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Technical Publication

SAM

Functional Description

E532187/00E

Printed in Germany

© 2005 Copyright MTU Friedrichshafen GmbH

Diese Veröffentlichung einschließlich aller ihrer Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken und Online-Diensten. Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Änderungen bleiben vorbehalten.

Printed in Germany

© 2005 Copyright MTU Friedrichshafen GmbH

This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic systems including data bases and online services. This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Subject to alterations and amendments.

Imprimé en Allemagne

© 2005 Copyright MTU Friedrichshafen GmbH

Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne. Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite. Modifications réservées.

Impreso en Alemania

© 2005 Copyright MTU Friedrichshafen GmbH

Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH. El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del personal de mantenimiento y de servicio. Nos reservamos el derecho de introducir modificaciones.

Stampato in Germania

© 2005 Copyright MTU Friedrichshafen GmbH

Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego o utilizzo, con particolare riguardo alla riproduzione, alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm e alla memorizzazione o all’elaborazione in sistemi elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH.

II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’utente al personale addetto alla manutenzione e alla condotta. Con riserva di modifiche.

Impresso na Alemanha

© 2005 Copyright MTU Friedrichshafen GmbH

A presente publicação, inclusive todas as suas partes, está protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a autorização

prévia e por escrito da MTU Friedrichshafen GmbH. Isto diz respeito em particular à reprodução, divulgação, tratamento, tradução, microfilmagem, e

a memorização e/ou processamento em sistemas eletrônicos, inclusive bancos de dados e serviços on-line.

Para evitar falhas ou danos durante a operação, os dizeres do manual devem ser respeitados. Quem explora o equipamento economicamente consequentemente deve colocá-lo à disposição do respetivo pessoal da conservação, e à dispositção dos operadores.

Salvo alterações.

Table of Contents

01

1 Function 03 1.1 Use 03 1.2 Overview of device functions 04 1.3 Ambient conditions
1
Function
03
1.1
Use
03
1.2
Overview of device functions
04
1.3
Ambient conditions
07
1.4
CAN communication link
12
1.5
Ethernet communication link (10/100BaseT)
13
1.6
RS422/RS232 communication link
15
1.7
Binary inputs with common ground
16
1.8
Binary inputs via optocoupler
19
1.9
Binary transistor outputs
22
1.10
Binary outputs:
Transistor sw itches
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24
1.11
Binary outputs:
Relay switche s
27
1.12
Binary outputs:
PWM outputs via L ow switches
29
1.13
Signal outputs to control display instruments
31
1.14
Interface for measuring sensor (analog IN)
33
1.15
Electrically isolated analog inputs
Frequency inputs
Removable memory
Fault display
C ontrol keys
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38
1.16
40
1.17
41
1.18
42
1 .19
4 3
1.20
Ex tendibility
44
1.21
Self-diagnosis (ITS)
46
1.22
Index
49

02

Table of Contents

Function

03

1

1.1

Function

Use

The SAM is primarily used for the following tasks:

• Connection of additional peripheral engine sensors and actuators.

• Conversion of CAN bus signals (data flow), e.g. ECU data and messages into separate signals. These signals are normally used to control measuring instruments or signal lamps in customer instrument panels.

• Evaluation of discrete signals, e.g. binary switches or analog values (e.g. speed demand from customer control panels or plant computers).

• Simple programmable logic for customer functions, e.g . speed regulation or power optimization for rail systems.

• Display of fault messages for service personnel on a small display.

• Adaptation of the MTU PCS5 bus to various customer bus systems.

• Automatic backup of all ECU data and the ECU-FSW (Functional Software).

• Upload and download of SAM data and ECU parameters via Ethernet 10BaseT using the TCP/IP protocol. The SAM must be installed in a protected and clean environment.

04

Function

1.2 Overview of device functions

View of SAM

04 Function 1.2 Overview of device functions View of SAM E532187/00E 05-11 © MTU

Function

05

Graphic representation of functional units

Function 05 Graphic representation of functional units Legend for graphic Item Designation Item Designation

Legend for graphic

Item

Designation

Item

Designation

1

Switching input (referenced to ground)

13

LCD display: 2 lines of 16 characters

2

Switching input (optocoupler input)

14

Connector for MCS5 I/O module signals

3

2* active: Frequency input active transmitter

16

 

20

* TOHI: 0.5A

5

2* passive: Frequency input inductive transmitter

17

 

17

12 * TOLO: 0.3A

8

* TOLO: 1.0A

6

Alternatively: Serial interface RS422 or RS232

18

PWM 1.5A TLOLOP: Ri=01

7

Ethernet interface

19

NO/NC relay 1A

9

PPC: Central processor

20

8

* (0 - 10V)

10

SRAM: 512Kbyte*16

21

Alternatively:

4

* (4 - 20mA)

4

* (0 - 10V)

06

Function

Item

Designation

Item

Designation

11

Flash ROM: 512Kbyte*32

   

12

Compact Flash Card: 32 or 64Mbyte

   

Explanation of abbreviations

Abbreviation

Description

TOHI

Transistor Output High (Source 0.5A from U Batt ).

