forcontrol.The100ArelaymaybeexchangedusingthesuppliedPCBforotherrelaysthatusetheindustrystandardfootprint.

BeforeusingtheMS5501,youmustconnectthecontrolcablefromtheMS5501totheSC5501.TherelaycontrolvoltageisprovidedfromtheSC5501,aswellasalltimingfunctions.TheMS5501containsancounterandBNCcon-nectorforeaseofuse.

ThecounterwillindicatethenumberofpulsesthathavebeensentfromtheSC5501.Notethateveniftherepetitionfrequencyistoofastforthemechanicalswitchtoreact,thecounterwillstillcountthepulses..

The counter counts the control pulses that are sent from the SC 5501, even if the timings are too fast for the electromechanical switch to react.

Resettingthecountermaybeperformedbypressingtheprovidedbuttonin-sidetheMS5501.Normallythisisdonewhenreplacingtherelay.

19

Resettingthecounter

TheMS5501isprovidedwitha100Arelayinstalledbydefault.ThePCBadapt-erwitha selectionof industry standard footprintsmayalsobe installedbyperformingthefollowingsteps.

Openingthehousingshouldbeachievedbyremovingthefourthumbscrewsindicatedinthefollowingpictureandgentlyliftingthehandlesoutwardsandupwards.

Openingthehousing

20


Removingthehousingcover

Theoldrelaymustberemoved.Startbyremovingthecablesconnectingtherelaytotheinputandoutputposts(highsideonly)usinga10mmwrench.Thiswillbeperformedtwotimes,ontheinputandoutputsidesoftheMS5501.

21The system should appear as in the following picture when the relay isremoved:

Uninstalled100Arelay

22


Reinstallingthe100Arelaymaybeachievedbyreversingtheabovesteps.

InstallingtheincludedPCBwithstandardrelayfootprintsmaybeinstalledus-ingthefollowingprocess.

InstallthesuppliedstudsandthePCBusingthesuppliedhardwareascrew-driverwithT25bit.

It should never be necessary to remove the negative connections inside the MS 5550. The AES 5501 was designed, in accordance to the standards, to open only the positive battery lead.

InstalltherelayPCB

The studs will require the use of washers (included) between the base of the ES 5501 and the stud.

23 The PCB containing the relay sockets uses two studs included with the AES 5501 system.

Next,connecttheincludedcabling.Thisincludestwosets:twoshortbatterycables,andasix-pincable.

Thesix-pincableprovidesthenecessarydrivevoltagestotherelay.Takecarewhen installing this cable.

Thetworedbatterycablesshouldbeconnectedfromthebatterystudstothecommonandnormallyopenconnectionsasshown.

24


Nextyouwillneedtoselectthevoltageforyourspecificrelay.TheincludedBoschrelayispartnumber0332019151andusesa12Vdrivevoltage.TheAES5501systemwasdesignedtoinclude12,24and42(36)voltdrivevoltagestotherelay.Thevoltagefortherelaycomesovertheshortsixpincableandisselectedasshowninthefollowingpicture.

Selectingthedrivevoltage

25 Carefully select the drive voltage of the relay installed before connecting the drive cable to the MS 5501. Degradation in performance or damage may result in incorrectly selected drive voltages.

The limitation in the supplied Bosch relay is 30 A. If another relay is installed, the entire system’s perfor-mance must be adapted to the relay current.

TheMS5501maybeclosedagainusingareverseprocessofthatgivenabove,andreconnectingthesixscrewsandthedrivecablefromtheSC5501.

Please note that the coil suppression diode is required. Mind the polarity of the diode when exchanging relays.

26


TheAN5501containstheartificialnetworkratedto100A,thenecessaryselect-ableimpedance,anextrabananaconnectorforexternalimpedancesandanoutputconnectorformonitoringifnecessary.

8 the an 5501

TheAN5501shallbeconnectedtotheSC5501usingthesuppliedcontrolcable.Asinanyoftheseexternalchassis,itisnotimportantwhichcableisconnected;anyofthethreeavailablemaybeused.

ToselecttheRSresistor,choosetheappropriateresistancevalueontheSC5501.Ifanexternalresistorshallbeused,selectingoff/externalontheSC5501willactivatetheExt.Rconnector.Payattentionthataresistorofsufficientpowerisusedbasedonyourbatteryvoltageusingthefollowingformula.

P=U2/R

The AN 5501

27

When an external resistor is used, care shall be taken to selectaresistorvalueofsufficientpowertowithstandthe battery voltage.

