TDAS G5 Data Acquisition System Hardware User`s Manual
Contents
1. EE Useful Commands FPGET myip 192 168 0 124 Click on EXIT when finished Using the New Settings Use the following steps to update the system with the new network parameters Is 2 3 Reboot the hardware to force the system to use the new setting s Find the tdas ini file in the TDAS Control program folder normally c dts_tdas and make a back up copy called tdas_backup ini Edit the file tdas ini using Notepad or any text editor Find the line titled Rack Inventory and change the IP address associated with the serial number for the TDAS G5 DAS to the new address Note Change only the IP address and not the DAS unit s serial number This is how the software will know how to search for the DAS at the new IP address Save the file Confirm your computer s Windows network settings match the new TDAS G5 network parameter s If changes are required to your computer please contact your network administrator for assistance Start the TDAS Control software and confirm that the TDAS G5 DAS is found at the new IP address support dtsweb com 16 Rev 32. as 10 000 Gs Under these conditions damage to the exterior and or interior of the unit is likely When transporting or shipping the unit treat it as you might a laptop computer and you should have no problems Should a TDAS G5 DAS be removed from its docking station we strongly recommend that you always cover the 216 position interface connector with the rubber cap provided with the unit and place it in the padded carrying case originally provided with your system support dtsweb com 6 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 WARNING The 216 position gold plated interface connector on the TDAS G5 DAS should be treated with great care It is through this interface that all signals enter and exit the DAS Any debris solvents or oil even from fingers can compromise the integrity of the connections signals If you feel the interface connector on your TDAS G5 DAS unit has become contami nated please contact DTS support before attempting any cleaning procedure Shock Rating TDAS G5 DAS units are designed to function routinely in a 500 G environment such as that experienced in severe in dummy applications All vehicle sled mounted systems are rated for and fully tested to 100 Gs 12 mS duration in all axes TDAS G5 equip ment can be mounted directly on a vehicle sled or other dynamic testing device Temperature Rating The TDAS G5 DAS uses extensive power management to minimize heat generation Temperature wil
3. have questions or you believe the system may not be working properly DTS has worldwide support for its products As part of its support team DTS has engineers with extensive product knowledge and crash test experience to help via telephone e mail or on site visits The best way to contact a DTS support engineer is to e mail support dtsweb com This e mail is immediately sent to all DTS support engineers and is the fastest way to get a reply to your request support dtsweb com 3 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 Introducing the TDAS G5 Data Acquisition System Each TDAS G5 Data Acquisition System DAS is a standalone 32 channel data acqui sition system To identify the specific hardware included with your system please see your packing list Overview of TDAS G5 DAS Features e Designed and manufactured to withstand in dummy and on vehicle dynamic testing environments e 32 programmable sensor input channels each with an independent excitation source true differential instrumentation amplifier anti alias filter 16 bit analog to digital converter and electronic identification EID support e 1to 100 KHz sampling rate adjustable Primary memory 70 seconds at 10K samples second RAM back up memory 7 seconds at 10K samples second non volatile flash Voltage insertion and shunt emulation 32 multi purpose digital input channels Ethernet 10 100BaseT Tx communications Simple 216 position int
4. 800008 eooooeo oeooooe eooooeo 08000080 eooooeo oeooooeo eooooeo 808000080 000000 Board references Ar aC Ok Z6 6t OIC TIC CIC ETL HIC SIC OTC ZIC 8IC Sensor channels 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 ex Rx O armed status out 2 Function RS232 Tx sig Rx armed status in 2 Function RS232 Rx n Ethernet datori ID digital Tox start record used for factory set up shield Tx power on sig shield common e common ex record status out O record status in guide pin hole filled blank filled blank filled blank filled blank filled blank 0000 000000000 guide pin hole filled blank filled blank ex ext power o ext power e sig ext power o guide pin hole shield ID digital O ID digital O ID digital guide pin hole event input O t sig ext power O event input O ex ext power O ext power O Sensor Channels 2 per 15 position strip TDAS G5 DAS 216 position Interface Connector Power Com A Power Com B support dtsweb com 9 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 TDAS G5 DAS Interface Connector Al TDAS G5 DAS functions are controlled through the power communication connectors at one end of the 216 position interface connector panel Proper orienta tion can be determined by locating the board references J1 J18 these are at the bottom of the panel closest to sensor channels 17 32 The pin outs and functions are sh