TOLO

Transistor Output Low (Drain 0.3A to U Batt_GND ).

TOLOP

Transistor Output Low Power (Drain 1.5A to U Batt_GND ).

Multipurpose channel involved when several signal types are stated. Channel function is defined in the course of SAM application engineering (project environment).

Function

07

1.3 Ambient conditions

Use

• Installation in enclosed control cabinets

• Suitable for rail mounting or screw mountin g on cabinet back wall (fixed installation)

• Suitable for connecting wires or stranded conductors up to AWG16 (US) (1.5 mm 2 )

Technical data of SAM

Term

Unit

 

Value

Installation position

 

As desired, however integral fault display should be legible.

Operating voltage

VDC

24 rated value (-50%; +30%)

Power consumption

W

Below 6 (0.25A at 24V) without additional loads

Degree of protection:

 

IP 40 as per DIN 40 050

Shock:

   

Rail mounting

10g, 11ms

Fixed installation

30g, 11ms

Vibration:

   

Rail mounting

Hz

2

- 12.8:Xpp < ± 3mm

12.8

- 1000:a < 1g [rms]

Fixed installation

Hz

2

- 12.8: Xpp < ± 3mm

12.8

- 100:a < 4g [rms]

Ambient temperature:

°C

-40 - +70 with circulating ambient air

Storage temperature:

°C

-40 - +100

Relative humidity

%

5

- 97, non-condensing

Color:

 

Blue (RAL5015)

Material:

%

Polycarbonate reinforced with 10% fiberglass

Dimensions:

mm

L x W x H (295 x 151 x 75)

Weight:

kg

Approx. 1.6

Note: Values specified above may vary when used in conjunction with MCS5 extension modules.

08

Function

EMI/EMC - Electromagnetic interference (general)

The SAM has been tested according to the following standards and meets the relevant limit values:

Standard

Testing

EN 55011

(Conducted Emission) 10 kHz - 30 MHz Class A

EN 55011

(Radiated Emission) 30 MHz - 1 GHz

IEC-60533:1999

(Conducted Emission) 10 kHz - 30 MHz (type test)

EC-60533:1999

(Radiated Emission) 150 kHz - 2 GHz (type test)

EN 61000-4-2

(ESD interference immunity) ±8kV

EN 61000-4-3

(Radiated interference immunity) 80MHz - – 2GHz

EN 61000-4-4

(Burst interference immunity) ±2kV

EN 61000-4-5

(Surge interference immunity) ±1kV/±2kV

EN 50155

(Surge interference immunity) ±1.8kV

EN 61000-4-17

(LF conducted interference) 0.03 – 10 kHz / 3Veff

EN 61000-4-29

(Mains fluctuation / STANAG 1008)

IEC 60092-504

(Dielectric strength) 550VAC / 10mA

EN 50155

(Isolation) 500V / 10MOhm

Function

09

Special application (automotive industry)

Standard

Testing

EN 55025:2003

(Conducted) Class 1

EN 55025:2003

(Emission) Class 1

EN 13309:2000

(Emission) EUB limit value

ISO 11452-2:2000

(Radiated) 1 MHz – 18 GHz 50V/m

ISO7637-2.2:2002

Pulse 1 - 600V / 50.0 / 5000 pulses level 4

Pulse 2a +50V / 2.0 / 5000 pulses level 4

Pulse 2b +20V / 0.05 / 10 pulses level 4

Pulse 3a - 200V / 50.0 / 1 hour level 4

Pulse 3b +200V / 50.0 / 1 hour level 4

Pulse 4 - 20V / 0.01 / 5 pulses level 4

Pulse 5a +73V / 2.0 / 1 pulses level 2

ISO 7637-3:1999

Pulse 3a - 500V / 50.0 / 10 minutes per cable

Pulse 3b - +500V / 50.0 / 10 minutes per cable

ISO 10605:2001

ESD operating test level 2

ESD packing and transport test level 1

Requirements for fulfillment of EMI/EMC limit values are as follows:

• The housing of the SAM must be connected to housing ground e.g. by a cable with a minimum cross-section of 2.5 mm 2 . Cable length shall not exceed 10 cm.

• Twisted-conductor cables only shall be used to connect sensors and actuators. Maximum length of shall not exceed 5 m for unshielded cables and 50 m for shielded cables (providing that cable harness impedance allows).