WherePistheresistorpower,UisthebatteryvoltageandRistheresistorvalueinOhms.

Thegroundjumper

TheAN5501containsajumperforconnectingthenegativebatteryinputter-minaltoground.Thisshouldbe leftconnectedusually (and isrequiredforconformancetoISO7637).TheoutputsideoftheANalsocontainsaspecialconnectionforthecalibrationadapter.Thiscanbeignoredduringdailyuse.

Matingsurfaceforthecalibrationadapter

28


TheAN5501alsohasaplaceforconnectingaresistorwhenusingtheexternalsettingontheSC5501.WhilemostcommonimpedancesareincludedintheAN5501,thesebananaconnectorscanbeusedforadditionalRS shuntresistors.

TheexternalRsjacks

299 the es 5501 electronic sWitch

TheES5501isthecontaineroftheelectronicswitchwithspecificationsoutlinedinISO7637-2.

The ES 5501

TheES5501isa100Afastelectronicswitch.Refertochapter6forcontrol.BeforeusingtheES5501,youmustconnectthecontrolcablefromtheES5501totheSC5550.TheES5501containsaBNCconnectorforeaseofuse.

30


10 operation

Ineverycase,itisimportanttoconsiderwheretheinputandoutputsofthesystemare. The input is always to the left of the various chassis, and theoutputisontheright.Thecablesareexchangeable,asisthepositionsoftheswitches,aslongastheinputsandoutputsareobserved.

The AES 5501 Emissions system

Intheaboveexample(hereshownwithbothswitches)theDCvoltage(battery)comesintheleftsideandtheDUTwouldbeconnectedontheright.

31Carefully observe cable placement, observingmaximum cable lengths andcableplacingrequirementsofyourstandard.

It is important to observe proper polarity when connect-ing the oscilloscope probe. Most oscilloscope probes have a ground connection. The AN 5501 is not isolated and failing to observe proper polarity can cause a short of the power supply to ground!

TheAES5501beingconfiguredforzerocablelength

Onceallcablesareinplaceandthevariouslengthsofcablesareobserved,providetheDCvoltagetotheDUTbyswitchingboththeMechanicalSwitchandElectronicSwitchto“On”.

TheAES5501canalsobeusedwiththesuppliedpins.TheallowstheusertoeffectivelyhavezerodistancebetweentheANandswitches.

32


Next,selectyourRSbyselectingtheresistancevalueontheSC5501.Toper-formtheslowpulse,forexample,selecttheMechanicalSwitch->Triggered,and use either theManual, Single, Internal fields to select the timing. AnyswitchintheDCpathmustbeselected“ON”or“Triggered”or“DC”willnotpasstotheDUT.

All switches in the DC path must be set to “On” or “Trig-gered” or no battery will be available to the DUT.

Throughout the system, a green LED means DC switched on, a red LED indicates an error condition, and an unlit LED indicates that the switch is switched off.

Cable lengths are strictly required by most standards, as is the cable height above the ground plane. Observe these restrictions carefully for a compliant test.

Afterallofyourcablesareconnectedand theDUT ispowered through theswitch(es)thenyouarereadytocreateadropout.Notethattheworstemis-sionsreturnsusuallyoccuratthetimeofswitchingthevoltageoffduetoin-ductivekickback.

3311 specifications

Complete system1: Batterycurrent 100A Inrushcurrent2 300Afor200ms Batteryvoltage 0to60VDC Shuntresistor(RS) 10,20,40,120Ω,Ext. Triggermodes External,internal, single,manual Batteryofftime(TOff) 10ms-10s±(10%+10ms) Battery on time (TOn) 0.5-10.5s±(10%+10ms) Mainsinputvoltage 85-264VAC,47-63Hz Availablerelay 12,24,36V(for42V voltage applications)Electronic: SwitchingtimeΔts 300ns±20%3

Voltagedrop <1V@25A Typ.<2.1V@100A Transientvoltage >440V protectionMechanicalswitch: Type Automotiverelay Contacts HighpurityAgNiwithno suppressionacrosscontacts Voltagerating >400VArtificialnetwork: Inductance 5μH Capacitance 0.1μF Resistance 50Ω Impedance AsperISO7637-2seeabove impedancecurveConnectors: 100AMCtype,countersunk,50mmaboveground planeHousing: Stainlesssteel,unpaintedunderside,screw terminalandearthconnections

34


Indicators: Counteronrelay,LEDindicatoroncontrollerfor mechanicalandelectronicswitchsMeasurement: MS5501,ES5501-directlyconnectedtooutputPorts: AN5501-5.6koutputimpedance(tooutput connector-necessaryforimprovedRF performance)

Alltolerances±10%unlessotherwisenoted.

