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Technical Publication

SAM Functional Description E532187/00E

Printed in Germany 2005 Copyright MTU Friedrichshafen GmbH Diese Verffentlichung einschlielich aller ihrer Teile ist urheberrechtlich geschtzt. Jede Verwertung oder Nutzung bedarf der vorherigen schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere fr Vervielfltigung, Verbreitung, Bearbeitung, bersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschlielich Datenbanken und Online-Diensten. Das Handbuch ist zur Vermeidung von Strungen oder Schden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfgung zu stellen. nderungen 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. Imprim en Allemagne 2005 Copyright MTU Friedrichshafen GmbH Tout droit rserv pour cet ouvrage dans son intgralit. Toute utilisation ou exploitation requiert au pralable laccord crit de MTU Friedrichshafen GmbH. Ceci sapplique notamment la reproduction, la diffusion, la modification, la traduction, larchivage sur microfiches, la mmorisation et / ou le traitement sur des systmes lectroniques, y compris les bases de donnes et les services en ligne. Le manuel devra tre observ en vue dviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous lexploitant de le mettre la disposition du personnel charg de lentretien et de la conduite. Modifications rserves. Impreso en Alemania 2005 Copyright MTU Friedrichshafen GmbH Esta publicacin se encuentra protegida, en toda su extensin, por los derechos de autor. Cualquier utilizacin de la misma, as como su reproduccin, difusin, transformacin, traduccin, microfilmacin, grabacin y/o procesamiento en sistemas electrnicos, entre los que se incluyen bancos de datos y servicios en lnea, precisa de la autorizacin previa de MTU Friedrichshafen GmbH. El manual debe tenerse presente para evitar fallos o daos durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposicin del personal de mantenimiento y de servicio. Nos reservamos el derecho de introducir modificaciones. Stampato in Germania 2005 Copyright MTU Friedrichshafen GmbH Questa pubblicazione protetta dal diritto dautore in tutte le sue parti. Ciascun impiego o utilizzo, con particolare riguardo alla riproduzione, alla diffusione, alla modifica, alla traduzione, allarchiviazione in microfilm e alla memorizzazione o allelaborazione 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 dallutente al personale addetto alla manutenzione e alla condotta. Con riserva di modifiche. Impresso na Alemanha 2005 Copyright MTU Friedrichshafen GmbH A presente publicao, inclusive todas as suas partes, est protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a autorizao prvia e por escrito da MTU Friedrichshafen GmbH. Isto diz respeito em particular reproduo, divulgao, tratamento, traduo, microfilmagem, e a memorizao e/ou processamento em sistemas eletrnicos, inclusive bancos de dados e servios on-line. Para evitar falhas ou danos durante a operao, os dizeres do manual devem ser respeitados. Quem explora o equipamento economicamente consequentemente deve coloc-lo disposio do respetivo pessoal da conservao, e disposito dos operadores. Salvo alteraes.

Table of Contents

01

Function 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22

.....................................................................

03 03 04 07 12 13 15 16 19 22 24 27 29 31 33 38 40 41 42 43 44 46 49

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overview of device functions Ambient conditions ..............................................

...................................................... .................................................. ..................................

CAN communication link

Ethernet communication link (10/100BaseT) RS422/RS232 communication link Binary inputs with common ground Binary inputs via optocoupler

.......................................... .........................................

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Binary transistor outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Binary outputs: Transistor switches Binary outputs: Relay switches ........................................

............................................

Binary outputs: PWM outputs via Low switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal outputs to control display instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface for measuring sensor (analog IN) Electrically isolated analog inputs Frequency inputs ...................................

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........................................................ ......................................................

Removable memory Fault display Control keys Extendibility

............................................................ ............................................................ ............................................................ ......................................................

Self-diagnosis (ITS) Index

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Table of Contents

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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.

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Function

1.2

Overview of device functions

View of SAM

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Graphic representation of functional units

Legend for graphic Item 1 2 3 5 6 7 9 10 Designation Switching input (referenced to ground) Switching input (optocoupler input) 2* active: Frequency input active transmitter 2* passive: Frequency input inductive transmitter Alternatively: Serial interface RS422 or RS232 Ethernet interface PPC: Central processor SRAM: 512Kbyte*16 Item 13 14 16 17 18 19 20 21 Designation LCD display: 2 lines of 16 characters Connector for MCS5 I/O module signals 20 * TOHI: 0.5A 17 12 * TOLO: 0.3A 8 * TOLO: 1.0A PWM 1.5A TLOLOP: Ri=01 NO/NC relay 1A 8 * (0 - 10V) Alternatively: 4 * (4 - 20mA) 4 * (0 - 10V)

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Function

Item 11 12

Designation Flash ROM: 512Kbyte*32 Compact Flash Card: 32 or 64Mbyte

Item

Designation

Explanation of abbreviations Abbreviation TOHI TOLO TOLOP Description Transistor Output High (Source 0.5A from UBatt). Transistor Output Low (Drain 0.3A to UBatt_GND). Transistor Output Low Power (Drain 1.5A to UBatt_GND).