10

Function

Electrical requirements

Term

Unit

Value

Operating voltage:

V

24, -50% to +30% (+12 - +32)

Admissible residual ripple less than 5% as per STANAG

1008.

Note: The processor is automatically reset if the voltage falls below 7.

Power supply:

W

Below 7. Without activated loads at SAM outputs Additional output current on positive or negative conductor shall not exceed 10 A DC in total.

Current terminals:

mm

5.08 terminals (spring-cage terminals)

• Wire diameter AWG14 (US) or 2.5 mm 2 recommended.

Electrical isolation:

V

• Supply ground is common reference potential (Common Ground) for all SAM electronics. This applies to the entire I/O range with the exception of certain electrically isolated channels.

• SAM electronics ground is not connected to housing ground.

• Signal cable shields must be connected to housing ground if applicable.

• Maximum direct current isolating voltage is 500 unless otherwise stated.

Mechanical design

Term

Unit

Value

Installation position:

 

• Horizontal (to facilitate legibility of fault display and inscriptions on SAM housing).

• Note that space is required to connect cabling at the top and bottom when installing the SAM in control cabinets.

• The device heats up as a result of power dissipation. Heat from the SAM dissipates through the back wall. Ensure that heat can be conducted away from the back wall of the SAM to the mounting frame. Do not allow neighboring devices to additionally heat up the SAM.

Signal connections

The SAM module is easily replaced. The input and output signal cables are equipped with modular connectors. Common function channels are combined in groups. The wires are connected using spring-cage terminal technology. Two wires may be connected to one terminal when the wires are crimped in a double-wire ferrule. For example, a Phoenix AL-TWIN 2* 0.75-10 may be used. Connector modules are plugged together. The connector modules are equipped with coding pins to preclude polarity reversal.

Function

11

Terminals

Term

Unit

Value

Terminal strip modules:

 

WAGO spring-cage terminals

Current-carrying capacity (at 70 °C):

A

10 per contact

Measuring voltage:

V

250

Measuring surge voltage:

V

2500

Wire cross-sections:

mm

2

Up to 1.5 or AWG15

Clamping range:

mm

2

0.08 – 1.5 or AWG15

Note:

Power supply and CAN bus connections feature different terminals (RM 5.08) and wires AWG14 (2.5 mm 2 ).

12

Function

1.4 CAN communication link

CAN communication link

Number of channels:

3 CAN interfaces; electrically isolated

CAN interface hardware conforms with the definition in ISO11998. The controller supports CAN version 2.0B/ (11/29 bit coding) . All interfaces are electrically isolated from each other and from the SAM electronics. The interface operates with a 5V voltage level. 3 CAN channels are provided on the boar d. Additional channels can be realized as an option using an MCS5 extension module, e.g. a CCB2-02 module. One separate Y-connector plug “twin-wire connection” is provided for each CAN channel. The terminal plug is equipped with the terminals described above. CAN bus communication should not be disrupted if a connection on the SAM is disconnected. A terminator (120 ohm) must be installed at the connector plug when the SAM is used as a bus terminator device. Note:

The connection (X4) for the MTU dialog unit features the signal lines for CAN_1 and CAN_2 and an additional 24V power supply.

Pin assignment:

Designation

PIN

X6

X7

X8

X4

CAN_1

CAN1H

3

   

H

CAN1L

2

   

G

GND_CAN1

1

   

M

CAN_2

CAN2H

 

3

 

B

CAN2L

 

2

 

C

GND_CAN2

 

1

 

L

CAN_3

CAN3H

   

3

 

CAN3L

   

2

 

GND_CAN3

   

1

 

Dialog

L batt+ (24V)

 

E

L GND

K

Function

13

1.5 Ethernet communication link (10/100BaseT)

Communication link (10/100BaseT)

Number of channels:

1 Ethernet interface; electrically isolated

Ethernet interface hardware conforms with the definition in IEEE802.3. A standard RJ-45 connector (Western connector) is provided on the board. The bus lines are coupled via a signal converter and are thus electrically isolated from th e SAM electronics.

are thus electrically isolated from th e SAM electronics. 1 Transmit 2 Receive 3 RJ-45 connection

1 Transmit

2 Receive

3 RJ-45 connection

The operating status of the interface is indicated by a yellow and red LED on the board.

• Link red LED; connection established to LAN device.

14

Function

• Bsy yellow LED; communication in progress.

Interface:

10/100Base_T (10/100Mbit/s, twisted conductor pairs).

Applications:

Connection to HUB:

Use patch cable CAT5 (1:1).

Connection to PC:

Use crossed cable CAT5.