1)Active,temperaturedependantcooling.TheES5501isdependingonduty cycle, approximately3minutesat100Awith100%dutycyclebefore the switchwillbedeactivatedforcooling.Seederatingbelow.2)WithsuppliedrelayorElectronicSwitch3)WithtestloaddefinedinISO7627-2.Purelyresistiveloadsdisplaytypically intherangeofafewmicroseconds.

ES5501switchingcurvewithtestload

35

ImpedancecurveoftheAN5501

Derateing ES 5501

60

65

70

75

80

85

90

95

100

0 10 20 30 40 50 60

ON-Time [min]

Ion

(100

% D

uty

Cyc

le, @

25°C

) [A

]

CurrentcapabilityofES5501

0

10

20

30

40

50

60

0.1 1 10 100

f [MHz]

ZPB

[Ω]

36


12 technical data

Mainsvoltage: 85...264VACPower(max.): 100WFuse: 2xT3.15A

PhysicalDimensions(LxWxH): ES5501 125x125x125mmMS5501 125x125x125mmAN5501 340x270x205mmWeight: ES5501 3.4kgMS 2.4kgSC5501 2.9kgAN5501 10kg

TemperaturerangeOperationat: +10to+40ºCStorageat: -10to+60ºCHumidity: 30to78%(noncondensing)Airpressure: 860to1060hPa

Environmental conditions

Dimensions and weights

37

ExceptfortherelayintheMS5501,therearenouserserviceablepartsinside.Forfuseselection,pleaseseethesectionontechnicaldata.

13 maintenance

13.1 CleaningCleaningtheAES5501shouldbeperformedusingonlyaclean,drycloth.Nodetergentsofanykindarerecommended.

13.2 CalibrationTheAES5501hastwopartsrequiringcalibration:TheES5501andAN5501.

13.2.1 Calibrating the AN 5501CalibrationoftheAN5501isperformedusingthecalibrationkitINA5500-CKwhichprovidesashortingconnectorfortheinputsideandaMCtoN-Typeconnectorfortheoutputsidewherethenetworkanalyzerisconnected.Thegroundingplugmustbeinplaceduringcalibration.

Formoredetailsoncalibration,seethecalibrationprocedureanddocumen-tationincludedintheINA5500-CK.

13.2.1 Calibrating the ES 5501Calibration of the ES 5501 is performed using the test load defined in ISO7637-2.ThisisavailableundermodelnumberINA5500-TL.Theswitchingtimeof300nsisonlyvalidusingthisload.Resistiveloadsandopencircuitmea-surementwillbedifferent.

38


Insidethepackaging,youwillfindthefollowingitems:

14 the package contents

1xMS5501Mechanicalswitch1xES5501Electronicswitch1xSC5501Systemcontroller3xControlcablesCalibrationcertificateUsersguide(thisguide)OscilloscopeprobecomplianttoISO7637-24xPinadapters(forzeromillimetresbetweendevices)4x4to6mmadapters2xAlternativerelayPCB,cableandhardware

3915 declaration of conformity

To find your local partner within Teseq®’sglobalnetwork,pleasegotowww.teseq.com

©December2010Teseq® Specifications subject to changewithout notice. Teseq® is an ISO-registeredcompany.Itsproductsaredesigned and manufactured underthestrictqualityandenvironmentalrequirements of the ISO 9001. Thisdocumenthasbeencarefullychecked.However, Teseq® does not assumeanyliabilityforerrorsorinaccuracies.

HeadquartersTeseq AG4542Luterbach,SwitzerlandT+41326814040F+41326814048sales@teseq.comwww.teseq.com

ChinaTeseq Company [email protected]

GermanyTeseq [email protected]

SingaporeTeseq Pte [email protected]

TaiwanTeseq [email protected]

USATeseq Inc.T+17324170501F+17324170511Tollfree+18884170501usasales@teseq.com

ManufacturerTeseq AG4542Luterbach,[email protected]

FranceTeseq [email protected]

JapanTeseq [email protected]

SwitzerlandTeseq [email protected]

UKTeseq [email protected]

aes 5501 automotive emissions system - teseq€¦ · aes 5501 - automotive emissions system 7 the...

Documents