TDAS G5 Docking Station Hardware User`s Manual
Contents
1. Battery Capacity The actual useful capacity will depend upon the number of channels in use the resistance of the connected sensors and whether or not the battery was fully charged before testing When fully charged the internal battery will provide at least 30 minutes of operational power when armed with a full sensor load Battery Life Cycle Charging practices can affect the useful operational life of the battery For example a battery that is used for short periods but never properly charged will have a relatively short life Conditioning the battery may be useful three deep discharge recharge cycles may help increase battery performance Most TDAS G5 Docking Stations but not all are designed to allow the user to replace the internal battery If your docking station has a removable battery compartment cover as shown in the mechanical drawing on page 16 your battery can be replaced with minimal effort Since all battery packs are manufactured to DTS specifications and are not commercially available you will need to contact DTS for pricing availability and instructions for battery replacement support dtsweb com 10 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 Power up and Power down Procedures The momentary switch located on the control panel is used to turn power on and off To turn on a TDAS G5 Docking Station press down and hold the switch for 3 4 seconds until the LED changes status2. referenced to common Ethernet Tx2 Ethernet Tx2 Common for start record and status inputs Ethernet Rx2 Ethernet Rx2 8 NE NE 4 pin POWER Connector EEG 2B 304 CLL panel view Suggested cable connector P N FGG 2B 304 CLADxx Power Power support dtsweb com 14 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 26 pin DIGITAL INPUT Connector EEG 2B 326 CLL panel view Suggested cable connector P N FGG 2B 326 CLADxx 6 Digital Input 4 21 22 23 8 Common 5 and 6 9 Digital Input6 Digital Input 7 Digital Input 14 NE UN 22 DigitalInputi5 23 _ Common 15 and 16 Common 13 and 14 Suggested Connector Sources DTS uses LEMO connectors on the TDAS G5 Docking Station If you need to purchase connectors we suggest first going to LEMO directly http www lemo com index html Their web site and worldwide sales team are very helpful Should you have difficulty obtaining a specific part number they can suggest connector variations or alternates and explain options that may be useful for your particular application Another U S source is Alpine Electronics www alpine electronics com in San Jose California They are a stocking distributor for LEMO and LEMO compatible connectors support dtsweb com 15 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 Appendix B Mechanical Sp
3. then release the switch The internal power up sequence takes 20 seconds to complete Please see the diagrams on page 10 for information on LED status To turn off a docking station press down and hold the switch for 3 4 seconds until the LED changes status then release the switch Please see the diagrams on page 10 for information on LED status Before restarting a docking station wait until all TDAS G5 DAS LEDs go completely dark and then wait 10 seconds more to be sure An incomplete power down power up cycle can result in errors so be certain to follow proper procedures Multiple interconnected TDAS G5 Docking Stations TDAS PRO rack systems should be powered up at least 10 seconds apart to avoid communication conflicts They may be powered up in any order Once power up of all systems is complete you can then start your TDAS Control software Communication Features The two 19 pin COM connectors on each TDAS G5 Docking Station control panel allow access to all communication features and status lines These connectors are functionally identical so you may use either one to connect the communication and trigger cables provided with your system Please see Appendix A for the connector specifics and pin assignments Communication Method The TDAS G5 Docking Station supports the industry standard Ethernet 10 100BaseT Tx communication method The docking station itself does not contain an IP addressable controller communica
4. systems However if high ambient temperatures expo sure to other heat sources or severely restricted airflow will cause case temperatures in excess of 50 C too hot to touch comfortably 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 Management A good power source is of paramount importance Each TDAS G5 Docking Station should be powered from either 1 A high quality 15 volt power supply with a current rating of at least 2 amps this would include the TDAS PLUS Distributor and TDAS PLUS Mini Distributor 2 A fully charged 12 volt battery with sufficient capacity for the application When installing power supply systems always consider voltage drops that may occur due to cables connectors power converters etc Always remember e To ensure the internal battery is fully charged the minimum input voltage received by the docking station at its power input connector must be 213 8 volts e DTS always recommends using an external power source during set up and check out This will ensure that the internal battery is always fully charged support dtsweb com 7 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 Power Consumption Power off When connected to sufficient external power the docking station will draw up to 600 mA for charging the internal battery Power on When a TDAS G5 system dock