Designation

Pin

X5

EIA/TIA-T 568 A standard

EIA/TIA- 568 B standard

Transmit data positive

Tx (+)

1

white/green

white/orange

Transmit data negative

Tx (-)

2

green

orange

Receive data positive

Rx (+)

3

white/orange

white/green

   

4

   
   

5

   

Receive data negative

Rx (-)

6

orange

green

   

7

   
   

8

   

Housing ground

 

9

   

Function

15

1.6 RS422/RS232 communication link

RS422/RS232 communication link

Number of channels:

1

serial interface; electrically isolated

Connection as per RS422, with one pair of t ransmit lines and one pair of receive lines. Channel may also be used as an RS232 communication link for minimum configuration with signals TxD, RxD and Signal_GND.

Pin assignment

Group

Designation

Pin

X14

   

Tx

1

Rx

4

RS232

RS232_GND

5

SAM_GND

6

Serial link

 

O1 ( TxB [+] )

1

O2 ( TxA [ -] )

2

RS422

I1 ( RxB [+] )

3

I2 ( RxA [ -] )

4

RS422_GND

5

 

SAM_GND

6

Standard configuration:

Baud rate:

1.2 to 19.2 kbaud

Data

8

bits

Parity

N

Stop bits

1

Data flow control

Xon/Xoff

16

Function

1.7 Binary inputs with common ground

Binary inputs with common ground

These channels may, for example, be connected by a line to a switch connecting +U Batt or U batt_GND to the input channel.

Term

Unit

Value

Number of channels

 

8 binary inputs with common U Batt_GND reference potential

Voltage range

 

U Batt_GND to +U Batt

Initial voltage without connection

V

3.8

Input impedance

kohm

~6.9 to GND

Rated input current:

   

Switch for +U Batt

mA

3.5

/24V

Switch for U Batt_GND

µA

 

-22 / 0V

Threshold voltage

 

Measured at input terminal; Signal source impedance is less than 10 ohm

Switch for +U Batt

V

Vin > 10 -> Contact closed (logic high) Vin < 9 -> Contact open (logic low) For Open-Load detection: (33 kohm contact parallel resistor) 9>V in > 4.2 -> Contact open (logic low) V in < 4.2 -> Contact open (Open Load)

Switch for U Batt_GND

V

V in < 1.9 -> Contact closed (logic high) V in > 1.9 -> Contact open (logic low)

For Open-Load detection: (33.2k contact parallel resistor)

1.9

< V in < 3.5 -> Contact open (logic low)

V in > 3.5 -> Contact open (Open Load)

DC isolation

 

None

Sampling rate

Hz

The sampling rate is determined by the software: E.g. 100

Signal filter

Hz

HW low-pass filter: fg = 500 *Note1

Contact bounce

ms

Masking by software e.g. 50 signal holding

Function

17

Function 17 1 VIN 2 A/D converter The input voltage is measured by an analog/digital converter

1 VIN

2 A/D converter

The input voltage is measured by an analog/digital converter ( 10 bit resolution). The switching thresholds are set by software parameters. This also makes it possible to det ect broken wires when the switch contacts are connected in parallel to a 33k resistor. The inputs may be switched to positive voltage (+U Batt ) or ground potential . The P-IN1 and P_IN2 channels are additionally connected to the TPU channels of the MPC565. This makes frequency measuring possible at these inputs. The HW low-pass filter cut-off frequency for these two channels is fg = 10kHz.

Frequency measuring requirements:

Term

Unit

Value

Switch-on threshold, HV threshold voltage (w.c.)

V

U signal > 11.1

Switch-off threshold, LV threshold voltage (w.c.)

V

U signal < 3.2

Switching hysteresis:

V

U hyst 2.7 to 4.1

Frequency:

Hz

32 to 6 kHz

U signal is the voltage at the SAM terminals.

18

Function

Pin assignment

Group

Designation

Pin

X14

X19

 

Bin/pulse

P_IN1

 

5

Bin/pulse

P_IN2

 

6

Bin

P_IN3

 

7

Bin

P_IN4

 

8

Binary inputs with common reference ground

Bin

P_IN5

 

9

Bin

P_IN6

 

10

 

Bin

P_IN7

 

11

Bin

P_IN8

7

 

Bin

GND

8

12

Function

19

1.8 Binary inputs via optocoupler

Binary inputs via optocoupler

Term

Unit

 

Value

Number of channels

 

20

electrically isolated binary inputs

Reference voltage

 

None: Each channel must be connected with two lines and is isolated from all other channels.

Voltage range

 

U

Batt_GND to +U Batt

Initial voltage without connection

   

None

Input impedance

kohm

~5.5 (load)

Rated input current:

   

Switch for +U Batt “ON”

 

mA

 

+4.0

Switch for U Batt_GND “OFF”

mA

0

Switching voltage

 

Measured at input terminal

V in >= 12 V

 

mA

I in > = 1.6 -> High

V in =< 9 V

mA

I in < 1.3 -> Low

(typical value is 10.5V threshold voltage)

V

For Open-Load detection: (33.2k contact parallel resistor)

V

in < 9.0 -> Contact open (logic low).