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

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1.3
Use

Ambient conditions

Installation in enclosed control cabinets Suitable for rail mounting or screw mounting on cabinet back wall (fixed installation) Suitable for connecting wires or stranded conductors up to AWG16 (US) (1.5 mm2)

Technical data of SAM


Term Installation position Operating voltage Power consumption Degree of protection: Shock: Rail mounting Fixed installation Vibration: Rail mounting Fixed installation Ambient temperature: Storage temperature: Relative humidity Color: Material: Dimensions: Weight: % mm kg Hz Hz C C % 2 - 12.8:Xpp < 3mm 12.8 - 1000:a < 1g [rms] 2 - 12.8: Xpp < 3mm 12.8 - 100:a < 4g [rms] -40 - +70 with circulating ambient air -40 - +100 5 - 97, non-condensing Blue (RAL5015) Polycarbonate reinforced with 10% fiberglass L x W x H (295 x 151 x 75) Approx. 1.6 10g, 11ms 30g, 11ms VDC W Unit Value As desired, however integral fault display should be legible. 24 rated value (-50%; +30%) Below 6 (0.25A at 24V) without additional loads IP 40 as per DIN 40 050

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

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Function

EMI/EMC - Electromagnetic interference (general)


The SAM has been tested according to the following standards and meets the relevant limit values: Standard EN 55011 EN 55011 IEC-60533:1999 EC-60533:1999 EN 61000-4-2 EN 61000-4-3 EN 61000-4-4 EN 61000-4-5 EN 50155 EN 61000-4-17 EN 61000-4-29 IEC 60092-504 EN 50155 Testing (Conducted Emission) 10 kHz - 30 MHz Class A (Radiated Emission) 30 MHz - 1 GHz (Conducted Emission) 10 kHz - 30 MHz (type test) (Radiated Emission) 150 kHz - 2 GHz (type test) (ESD interference immunity) 8kV (Radiated interference immunity) 80MHz - 2GHz (Burst interference immunity) 2kV (Surge interference immunity) 1kV/2kV (Surge interference immunity) 1.8kV (LF conducted interference) 0.03 10 kHz / 3Veff (Mains fluctuation / STANAG 1008) (Dielectric strength) 550VAC / 10mA (Isolation) 500V / 10MOhm

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Special application (automotive industry)


Standard EN 55025:2003 EN 55025:2003 EN 13309:2000 ISO 11452-2:2000 ISO7637-2.2:2002 Testing (Conducted) Class 1 (Emission) Class 1 (Emission) EUB limit value (Radiated) 1 MHz 18 GHz 50V/m 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 mm2. 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).

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Function

Electrical requirements
Term Operating voltage: Unit V Value 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. Below 7. Without activated loads at SAM outputs Additional output current on positive or negative conductor shall not exceed 10 A DC in total. 5.08 terminals (spring-cage terminals) Wire diameter AWG14 (US) or 2.5 mm2 recommended. 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.

Power supply:

Current terminals:

mm

Electrical isolation:

Mechanical design
Term Installation position: Unit Value 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.

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Terminals
Term Terminal strip modules: Current-carrying capacity (at 70 C): Measuring voltage: Measuring surge voltage: Wire cross-sections: Clamping range: A V V mm2 mm2 Unit Value WAGO spring-cage terminals 10 per contact 250 2500 Up to 1.5 or AWG15 0.08 1.5 or AWG15

Note: Power supply and CAN bus connections feature different terminals (RM 5.08) and wires AWG14 (2.5 mm2).

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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 board. 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 CAN_1 PIN CAN1H CAN1L GND_CAN1 CAN_2 CAN2H CAN2L GND_CAN2 CAN_3 CAN3H CAN3L GND_CAN3 Dialog Lbatt+ (24V) LGND 3 2 1 3 2 1 3 2 1 E K X6 X7 X8 H G M B C L X4

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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 the SAM electronics.

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.

