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
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
Removingthehousingcover
Theoldrelaymustberemoved.Startbyremovingthecablesconnectingtherelaytotheinputandoutputposts(highsideonly)usinga10mmwrench.Thiswillbeperformedtwotimes,ontheinputandoutputsidesoftheMS5501.
21The system should appear as in the following picture when the relay isremoved:
Uninstalled100Arelay
22
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
TheAN5501alsohasaplaceforconnectingaresistorwhenusingtheexternalsettingontheSC5501.WhilemostcommonimpedancesareincludedintheAN5501,thesebananaconnectorscanbeusedforadditionalRS shuntresistors.
TheexternalRsjacks
299 the es 5501 electronic sWitch
TheES5501isthecontaineroftheelectronicswitchwithspecificationsoutlinedinISO7637-2.
The ES 5501
TheES5501isa100Afastelectronicswitch.Refertochapter6forcontrol.BeforeusingtheES5501,youmustconnectthecontrolcablefromtheES5501totheSC5550.TheES5501containsaBNCconnectorforeaseofuse.
30
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
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
AES 5501 - Automotive Emissions System
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]
Top Related