 

9.0 > V in > 2.1-> Contact open (Open Load).

DC isolation

V

DC

>

= 500

Sampling rate

Hz

The sampling rate is determined by the software: E.g.

 

100.

Signal filter

Hz

HW low-pass filter: fg = 500

Contact bounce

ms

by software e.g. 50 signal holding.

Online self-diagnosis

kohm

 

Yes:

Wire break (when switch is connected in parallel with a

33

resistor).

20

Function

20 Function 1 A/D converter 2 U in 3 I in The secondary voltage of the

1 A/D converter

2 U in

3 I in

The secondary voltage of the optocoupler is measured by an analog/digital converter (10 bit resolution). The switching thresholds are set by software parameters. This also makes it possible to detect broken wires when the switch contacts are connected in parallel to a 33kohm resistor.

Pin assignment

Group

Designation

Pin

X2

X3

X11

X12

OKI_switch

B_OKI_CH1

B_IN1_H

 

1

   

B_IN1_L

 

2

   

B_OKI_CH2

B_IN2_H

 

3

   

B_IN2_L

 

4

   

B_OKI_CH3

B_IN3_H

 

5

   

B_IN3_L

 

6

   

B_OKI_CH4

B_IN4_H

 

7

   

B_IN4_L

 

8

   

B_OKI_CH5

B_IN5_H

 

9

   

B_IN5_L

 

10

   

B_OKI_CH6

B_IN6_H

 

11

   

B_IN6_L

 

12

   

B_OKI_CH7

B_IN7_H

     

1

B_IN7_L

     

2

B_OKI_CH8

B_IN8_H

     

3

B_IN8_L

     

4

Function

21

Group

Designation

Pin

X2

X3

X11

X12

 

B_OKI_CH9

B_IN9_H

     

5

B_IN9_L

     

6

B_OKI_CH10

B_IN10_H

     

7

B_IN10_L

     

8

B_OKI_CH11

B_IN11_H

     

9

B_IN11_L

     

10

B_OKI_CH12

B_IN12_H

     

11

B_IN12_L

     

12

B_OKI_CH13

B_IN13_H

1

     

B_IN13_L

2

     

B_OKI_CH14

B_IN14_H

3

     

B_IN14_L

4

     

B_OKI_CH15

B_IN15_H

5

     

B_IN15_L

6

     

B_OKI_CH16

B_IN16_H

7

     

B_IN16_L

8

     

B_OKI_CH17

B_IN17_H

9

     

B_IN17_L

10

     

B_OKI_CH18

B_IN18_H

11

     

B_IN18_L

12

     

B_OKI_CH19

B_IN19_H

   

1

 

B_IN19_L

   

2

 

B_OKI_CH20

B_IN20_H

   

3

 

B_IN20_L

   

4

 

22

Function

1.9 Binary transistor outputs

Binary transistor outputs

The High switches and the Low switches are connected internally on the SAM. Activation as High or Low switch is set by the software. The two output types are determined in the project application environment. The substrate diodes of the output transistors operate like clamp diodes. An additional external clamp diode, as normally used for inductive loads (relays, valve coils), is superfluous. Combination of High switches and Low switches:

superfluous. Combination of High switches and Low switches: 1 High switch (BTS480R) 2 Low switch (TLE6240GP)

1 High switch (BTS480R)

2 Low switch (TLE6240GP)

3 Diagnostic current source

Group

Designation

Pin

X17

X18

Power activation

Transistor outputs

BIN_OUT_CH1

3

 

BIN_OUT_CH2

4

 

BIN_OUT_CH3

5

 

BIN_OUT_CH4

6

 

BIN_OUT_CH5

7

 

BIN_OUT_CH6

8

 

BIN_OUT_CH7

9

 

BIN_OUT_CH8

10

 

BIN_OUT_CH9

11

 

BIN_OUT_CH10

12

 

BIN_OUT_CH11

 

1

BIN_OUT_CH12

 

2

BIN_OUT_CH13

 

3

BIN_OUT_CH14

 

4

BIN_OUT_CH15

 

5

Function

23

Group

Designation

 

Pin

X17

X18

   

BIN_OUT_CH16

 

6

BIN_OUT_CH17

 

7

BIN_OUT_CH18

 

8

BIN_OUT_CH19

 

9

BIN_OUT_CH20

 

10

Load supply voltage

+L Batt

 

2 12

Reference ground for load

L

GND

 

1 11

24

Function

1.10 Binary outputs: Transistor switches

Binary outputs: Transistor High switches

Term

 

Unit

Value

Number of channels

 

20 Transistor High switches Note: These channels are used in common with the transistor Low switches.

Reference voltage

 

Two terminals are provided separately

for supply voltage +U Batt and U

(use wire cross-section AWG 15 mm or

Batt_GND

2

1.5

mm 2 ).