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Function

Bsy yellow LED; communication in progress. Interface: Applications: 10/100Base_T (10/100Mbit/s, twisted conductor pairs). Connection to HUB: Use patch cable CAT5 (1:1). Connection to PC: Use crossed cable CAT5.

Designation Transmit data positive Transmit data negative Receive data positive

Pin Tx (+) Tx (-) Rx (+)

X5 1 2 3 4 5

EIA/TIA-T 568 A standard white/green green white/orange

EIA/TIA- 568 B standard white/orange orange white/green

Receive data negative

Rx (-)

6 7 8

orange

green

Housing ground

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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 transmit 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 Tx RS232 Rx RS232_GND SAM_GND Serial link RS422 O1 ( TxB [+] ) O2 ( TxA [ -] ) I1 ( RxB [+] ) I2 ( RxA [ -] ) RS422_GND SAM_GND X14 1 4 5 6 1 2 3 4 5 6

Standard configuration:
Baud rate: Data Parity Stop bits Data flow control 1.2 to 19.2 kbaud 8 bits N 1 Xon/Xoff

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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 +UBatt or Ubatt_GND to the input channel. Term Number of channels Voltage range Initial voltage without connection Input impedance Rated input current: Switch for +UBatt Switch for UBatt_GND Threshold voltage Switch for +UBatt V mA A 3.5 /24V -22 / 0V Measured at input terminal; Signal source impedance is less than 10 ohm Vin > 10 -> Contact closed (logic high) Vin < 9 -> Contact open (logic low) For Open-Load detection: (33 kohm contact parallel resistor) 9 > Vin > 4.2 -> Contact open (logic low) Vin < 4.2 -> Contact open (Open Load) Vin < 1.9 -> Contact closed (logic high) Vin > 1.9 -> Contact open (logic low) For Open-Load detection: (33.2k contact parallel resistor) 1.9 < Vin < 3.5 -> Contact open (logic low) Vin > 3.5 -> Contact open (Open Load) None Hz Hz ms The sampling rate is determined by the software: E.g. 100 HW low-pass filter: fg = 500 *Note1 Masking by software e.g. 50 signal holding V kohm Unit Value 8 binary inputs with common UBatt_GND reference potential UBatt_GND to +UBatt 3.8 ~6.9 to GND

Switch for UBatt_GND

DC isolation Sampling rate Signal filter Contact bounce

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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 detect broken wires when the switch contacts are connected in parallel to a 33k resistor. The inputs may be switched to positive voltage (+UBatt) 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 Switch-on threshold, HV threshold voltage (w.c.) Switch-off threshold, LV threshold voltage (w.c.) Switching hysteresis: Frequency: Unit V V V Hz Value Usignal > 11.1 Usignal < 3.2 Uhyst 2.7 to 4.1 32 to 6 kHz Usignal is the voltage at the SAM terminals.

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Function

Pin assignment
Group Designation Bin/pulse Bin/pulse Bin Binary inputs with common reference ground Bin Bin Bin Bin Bin Bin Pin P_IN1 P_IN2 P_IN3 P_IN4 P_IN5 P_IN6 P_IN7 P_IN8 GND 7 8 12 X14 X19 5 6 7 8 9 10 11

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1.8

Binary inputs via optocoupler

Binary inputs via optocoupler


Term Number of channels Reference voltage Voltage range Initial voltage without connection Input impedance Rated input current: Switch for +UBatt ON Switch for UBatt_GND OFF Switching voltage Vin >= 12 V Vin =< 9 V (typical value is 10.5V threshold voltage) mA mA V mA mA +4.0 0 Measured at input terminal Iin > = 1.6 -> High Iin < 1.3 -> Low For Open-Load detection: (33.2k contact parallel resistor) Vin < 9.0 -> Contact open (logic low). 9.0 > Vin > 2.1-> Contact open (Open Load). > = 500 The sampling rate is determined by the software: E.g. 100. HW low-pass filter: fg = 500 by software e.g. 50 signal holding. Yes: Wire break (when switch is connected in parallel with a 33 resistor). kohm Unit Value 20 electrically isolated binary inputs None: Each channel must be connected with two lines and is isolated from all other channels. UBatt_GND to +UBatt None ~5.5 (load)