5. DDTS 909 Electric Ave Suite 206 Seal Beach CA 90740 USA Phone 1 562 493 0158 Fax 1 562 493 3158 www dtsweb com TDAS G5 Data Acquisition System Hardware User s Manual August 2004 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 Table of Contents DIS SUDDOITiiisessassiessuE ETT ESNRREEESEMEEE EE URREUEDN ERE TESENEIE EON EEES EON EEEUEDNCEEEE FUNNEEE EK DNE NER 3 Introducing the TDAS G5 Data Acquisition System eere n nnn 4 Overview of TDAS G5 DAS Features iisciaexuiwwi e i E n an E RC CICR RC RE ERR RR CERT ER ER RC RR RR RR 4 PUE Ts ANOS cr 4 Excitation Ss OUNCCS RRRORINERR CNET 4 JPN O CONNECT OI eoen EE T TI TTE 4 Shunt Calibration ReslSEOES aerian Eaa ADIPI TEE SUDO ERN ERDA 5 MUNE EMAON ies erra EAA E HERR E eISU ENTE UU MU PaE IGNI UECENPII RT TIRE MENNE 5 Hardware dil BIS xorssascivima E P cnet IN FEE DII ERIGI NM Era PUER PIPPTEIPSD NIMM PEE 5 Ese e RR 6 MEMOR SIZO ae d IUNEERMM NM DIM UR UPPER EMPIRE EEUU ERES 6 Basic Care and Handling ssseessxwsaiaietin piam RE REOR NAUIUR DUM NOR ODE RR NICA UY UR NN RED 6 vinee dig 7 POMPE raU IRGQUING ne ceaccnancemn cous coasted uEIETIDIE E NEL IPIE DEI Un E RE 7 Power Considerall ols sve uns iV nran aaa 7 Power Consumption and Management ssssssssseeee nennen nhanh nna nnns 8 Power Require
6. e computer and DAS unit are communicating NOTE Both the computer and DAS unit must be on the same netmask for Discovery to be successful If Discovery is not successful please contact DTS for assistance Change the Network Parameters Once communication has been established use terminal mode from within the TDAS Control software to change the network parameters The TDAS G5 DAS boot firmware recognizes the following standard firmware parameters myip specifies the target s IP address required netmask subnet mask required gateway gateway IP address if needed see your network administrator support dtsweb com 14 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 The following commands are used to read and set the network parameters fpget Get parameter print parameter from flash memory Command fpget name read parameter fpset Set parameter set parameter into flash memory Command fpset lt name gt value set parameter Confirm or change the TDAS S N field Type the command on the Input Command line Click GO or hit the return key 5M0124 efi Bank ammand fpset myip 192 168 0 124 The response is FPSET myip 192 168 0 124 ET To verify the change type support dtsweb com 15 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 The response is Terminal Mode TDAS S N 5M0124 v f Bak v peua S 41 mo fe
7. erface connector LED indicators for communication calibration power arm status and event status e Back up battery input for safe operation even with loss of primary power Please see the DTS web site www dtsweb com for the latest hardware specifications Input Range The nominal sensor input range is 2 5 volts differential at a gain of 1 The maxi mum common mode voltage range is 0 1 to 4 8 volts Excitation Sources All excitation sources are individually regulated and limited to ensure reliable operation even with shorted cables The standard excitation voltage is 5 0 volts Other factory options are available Excitation sources are not turned on until the software initial izes the system during the Real Time or Collect Data modes Sensor Connectors The TDAS G5 DAS is supplied with a 216 position interface connector that has sensor connections as shown below The pin outs and functions are detailed on page 9 support dtsweb com 4 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 Excitation 5 volts 20 mA Shunt Check Driver Gain G5 Sensor Calibration Connector A Tt e TEX E ID digital Shield Tso Pte lex Contact Closure Diversified Technical Systems Inc 2004 All Rights Reserved Sensor Connections Shunt Calibration Resistors Conventional shunt calibration resistors are not supported in the TDAS G5 DAS Shunt emulation is used to perform shunt checks Shun
8. ignal condi tioning electronics filter circuits and analog to digital converters are in a shutdown state The processor and support circuitry are always powered The processor will remain in a reduced power state when not performing tasks When the user runs a test set up the software automatically energizes all 32 channels The current draw per TDAS G5 DAS will increase from 190 mA at idle to as much as 800 mA when the system is fully armed and powering 350 ohm bridges with 5 volt excitation Once the system has been armed for data collection all circuits remain in a full power state until the system finishes storing data After the data collection routine is com plete the TDAS G5 DAS de energizes several circuits to minimize power consumption It takes a maximum of 125 seconds for 70 seconds of data at 10K samples second after the end of the data storage window for the TDAS G5 DAS to return to the idle state which then allows communication and download Power Requirements and Memory Retention RAM is the primary means for data storage The flash memory is a back up system used to store a predetermined portion of the test data in case both primary and back up power is lost This data subset contains both pre and post trigger data up to 5 MB Users should select the pre event time carefully to ensure that the post event region of interest is also included and written to flash If power is lost after flash memory has been written the data c