Voltage range

V

+U Batt (12 - 45)

Initial voltage without connection

V

2.3

- 3.7

Impedance in ON state

m

Less than 320 per channel

Output current

   

ON

state

A

Less than or equal to - 0.5

OFF state

µA

Less than or equal to + or – (50 - 150)

DC

isolation

 

None

Switching cycle

Hz

The switching rate is determined by the software:

Less than 10 admissible

Signal filter

nF

Capacitor with 100 to U Batt_GND (EMI/EMC)

Short circuit

A

Self-protection commencing at 0.7 and reaching to 1.9.

Online self-diagnosis

 

Yes, Note*

Note*: Minimum load current must exceed 500µA to avoid associated fault messages. This means that load impedance should be less than 30 kohm. The outputs offer the following benefits:

• Overload protection with thermal breaking

• Overvoltage protection (Load Dump Protection)

• Possibility of switchin g inductive loads: (1 joule per channel when the channels are switched simultaneously, otherwise 10 joules per channel)

Function

25

Binary outputs: Transistor Low switches

Term

Unit

Value

Number of channels

   

20 transistor Low switches Note: These channels are used together with the transistor High switches (see above). The number of Low transistors is divided into 12 low-current and 8 high-current outputs.

Reference voltage

 

mm

2

Two terminals are provided separately for supply voltage +UBatt and UBatt_GND (use wire cross-section AWG 15 or 1.5).

Voltage range

 

V

+U Batt (up to 12 - 45)

Initial voltage without connection

 

V

2.3

- 3.7

Impedance in ON state

     

Low current

1.3

per channel

High current

0.2

per channel

Output current in ON state

   

Low current

A

Rated value less than or equal to 0.3 per channel

BT_OUT1…

BT_OUT6

and

BT_OUT11…BT_OUT16

High current

A

Rated value less than or equal to 1.0 per channel

BT_OUT7…BT_OUT10

 

BT_OUT17…BT_OUT20

Output current in OFF state

   

Low current

µA

Max. - or + (50 - 150)

High current

µA

Max. - or + (100 - 300)

DC isolation

 

None

Switching cycle

 

Hz

The switching rate is determined by the software: Less than 10 admissible

Signal filter

nF

Capacitor with 100 to U Batt_GND

Short circuit

 

Self-protection commences at:

A

1

to 2 for low current

A

6

to 12 for high current

Online self-diagnosis

   

Yes, Note*

Note*: Minimum load current must exceed 1mA to avoid associated fault messages. This means that load impedance should be less than 11 kohm.

26

Function

Benefits

The outputs offer the following benefits:

• Overload protection with thermal breaking

• Overvoltage protection (Load Dump Protection)

The outputs BT_OUT9 and BT_OUT10 may also be used as PWM outputs.

Function

27

1.11 Binary outputs: Relay switches

Binary outputs: Relay switches

Number of channels

4 monostable relays with switching contacts

Reference voltage

None: Each channel must be connected with two lines and is isolated from all other channels.

Voltage range

Less than 36VDC

Contacts

Switching contacts (connected as NO contact or NC contact)

Impedance in ON state

Less than 20 m

Output current

 

ON

state

Less than 1.0 A per channel

OFF state

Less than or equal to 100 µA per channel; a varistor lies above the contacts.

DC

isolation

Isolation less than 300V DC

Switching cycle

The switching rate is determined by the software: Less than 1Hz

Switching cycles at

 

10W

10 6 (resistive load) max.

1W

10 7 (resistive load) max.

Self-protection

Overcurrent protection by multifuse (nom. 1A) Overvoltage protection by varistor (nom. 36V)

28

Function

Online self-diagnosis

Yes

Offline diagnosis

Yes

Pin assignment

Group

Designation

Pin

X15

Relay outputs

BIN_OUT_Rel1

COM1

1

 

NC1

2

 

NO1

3

BIN_OUT_Rel2

COM2

4

 

NC2

5

 

NO2

6

BIN_OUT_Rel3

COM3

7

 

NC3

8

 

NO3

9

BIN_OUT_Rel4

COM4

10

 

NC4

11

 

NO4

12

Function

29

1.12 Binary outputs: PWM outputs via Low switches

Binary outputs: PWM outputs via Low switches

Term

 

Unit

 

Value

Number of channels

 

2

transistor Low switches

Reference voltage

 

U Batt_GND circuit Two terminals are provided separately for the supply voltage +U Batt and Switch L GND (use wire cross-section AWG 15 mm 2 or 1.5 mm 2 ).