DC isolation Sampling rate Signal filter Contact bounce Online self-diagnosis

VDC Hz Hz ms kohm

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Function

1 A/D converter 2 Uin 3 Iin

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 OKI_switch Designation B_OKI_CH1 Pin B_IN1_H B_IN1_L B_OKI_CH2 B_IN2_H B_IN2_L B_OKI_CH3 B_IN3_H B_IN3_L B_OKI_CH4 B_IN4_H B_IN4_L B_OKI_CH5 B_IN5_H B_IN5_L B_OKI_CH6 B_IN6_H B_IN6_L B_OKI_CH7 B_IN7_H B_IN7_L B_OKI_CH8 B_IN8_H B_IN8_L X2 X3 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 X11 X12

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Group

Designation B_OKI_CH9

Pin B_IN9_H B_IN9_L

X2

X3

X11

X12 5 6 7 8 9 10 11 12

B_OKI_CH10

B_IN10_H B_IN10_L

B_OKI_CH11

B_IN11_H B_IN11_L

B_OKI_CH12

B_IN12_H B_IN12_L

B_OKI_CH13

B_IN13_H B_IN13_L

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4

B_OKI_CH14

B_IN14_H B_IN14_L

B_OKI_CH15

B_IN15_H B_IN15_L

B_OKI_CH16

B_IN16_H B_IN16_L

B_OKI_CH17

B_IN17_H B_IN17_L

B_OKI_CH18

B_IN18_H B_IN18_L

B_OKI_CH19

B_IN19_H B_IN19_L

B_OKI_CH20

B_IN20_H B_IN20_L

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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:

1 High switch (BTS480R) 2 Low switch (TLE6240GP) 3 Diagnostic current source

Group Power activation

Designation Transistor outputs

Pin BIN_OUT_CH1 BIN_OUT_CH2 BIN_OUT_CH3 BIN_OUT_CH4 BIN_OUT_CH5 BIN_OUT_CH6 BIN_OUT_CH7 BIN_OUT_CH8 BIN_OUT_CH9 BIN_OUT_CH10 BIN_OUT_CH11 BIN_OUT_CH12 BIN_OUT_CH13 BIN_OUT_CH14 BIN_OUT_CH15 3 4 5 6 7 8 9

X17

X18

10 11 12 1 2 3 4 5

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Group

Designation

Pin BIN_OUT_CH16 BIN_OUT_CH17 BIN_OUT_CH18 BIN_OUT_CH19 BIN_OUT_CH20

X17 6 7 8 9

X18

10 2 1 12 11

Load supply voltage Reference ground for load

+LBatt LGND

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Function

1.10

Binary outputs: Transistor switches

Binary outputs: Transistor High switches


Term Number of channels Unit Value 20 Transistor High switches Note: These channels are used in common with the transistor Low switches. Two terminals are provided separately for supply voltage +UBatt and UBatt_GND (use wire cross-section AWG 15 mm2 or 1.5 mm2). V V m +UBatt (12 - 45) 2.3 - 3.7 Less than 320 per channel

Reference voltage

Voltage range Initial voltage without connection Impedance in ON state Output current ON state OFF state DC isolation Switching cycle

A A

Less than or equal to - 0.5 Less than or equal to + or (50 - 150) None

Hz

The switching rate is determined by the software: Less than 10 admissible Capacitor with 100 to UBatt_GND (EMI/EMC) Self-protection commencing at 0.7 and reaching to 1.9. Yes, Note*

Signal filter Short circuit Online self-diagnosis

nF A

Note*: Minimum load current must exceed 500A 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 switching inductive loads: (1 joule per channel when the channels are switched simultaneously, otherwise 10 joules per channel)

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Binary outputs: Transistor Low switches


Term Number of channels Unit Value 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. mm2 Two terminals are provided separately for supply voltage +UBatt and UBatt_GND (use wire cross-section AWG 15 or 1.5). +UBatt (up to 12 - 45) 2.3 - 3.7

Reference voltage

Voltage range Initial voltage without connection Impedance in ON state Low current High current Output current in ON state Low current BT_OUT1..BT_OUT6 and BT_OUT11BT_OUT16 High current BT_OUT7BT_OUT10 BT_OUT17BT_OUT20 Output current in OFF state Low current High current DC isolation Switching cycle Signal filter Short circuit

V V

1.3 per channel 0.2 per channel

Rated value less than or equal to 0.3 per channel

Rated value less than or equal to 1.0 per channel

A A

Max. - or + (50 - 150) Max. - or + (100 - 300) None

Hz nF

The switching rate is determined by the software: Less than 10 admissible Capacitor with 100 to UBatt_GND Self-protection commences at:

A A Online self-diagnosis

1 to 2 for low current 6 to 12 for high current 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.