9. l be affected by four primary factors 1 Ambient air temperature and airflow 2 Sunlight exposure 3 Sensor load and 4 Length of time armed Since the system draws the most power when armed running the calibrations and arming as late as possible will minimize self heating It is unlikely that the units will be damaged by excessive heat because power is internally limited by self resetting thermal fuses the units will simply shut down when they get too hot Most implemen tation scenarios use one of the two available TDAS G5 docking stations either of which provide an adequate heat sink under normal operating conditions If two or more of the above factors will cause case temperatures in excess of 50 C the airflow created by a small fan will increase heat transfer by a factor of 3 to 5 Additionally always shield the units from exposure to direct sunlight Power Considerations A good power source is of paramount importance Each TDAS G5 DAS should be powered from a fully charged 12 volt battery or a high quality power supply with a nominal output voltage of 13 8 volts 11 15 volt range with a capacity of 2 amps When assessing power requirements please consider any voltage drops that may occur due to cables connectors power converters etc support dtsweb com 7 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 Power Consumption and Management When the TDAS G5 DAS is initially powered all sensor excitation sources s
10. m support dtsweb com 13 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 Appendix C Changing the TDAS G5 DAS Network Parameters TDAS G5 systems communicate using the industry standard Ethernet protocol Your TDAS G5 DAS was shipped with fixed IP address myip and subnet mask netmask parameters already loaded in the flash memory of the microcontroller The steps below describe the process to change the DAS unit s Ethernet parameters Note This process may require the help of your network administrator If your in house network support person is not available we encourage you to contact DTS for help CAUTION Great care should be taken when changing any network parameters The IP address and subnet mask should not be changed without full knowledge of the impact on the communication environment If you have any questions please contact your network administrator for help Establish Communication Using the TDAS Firmware Loader provided with the TDAS Control software establish communication with the DAS unit To do this change the fields to the appropriate hardware G5 serial number of the DAS unit and communication method Ethernet You can ignore the IP address field for the moment Click on the Discovery button to search the network for the requested serial number If the serial number is found the IP address field will be updated with the current address for that DAS unit This step is performed to ensure that th
11. ments and Memory Retention csse nnn 8 External Power PEIOVISIOPIS sites trainin SIVE M pd CS qa dur UPON ER DR SN GU DIR A IUUD quU UR 8 Communication Features x usuxsau REESE A RAE RREEERRENEKSNRRESESRRRNSNEESERENERRKANERRNEZRSRN RN E TRE 8 Communication Method cssssseesseeseen nenne hhhna hne nna nnn aa nnns 8 ED INOI ACON errre r EEEE EEEE EEA A EEE TE 8 TDAS G5 DAS Interface Connector iiisctiiiiseeinecsientieinieutininanentesinentivnninenturenadins 10 Application Support Equipmient iusesasuia siia RR RR ERR ED RT RR EC RR 10 ipummy and TDAS G5 Docking Stations ccccccsceeeeeeceeeceevaueceeeuuevaneuaneaueeas 10 Appendix A Guide to TDAS G5 DAS LED Indicators eeeerrrr 12 Appendix B Mechanical Specifications eorr eene rena n nnn n 13 Appendix C Changing the TDAS G5 DAS Network Parameters 14 Establish Communication ssssssacrdina vice xit ina oer S ror Et Oe Fa CR EROR aor Kx E ordei E aa 14 Change the Network Parameters ssseseeesseeeen nena nme emanare nnn 14 Using rhe New SSLEITIOS caseus itae ekeni AEREN de ERAI RE VERG peior ibid dr VM TE DATEI EUR 16 Appendix D Hardware Configuration Specifications 17 support dtsweb com ii Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 DTS Support DTS systems are designed to be simple to operate and reliable but there may be times when you
12. ontained in the flash can be downloaded after power is restored External Power Provisions The TDAS G5 DAS does not contain any internal power source but has connector inputs for both primary and back up power sources Actual useful back up capacity will depend upon the number of channels in use the resistance of the connected sensors the supply s rating and whether or not it was fully charged before testing Communication Features Communication Method The TDAS G5 DAS supports the industry standard Ethernet 10 100BaseT Tx communi cation method Communication is enabled after the boot up sequence has completed 20 seconds See Appendix D for the network parameters of your equipment LED Indicators The TDAS G5 DAS has five LEDs red yellow green which provide ongoing status information Appendix A contains more detailed descriptions of the LED indicators COM Provides status on communications with the docking station and DAS CAL Provides calibration status PWR Provides status on power to the DAS ARM Provides arm start record and event status STAT Provides general status support dtsweb com 8 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 Sensor channels 000000 eooooeo oceooooo eooooeo oeoooooQJ r e0o0oo0ooeo oeoooooQ eooooeo oeoooooQj uU e00000e60 000000909 O eooooeo o6eooo00e eooooeo oeooooe co eooooeo oeooooQj o eooooeo oeooooeo eooooeo 88000080 eooooeo 0