Voltage range

 

+ U Batt

Initial voltage without connection

   

Impedance in ON state

m

150 - 250 per channel

Output current in ON state

   

ON

state

A

Less than or equal to 1.5 per channel

OFF state

µA

Max. +/-100

DC

isolation

   

None

Output signal

   

Frequency

Hz

5 to 500 adjustable by software

ON/OFF ratio

%

1 - 100 ; 0: Off

Accuracy (PWM)

%

0.3 of measuring range 60 - 200 Hz

Signal filter

nF

Capacitor with 30 to U Batt_GND

Short circuit

A

Self-protection commencing at 3 and reaching to 6. For switching transistor and supply line.

Online self-diagnosis

 

Yes

The outputs offer the following benefits:

• Overload protection with thermal breaking

• Operation automatically restored after fault rectification

• A free-wheeling diode on the +U Batt supply rail allows switching of inductive loads.

Integral current regulation:

Current measuring for operation of linear magnets is envisaged. The coil current is measured and signaled to the processor via an A/D converter. The processor software corrects the PWM output ratio on the basis of the desired coil current. This is a closed-loop control circuit the dynamic parameters of which can be set by the software. The supply of the coil L Batt + is protected against short-circuit. The response time of the current regulator is appr ox.: Settling time =< 200ms. The coil current is measured by a 100 m measuring resistor. Precise current regulation in the closed-loop control circuit only applies to the output frequency range of 100Hz to 200 Hz. Attainable settling accuracy is = < 0.3 % at 1A current.

30

Function

30 Function 1 Measuring resistor 2 L B a t t +, short-circuit-proof 3 PWM –

1 Measuring resistor

2 L Batt +, short-circuit-proof

3 PWM – control signal

Pin assignment

Group

Designation

Pin

X14

   

PWM1_L

10

PWM

PWM_CH1

PWM1_H

9

control

 

PWM2_L

12

PWM_CH2

PWM2_H

11

Function

31

1.13 Signal outputs to control display instruments

Signal outputs to control display instruments

These outputs are used to control display instrument s or other measuring instruments. 8 channels are provided to control instruments with a 0 - +10 V voltage input. Four of these channels are prepared for additional 0 - 20 mA current signals. The external load of the current channels must be less than 400 ohm. The choice of voltage or current channels for the respective application is made in the application engineering phase.

General

Signal scaling: Scaling parameters can be set by the software. The DC output voltage or current is generated by PWM processor channels. The processor PWM signal is buffered, routed via a low-pass filter and finally amplified.

PWM frequency

1710 Hz

PWM ratio

0 - 100%

Group

Designation

Pin

 

X1

X10

Instrument control

Volt_out

V_OUT1

 

1

 

voltage output

V_OUT2

 

2

 

V_OUT3

 

3

 

V_OUT4

 

4

 

V_OUT5

 

5

 

V_OUT6

   

9

V_OUT7

   

10

V_OUT8

   

11

Common GND

A

GND

 

12

Curr_out

C_OUT1

 

6

 

Current output

C_OUT2

 

7

 

C_OUT3

 

8

 

C_OUT4

 

9

 

Common GND

A

GND

10

 

Auxiliary voltage

24V/-1A

L

batt+

11

 

L

GND

12

 

32

Function

Voltage outputs

Term

Unit

Value

Number of channels

 

8 voltage inputs with common U Batt_GND reference potential

Reference voltage

 

U Batt_GND (AGND)

Voltage range

V

+0 – +10

Accuracy

%

0.3 of measuring range**

Initial voltage without

V

0 - 10

connection

Impedance in ON state

0

Output current

mA

Less than or equal to 8 admissible

DC

isolation

 

None

Settling time

ms

Less than 60.

Short-circuit protection

mA

The output voltage is automatically reduced when current intensity exceeds 20 - 30. Short-circuit proof to +U Batt and

U Batt_GND.

** The value indicates accuracy in the temperature range –20 °C to 75 °C and for an operating period of one year after device manufacture. A factor of 0.05% p.a. must be allowed when determining long-term accuracy.

Current outputs

Term

Unit

Value

Number of channels

 

4

current outputs with common

U Batt_GND reference potential

Current

 

Source to U Batt_GND

Current intensity range

mA DC

0

- 20

Accuracy

%

0.3 of measuring range**

Max. load impedance (load)

Less than 400.

Max. output voltage

VDC

Less than 10.

DC

isolation

 

None

Settling time

ms

Less than 60.

Short-circuit protection

 

Short-circuit proof to +U Batt and

U Batt_GND

** The value indicates accuracy in the temperature range –20 °C to 75 °C and for an operating period of one year after device manufacture. A factor of 0.05% p.a. must be allowed when determining long-term accuracy. Note: These outputs supply current. This means that the current from SAM flows via an external instrument to U Batt_GND .