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Function

Benefits
The The outputs offer the following benefits: Overload protection with thermal breaking Overvoltage protection (Load Dump Protection) outputs BT_OUT9 and BT_OUT10 may also be used as PWM outputs.

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1.11

Binary outputs: Relay switches

Binary outputs: Relay switches


Number of channels Reference voltage Voltage range Contacts Impedance in ON state Output current ON state OFF state DC isolation Switching cycle Switching cycles at 10W 1W Self-protection 106 (resistive load) max. 107 (resistive load) max. Overcurrent protection by multifuse (nom. 1A) Overvoltage protection by varistor (nom. 36V) Less than 1.0 A per channel Less than or equal to 100 A per channel; a varistor lies above the contacts. Isolation less than 300V DC The switching rate is determined by the software: Less than 1Hz 4 monostable relays with switching contacts None: Each channel must be connected with two lines and is isolated from all other channels. Less than 36VDC Switching contacts (connected as NO contact or NC contact) Less than 20 m

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Function

Online self-diagnosis Offline diagnosis Pin assignment Group Relay outputs Designation BIN_OUT_Rel1

Yes Yes

Pin COM1 NC1 NO1 1 2 3 4 5 6 7 8 9 10 11 12

X15

BIN_OUT_Rel2

COM2 NC2 NO2

BIN_OUT_Rel3

COM3 NC3 NO3

BIN_OUT_Rel4

COM4 NC4 NO4

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1.12

Binary outputs: PWM outputs via Low switches

Binary outputs: PWM outputs via Low switches


Term Number of channels Reference voltage Unit Value 2 transistor Low switches UBatt_GND circuit Two terminals are provided separately for the supply voltage +UBatt and Switch LGND (use wire cross-section AWG 15 mm2 or 1.5 mm2). + UBatt

Voltage range Initial voltage without connection Impedance in ON state Output current in ON state ON state OFF state DC isolation Output signal Frequency ON/OFF ratio Accuracy (PWM) Signal filter Short circuit Hz % % nF A A A m

150 - 250 per channel

Less than or equal to 1.5 per channel Max. +/-100 None

5 to 500 adjustable by software 1 - 100 ; 0: Off 0.3 of measuring range 60 - 200 Hz Capacitor with 30 to UBatt_GND Self-protection commencing at 3 and reaching to 6. For switching transistor and supply line. Yes

Online self-diagnosis The

outputs offer the following benefits: Overload protection with thermal breaking Operation automatically restored after fault rectification A free-wheeling diode on the +UBatt 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 LBatt+ is protected against short-circuit. The response time of the current regulator is approx.: 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 200Hz. Attainable settling accuracy is = < 0.3 % at 1A current.

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Function

1 Measuring resistor 2 LBatt+, short-circuit-proof 3 PWM control signal

Pin assignment
Group Designation PWM_CH1 PWM control PWM_CH2 Pin PWM1_L PWM1_H PWM2_L PWM2_H X14 10 9 12 11

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1.13

Signal outputs to control display instruments

Signal outputs to control display instruments


These outputs are used to control display instruments 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 PWM ratio 1710 Hz 0 - 100%

Group Instrument control

Designation Volt_out voltage output

Pin V_OUT1 V_OUT2 V_OUT3 V_OUT4 V_OUT5 V_OUT6 V_OUT7 V_OUT8

X1 1 2 3 4 5

X10

9 10 11 12 6 7 8 9 10 11 12

Common GND Curr_out Current output

AGND C_OUT1 C_OUT2 C_OUT3 C_OUT4

Common GND Auxiliary voltage 24V/-1A

AGND Lbatt+ LGND

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Voltage outputs
Term Number of channels Reference voltage Voltage range Accuracy Initial voltage without connection Impedance in ON state Output current DC isolation Settling time Short-circuit protection ms mA V % V mA Unit Value 8 voltage inputs with common UBatt_GND reference potential UBatt_GND (AGND) +0 +10 0.3 of measuring range** 0 - 10 0 Less than or equal to 8 admissible None Less than 60. The output voltage is automatically reduced when current intensity exceeds 20 - 30. Short-circuit proof to +UBatt and UBatt_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 Number of channels Current Current intensity range Accuracy Max. load impedance (load) Max. output voltage DC isolation Settling time Short-circuit protection ms mA DC % VDC Unit Value 4 current outputs with common UBatt_GND reference potential Source to UBatt_GND 0 - 20 0.3 of measuring range** Less than 400. Less than 10. None Less than 60. Short-circuit proof to +UBatt and UBatt_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 UBatt_GND.