13. own in the figure above WARNING Do not apply external voltages to the event communication status or control output and inputs this could result in damage to the unit Application Support Equipment ipummy and TDAS G5 Docking Stations The most common method of using a TDAS G5 DAS is within a docking station Two types of docking stations are available in dummy iDummy and on vehicle TDAS G5 Docking Station TDAS G5 DAS units can be moved from in dummy to on vehicle applications as needed Connector interface DAT ACQUISITION SYSTEM Flex circuit cable Dor Ww WW dts Web co COM In dummy docking station In dummy Docking Station Configuration The iDummy docking station allows for easy installation and removal of the TDAS G5 DAS into virtually any crash dummy type Signals enter and exit the TDAS G5 DAS through the interposer and pass through the flex circuit cable to the connector support dtsweb com 10 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 interface panel where the dummy s sensors are connected Communications are also accomplished through the connector interface panel A single dummy can contain many in dummy docking stations Control Sensor connector panel pane with 32 LEMO connectors TDAS GS 1 16 i P inis dL IE TION DTS On vehicle Docking Station The TDAS G5 Docking Station allows for easy installation and removal of the TDAS G5 DAS in
14. t Emulation The TDAS G5 DAS uses shunt emulation to perform shunt checks Shunt emulation eliminates the need for conventional shunt resistors and is enabled when Emulation is chosen in the SIF as the shunt calibration method This method applies a precise current to a connected sensor and checks for expected deflection based on sensor impedance Shunt checks are performed under software control settings are calcu lated by the software and the applied shunt signal is automatically scaled to an appropriate percentage of the requested range Please see the TDAS Control software manual for additional information Hardware Filters Each TDAS G5 DAS measurement channel has a fixed four pole Butterworth anti aliasing filter with a standard 3 dB knee point at 4000 Hz Each channel also has a software controlled variable five pole Butterworth filter which is adjustable from 50 to 5000 Hz These two filters may be used together to provide an effective Butterworth response with up to nine poles The TDAS Control software automatically chooses the best filter setting for a chosen sampling rate The relationship between sampling rate and anti alias filter knee point is contained in a look up table in the TDAS G5 DAS support dtsweb com 5 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 initialization file called tdas ini DTS can provide assistance to help ensure that end users employ filter settings that meet their requirements EID S
15. to a rugged enclosure useful for on board testing applications Power commu nication and event signals are easily accessible via the control panel A variety of larger sensor connectors such as LEMO 1B or equivalent can be easily connected via a compact sensor connector panel The on vehicle docking station also includes a powerful back up battery for safe operation even if primary power is lost support dtsweb com 11 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 Appendix A Guide to TDAS G5 DAS LED Indicators eas ue mm DAS LED COM r Computer communicating with docking station mo No active communication O Calibrationin progress o Q joe S Q wed So r Power warning 9 6 10 2 volts Power critical 9 6 volts Received start record signal waiting for event signal TDAS G5 DAS no longer armed or no longer collecting data or received event signal STAT No faults detected No faults detected r Received event signal Fault occurred either Low battery Docking station fault System armed and waiting for start record or event signal TDAS G5 DAS fault Green Yellow Red LED off support dtsweb com 12 Rev 3 TDAS G5 DAS Hardware User s Manual August 2004 Appendix B Mechanical Specifications Weight 200 grams 3 374 inches 85 7 mm 0 472 inches 12 mm 0 984 inches 25 mm 2 677 inches 68 mm 1 732 inches 0 158 inches diam 0 197 inches 4 0 mm dia
16. upport Each TDAS G5 DAS measurement channel supports communication with silicon serial number devices manufactured by Dallas Semiconductor Maxim Integrated Products When you connect an ID chip to the proper pins on the sensor connector the TDAS Control software can automatically read these devices and correlate the serial number with channel set up information stored in a Sensor Information File SIF Memory Size Each TDAS G5 DAS contains 50 MB of volatile RAM and 5 MB of non volatile flash memory For each sensor channel the maximum samples available via RAM is 10K samples second for 70 seconds for flash memory the maximum samples available is 10K samples second for 7 seconds WARNING Reliable high quality primary and back up power sources are very important for data retention If primary and back up power is lost all data contained in the RAM will be deleted Basic Care and Handling TDAS G5 systems are designed to be as simple to operate as possible but it is impor tant that you carefully follow recommended procedures to ensure maximum reliability TDAS G5 DAS units are precision devices designed to operate reliably in dynamic testing environments Though resistant to many external environmental conditions care should be taken not to subject the unit to harsh chemicals submerge it in water or drop it onto any hard surface WARNING Electronic equipment dropped from desk height onto a solid floor may experience as much
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