Function

33

1.14 Interface for measuring sensor (analog IN)

Interface for measuring sensor (analog IN)

The eight analog multi-purpose measuring inputs facilitate alternative measuring of temperatures or voltages and currents.

Pin assignment

Group

Designation

Pin

X16

X20

Analog multi-

AN_CH1

A_Supp_CH1

 

1

purpose inputs

A_In_CH1

 

2

A_GND

 

3

AN_CH2

A_Supp_CH2

 

4

A_In_CH2

 

5

A_GND

 

6

AN_CH3

A_Supp_CH3

 

7

A_In_CH3

 

8

A_GND

 

9

AN_CH4

A_Supp_CH4

 

10

A_In_CH4

 

11

A_GND

 

12

AN_CH5

A_Supp_CH5

1

 

A_In_CH5

2

 

A_GND

3

 

AN_CH6

A_Supp_CH6

4

 

A_In_CH6

5

 

A_GND

6

 

AN_CH7

A_Supp_CH7

7

 

A_In_CH7

8

 

A_GND

9

 

AN_CH8

A_Supp_CH8

10

 

A_In_CH8

11

 

A_GND

12

 

Temperature sensors

Used for:

• PT1000, Ni1000 temperature sensors

• PT100, Ni100 temperature sensors

34

Function

• NTC temperature sensors, e.g. Bosch NTC 284 509 049 (71 - 45k )

Temperature inputs

Term

Unit

 

Value

Number of channels

 

8 commonly used with voltage inputs.

Voltage range

V

+5; AGND

Measuring current:

   

PT1000

mA

 

2.5

PT100

mA

4.5

NTC

mA

2-5

Input impedance

kohm

1

Accuracy of electronics:

   

PT1000

K

±

0.4 (measuring range: -20°C - 120°C)

PT100

K

±

5 (measuring range: -20°C - 650°C)

NTC

K

±

4 (measuring range: -20°C - 120°C)

Short-circuit protection

   

Yes

DC isolation

   

None

Sampling rate

Hz

The sampling rate is determined by the software:

E.g. 100.

Signal filter

Hz

HW low-pass filter: f < 20.

Online self-diagnosis

   

Yes

** The values indicate accuracy in the temperature range –20 °C to 75 °C and for an operating period of one year after device manufacture. A factor of 0.05% p.a. must be allowed when determining long-term accuracy.

Measuring method:

A 5V reference voltage is applied to the sensor resistor.

The measuring current is generated from the temperature impedance and the inherent impedance

of the measuring channel (conductors and contacts).

The temperature-dependent voltage is decoupled by an amplifie r and supplied to the 12-bit analog/digital converter.

Function

35

Function 35 1 A/D channel 2 IN: PT1000, PT100, NTC Analog inputs for voltage/current Used for:

1 A/D channel

2 IN: PT1000, PT100, NTC

Analog inputs for voltage/current Used for:

• Voltage measuring 0 - 5V or 0 - 10V

• Current measuring 0 - 24mA

• Operation of 8 external measuring sensors with 5V supply

Example: Potentiometer or measuring sensor with 5V supply

Example: Potentiometer or measuring sensor with 5V supply 1 A/D channel 2 Potentiometer or 5V pressure

1 A/D channel

2 Potentiometer or 5V pressure sensor

36

Function

Example: Voltage measuring 5V or 10V

36 Function Example: Voltage measuring 5V or 10V 1 A/D channel 2 0 - 5V or

1 A/D channel

2 0 - 5V or 0 - 10V

3 IN: 0 - 10V

Example: Current measuring

2 0 - 5V or 0 - 10V 3 IN: 0 - 10V Example: Current measuring

1 A/D channel

2 Sensor 0 - 20mA

3 IN: 0 - 20mA

Term

 

Unit

Value

Number of channels

 

commonly used with temperature inputs

8

Reference potential

 

U Batt_GND (AGND)

Voltage measuring

   

Voltage range

V

0

- +5; 0 - +10

Impedance

k

100

Current measuring

   

Function

37

Term

Unit

Value

Current range

mA

0

- 30

Load

150

Accuracy of electronics

%

0.2 of measuring range**

Sensor supply

   

Voltage

V

5; 0.1 %**

Current intensity

mA

- 20 DC (current intensity limited internally)

0

Potentiometer supply

   

Voltage

V

5; 0.1 %**

Current intensity

mA

- 20 DC (current intensity limited internally)

0

Pin

assignment

   

A_SUPPx

V

5

potentiometer/sensor supply

A_IN1

Measuring voltage/current input

A_GND

Measuring ground

Short-circuit protection

   

A_SUPPx ->(V Batt+ ; V Batt- )

Yes

A_IN1 ->(V Batt+ ; V Batt- )