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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 Analog multipurpose inputs Designation AN_CH1 Pin A_Supp_CH1 A_In_CH1 A_GND AN_CH2 A_Supp_CH2 A_In_CH2 A_GND AN_CH3 A_Supp_CH3 A_In_CH3 A_GND AN_CH4 A_Supp_CH4 A_In_CH4 A_GND AN_CH5 A_Supp_CH5 A_In_CH5 A_GND AN_CH6 A_Supp_CH6 A_In_CH6 A_GND AN_CH7 A_Supp_CH7 A_In_CH7 A_GND AN_CH8 A_Supp_CH8 A_In_CH8 A_GND 1 2 3 4 5 6 7 8 9 10 11 12 X16 X20 1 2 3 4 5 6 7 8 9 10 11 12

Temperature sensors
Used for: PT1000, Ni1000 temperature sensors PT100, Ni100 temperature sensors E532187/00E 05-11 MTU

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Function

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

Temperature inputs
Term Number of channels Voltage range Measuring current: PT1000 PT100 NTC Input impedance Accuracy of electronics: PT1000 PT100 NTC Short-circuit protection DC isolation Sampling rate Signal filter Online self-diagnosis Hz Hz K K K 0.4 (measuring range: -20C - 120C) 5 (measuring range: -20C - 650C) 4 (measuring range: -20C - 120C) Yes None The sampling rate is determined by the software: E.g. 100. HW low-pass filter: f < 20. Yes mA mA mA kohm 2.5 4.5 2-5 1 V Unit Value 8 commonly used with voltage inputs. +5; AGND

** 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 amplifier and supplied to the 12-bit analog/digital converter.

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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

1 A/D channel 2 Potentiometer or 5V pressure sensor

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Function

Example: Voltage measuring 5V or 10V

1 A/D channel 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 Number of channels Reference potential Voltage measuring Voltage range Impedance Current measuring

Unit

Value 8 commonly used with temperature inputs UBatt_GND (AGND)

V k

0 - +5; 0 - +10 100

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Term Current range Load Accuracy of electronics Sensor supply Voltage Current intensity Potentiometer supply Voltage Current intensity Pin assignment A_SUPPx A_IN1 A_GND Short-circuit protection A_SUPPx ->(VBatt+; VBatt-) A_IN1 ->(VBatt+; VBatt-) A_GND ->(VBatt+; VBatt-) DC isolation Sampling rate Signal filter Online self-diagnosis

Unit mA %

Value 0 - 30 150 0.2 of measuring range**

V mA

5; 0.1 %** 0 - 20 DC (current intensity limited internally)

V mA

5; 0.1 %** 0 - 20 DC (current intensity limited internally)

5 potentiometer/sensor supply Measuring voltage/current input Measuring ground

Yes Yes A Yes (SAM device fuse 15) None Hz Hz The sampling rate is determined by the software: E.g. 100 HW low-pass filter: f g = 20 Yes (monitoring of range violations adjustable by software)

** 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. Input function can be selected between 5V, 10V and 20mA measuring in the application engineering phase.

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1.15

Electrically isolated analog inputs

Electrically isolated analog inputs


Used for: Voltage measuring 0 - 5V or 0 - 10V Current measuring 0 - 20mA Term Number of channels Reference potential Unit Value 2 multi-purpose inputs Both channels have a common reference potential (Common GND), which is electrically isolated from UBatt_GND of the SAM electronics.

Voltage measuring Voltage range Impedance Current measuring Current range Load Accuracy of electronics Pin assignment +IN_V_CHx -> A/D_OPT_GND +IN_I_CHx -> A/D_OPT_GND A/D_OPT_+5V Short-circuit protection All poles to UBatt_GND All poles to +UBatt DC isolation Sampling rate Signal filter Online self-diagnosis Hz Hz Yes Yes Yes The sampling rate is determined by the software: E.g. 100 HW low-pass filter: f = 20 Yes (monitoring of range violations adjustable by software) V mA Measuring voltage 0 - 10 or 0 - 5 Measuring current input 0 - 20 Supplies Vpp (5.0V/10mA) to control an external potentiometer. mA % 0 - 24 150 0.3 of measuring range** V k 0 - +5; 0 - +10 47

** 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. Configuration: Input adjustable between 5V, 10V and 20mA measuring in the application engineering phase.

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1 A/D converter optocoupler 2 Voltage measuring 3 Current measuring

Pin assignment Group OKI_Analog Designation O-AN_CH1 Pin A/D_OPT_+5V +IN_V_CH1 +IN_I_CH1 A/D_OPT_GND O-AN_CH2 A/D_OPT_+5V +IN_V_CH2 +IN_I_CH2 A/D_OPT_GND 5 6 7 8 9 10 11 12 X11

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1.16

Frequency inputs

Frequency inputs
Normal use: Speed measuring via a gear and an inductive sensor (without auxiliary voltage). Term Number of channels Reference potential Signal measuring Maximum signal Hysteresis Impedance Frequency range Accuracy of electronics Configuration Short-circuit protection DC isolation Signal filter Online self-diagnosis kHz Yes None HW low-pass filter: fg = 15 Yes (monitoring of range violations adjustable by software). V k Hz % 1.2 Vpp < U input < 100Vpp Positive threshold at 0, negative threshold at -620mV. Ri =2 x 24 5 to 10kHz 0.1 (frequency measuring range)**. Unit Value 2 x 2-pole differential inputs Differential input

Note: The frequency range specified applies when the minimum signal level is supplied by the measuring sensors. Note signal forms from inductive sensors or active sensors used e.g. HAL sensors. A differential + and - signal is required for the frequency input. **Depending on software signal processing. Mean value calculation should include as many signal periods as possible in order to attain adequate signal quality. This can be set in the application engineering phase.

Pin assignment
Pin assignment Group Frequency inputs Designation SPEED_CH1 Pin F_IN1H F_IN1L SPEED_CH2 F_IN2H F_IN2L X19 1 2 3 4

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1.17

Removable memory

Removable memory
The need for a removable storage medium (i.e. Compact Flash) primarily results from the conditions of use and maintenance of the ADEC governor. Compact-Flash (CF) 32Mb 3.3 V supply voltage Block erasing and block programming Using the Compact Flash CF memory card facilitates future use of higher storage capacity cards e.g. 64 MB or 256 MB. The Compact Flash operates with a file management system. Application engineering data and backup data incl. (FSW_SW) of the ADEC governor are stored on the CF. Following device manufacture and testing, the SAM incorporates firmware which includes the various I/O channel drivers and the initial program loader software. User-related software (application software) is first transmitted when the CF is installed in the SAM. Note: The CF shall only be installed and removed when the SAM is de-energized.

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1.18
Display

Fault display

Two-line B/W LCD for 16 ASCII characters per line. Background illumination of the display can be deactivated by the software. General fault messages and fault codes are shown on the display. Fault descriptions are provided in the relevant application descriptions.

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1.19

Control keys

Control keys
Four miniature keys are provided on the SAM to operate the display. Examples of functions are: ESC ENTER Step back in menu Step forward in menu

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1.20

Extendibility

Extendibility
I/O capacity can be extended by inserting as many as three MCS5 I/O modules. The SAM board is prepared to accommodate as many as three MCS5 I/O modules. A list of I/O modules supported by the SAM is attached. Note: Electrical characteristics and specifications of these modules may vary. When using MCS5 I/O modules (MCS5 documentation) technical specifications must be observed. Note the following restrictions: Use one (Multi-Communication Module) only, it must be inserted in slot 3. Use max. two frequency measuring modules, e.g. MFB1, these must be inserted in slot 1 and/or slot 2.

Pin assignment
Group MCS5 I/O module extension Designation Slot_1 Corresponding PIM PIN n01 Module Pin PIN_1 X10 X21 1 X22 X23

n02 n03 n04 n05 n06 n07 n08 n09 n10 n11 n12 n13 n15 n14 n16 Slot_2 n01 n02 n03 n04 n05 n06

PIN_2 PIN_3 PIN_4 PIN_5 PIN_6 PIN_7 PIN_8 PIN_9 PIN_10 PIN_11 PIN_12 PIN_13 PIN_14 PIN_15 PIN_16 PIN_1 PIN_2 PIN_3 PIN_4 PIN_5 PIN_6

2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10

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Group

Designation

Corresponding PIM PIN n07 n08 n09 n10 n11 n12 n13 n14 n15 n16

Module Pin PIN_7 PIN_8 PIN_9 PIN_10 PIN_11 PIN_12 PIN_13 PIN_14 PIN_15 PIN_16 PIN_1 PIN_2 PIN_3 PIN_4 PIN_5 PIN_6 PIN_7 PIN_8 PIN_9 PIN_10 PIN_11 PIN_12 PIN_13 PIN_14 PIN_15 PIN_16 1 2 3 4 5 6 7 8

X10

X21

X22 11 12

X23

Slot_3

n01 n02 n03 n04 n05 n06 n07 n08 n09 n10 n11 n12 n13 n14 n15 n16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

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1.21

Self-diagnosis (ITS)

Self-diagnosis (ITS)
The SAM features self-monitoring where appropriate from the technical viewpoint. The following tests are performed during initialization following power-up: RAM memory (R/W) Flash memory (CRC) Peripheral interface tests Communication link tests Rapid diagnosis by LED: The SAM is equipped with a DILA (diagnosis lamp), an LED which indicates the status of the SAM. Steady Flashing Dark SAM in order SAM faulty SAM power supply missing

The function of this LED is the same as the DILA in ECU 7. Offline diagnosis A straightforward diagnostic method allows service personnel to perform troubleshooting quickly and easily in case of a fault in the SAM. Proceed as follows: Place the SAM device on a table leaving only the power supply lines connected. Press the and Enter keys simultaneously and switch on the power supply at the same time. Release the keys after a few seconds and observe the display for approximately 10 seconds. Any faulty channels are displayed. Supported MCS5 I/O modules Designation AIB 1-02 Analog Input Board AIB 2-02 Analog Input Board AIB 3-02 Analog Input Board AIB 4-01 Analog Input Board BIB 1-02 Binary Input Board BIB 2-01 Binary Input Board Board no. 529 530 93 12 Drawing / documentation 529 539 83 02 529 531 57 91 529 539 40 02 529 531 29 91 529 539 39 02 529 531 28 91 529 539 50 02 529 531 34 91 529 539 79 02 529 531 53 91 504 539 66 03 504 531 01 90 Use in SAM slot 1 x Use in SAM slot 2 x Use in SAM slot 3 x

529 530 39 12

529 530 38 12

529 530 49 12

529 530 88 12

504 530 08 97

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Designation BOB 1-02 Binary Output Board BOB 1-02/A Binary Output Board BOB 2-02 Binary Output Board BOB 3-01 Binary Output Board EGB 1-01 Exhaust Gas Board IIB 1-01 Instrument Input Board INB 2-01 Instrument Board MFB1_01 Multi-Function Board CCB2_02 Multi Communication Board

Board no. 529 530 86 12

Drawing / documentation 529 539 77 02 529 531 51 91 529 539 85 02 529 531 51 91 529 539 78 02 529 531 52 91 504 539 78 03 504 531 10 90 504 539 54 03 504 531 91 93 504 539 64 03 504 531 99 93 504 539 84 03 504 531 15 90 504 539 56 03

Use in SAM slot 1 x

Use in SAM slot 2 x

Use in SAM slot 3 x

529 530 95 12

529 530 87 12

504 530 39 97

504 530 74 92

504 530 98 92

504 530 54 97

504 530 76 92

X 000 134 34

X 000 134 35

X: Supported by SAM Note on application engineering: The MCS5 I/O modules listed above are installed in cassettes and supplied for use in the corresponding SAM slot. These coded modules are slot-specific and are listed under a dedicated item number at MTU. First take stock when initially using such modules.

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Function

Design of the SAM (all parts illustrated)

1 Modules 2 Module 3 Software

4 Housing 5 Board 6 Board

7 Cap 8 Screws 9 Lock

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1.22

Index
A
Frequency inputs 07 ...................... 40 .....................

Ambient conditions

B
Binary inputs via optocoupler . . . . . . . . . . . . . Binary inputs with common ground . . . . . . . . . Binary outputs: PWM outputs via Low switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Binary outputs: Relay switches . . . . . . . . . . . . Binary outputs: Transistor switches . . . . . . . . Binary transistor outputs . . . . . . . . . . . . . . . . . 19 16 29 27 24 22

I
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface for measuring sensor (analog IN) . . . 49 33

O
Overview of device functions ............. 04

R
Removable memory . . . . . . . . . . . . . . . . . . . . RS422/RS232 communication link . . . . . . . . . 41 15

C
CAN communication link . . . . . . . . . . . . . . . . . Control keys . . . . . . . . . . . . . . . . . . . . . . . . . . 12 43

S
Self-diagnosis (ITS) . . . . . . . . . . . . . . . . . . . . Signal outputs to control display instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 31

E
Electrically isolated analog inputs . . . . . . . . . . Ethernet communication link (10/100BaseT) . . . . . . . . . . . . . . . . . . . . . . . . Extendibility . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 13 44

U
Use ................................. 03

F
Fault display .......................... 42

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