5. the docking station When not in use or if shipping is required we suggest that you always place the unit in the padded carrying case originally provided with your system support dtsweb com 6 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 WARNING The 216 position gold plated interface connector on the docking station 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 compro mise the integrity of the connections signals If you feel the interface connector on your docking station has become contaminated please contact DTS support before attempting any cleaning procedure Shock Rating All TDAS G5 vehicle sled mounted systems are rated for and fully tested to 100 Gs 12 msec duration in all axes TDAS G5 equipment can be mounted directly on a vehicle sled or other dynamic testing device Mounting methods and mounting bolt selection should be carefully calculated so as to withstand expected shock loading See Appendix B for the mechanical specifications Thermal Considerations TDAS G5 systems use extensive power management to minimize heat generation Since the system draws the most power when armed running the calibrations and arming as late as possible will minimize self heating It is extremely unlikely that excessive heat will ever be an issue in real world testing applications using TDAS G5
6. 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 Docking Station Hardware User s Manual TDAS G DOCKING STATION ROS Dy KS December 2004 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 Table of Contents DTS SupDOEt iiioooiiia erae xas tun xRaR ERR ERRERI wa KRaERGRV ERROR vun NMREKSREERRRREEaEERURKEFERREUENEEERURKEER 3 Introducing the TDAS G5 Docking Station ee eese eese nnn nnn nnn 4 Overview of TDAS G5 Docking Station Features eere nennen 4 Input RANGE ernati ered eteteet N EAE EE E ET AE sawed scaled EETA araa 4 EXGitatiOn SOUCO Sa iea e a noua E uu nni sio edis T a aa e aa vate 4 SENSON CONNECLOLS irisan E aa ce a E R AA a E E 5 Digital InpUbs er a a A a CET Vue a A eT Ter rr a cu ux 5 Control Panel saisan diuo er aa diesen rus ool v ad a A da dna URN REMIS 5 Basic Care and Handling rri ana os aiu u naa ERARRES RAV RR REERRERAREERRE RRRRRRUENRURRNRRRKRYREREER 6 Shock RAINO sorn eiaa vieievk IR Rt PEE prd Ls sag DA OMS AIEO YA LATUR SAT EPIA uM A TIAE MP SAT II 7 Thermal Considerations cus Er 7 Power Management s ssssssss55555 555 55 555555500uu5500u15550uunnnuunnnnnnnnnnnnnnnn nnn 7 Power CORSUMPUION avs rae sceau ur v a n On Oe OR e o e OX t Bo D E D KU E ER D VE E 8 TDAS G5 Docking Station Internal Battery ssssssseesseeeen nennen 8 Char
7. e outlined below Note that the docking station does not need to be turned on in order to charge the internal battery It is also not necessary to install a TDAS G5 DAS unit when charging the docking station The ON LED is an indicator of battery status A discussion of the LED indicator begins on page 9 1 Docking station implemented without an external battery Connect a 15 volt power source to the docking station POWER input Use this charging set up for several hours before testing overnight works well The docking station does not need to be turned on in order to charge the internal battery The docking station may be charged with or without a TDAS G5 DAS installed 15 VDC 2 A Power Supply non rugged off board or TDAS PLUS Distributor or TDAS G5 Docking Station AC power TDAS PLUS Mini Distributor This configuration can also be used during pre test set up and check out to ensure a full charge support dtsweb com 8 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 2 Docking station using an external on board battery Connect the docking station to a crashworthy 12 volt lead acid battery then connect a high quality battery charger to the battery As the external battery charges above 13 volts the docking station s internal battery will also charge In this way all batteries including the primary external battery will charge fully AC power TDAS G5 D
8. ecifications Weight 2502 grams LEMO 1B sensor connector panel TDAS G5 DAS not included Torque specification for screws 4 fastening connector Torque specification for screws 4 fastening DAS panel 1 4 to 1 7 Nm or 12 to 15 6 in Ilb d 1 6 to 1 8 Nm or 14 to 16 in Ib ww 9 00T seuoul T96 Hi w a 3 Q 2 o hn w d 3 3 Cover for battery compartment typ M8 x 1 25 pitch screws should penetrate docking station 12 mm 0 492 inches 8 76 inches 222 504 mm 12 497 mm 1 969 inches 50 013 mm 2 362 inches 60 mm 9 252 inches 235 mm 0 394 inches 10 008 mm WARNING The torque specification is critical for proper connection of the TDAS G5 DAS 1 6 to 1 8 Nm or 14 to 16 in ib and sensor connector panels 1 4 to 1 7 Nm or 12 to 15 6 in Ib If the bolts are tightened too little good contact will not be made if they are tightened too much damage may result Please use a torque wrench if possible support dtsweb com 16 Rev 2
9. ging the Battery eenei breites ee aae aio durs piri al Qaa Pod adhi et a EUR ORG reasons 8 LED IDOI COLE i retia RV EEEE Mte apu Rute Sanat Meinl causer sett haces abut et ues 9 Battery Capacity rdi Sew iaa Ress Rcg dance tava SE REDE heli Ld TERRA CR REDEE OA ata 10 Battery Eife CyCle serrr oT EE RETE ee On ERR veil EPEA FER ex FERE RACE ava anes 10 Power up and Power down Procedures eecseeeeseeeeee enne hnnen nnn annnm nn 11 Communication Features 2 0 ois con csissua uA DRR SA DEUSRRRERRESRERURSPRN RS MAR ARRANRURUS 11 COMMUNICATION Methode ieei eee oap e tua sagen take eI va eo eo ein dices PE VEL paate iihi ear Does 11 Using Multiple TDAS G5 Docking Stations eeesseesese esee ehe nnn hannah nnn a 11 Auxiliary SIO al S viso cover ad cuEecens duse kv whS a E endoru M ee cav plv iu XL R ve T Ve de dara Td 12 Start Record JAPU cuida conde xxu pot Px USO EX ERE da DUE ER o e od ra CU E Rb ERR 12 Status OutbUt SIgnaliu iiss tvwenasas ee ERR ERA DES ERXERE NEA RAE ERES EE WEEEERIRAR AREE ETE Qa ET 12 Using the Event InpUEL oiii esaoisa xu 5e rd aa eauE Za EX UE ARRRREESRISSXRREERRSRREIRREX NECRARERERS 13 Appendix A Control Panel Connector Information 14 Suggested Connector Sources ceeeseeeeseeeeseeee seen h sena hn nanus rna nnn n nnn 15 Appendix B Mechanical Specifications ee eese eese eese nnne nnn nnns 16 Appendix C Hardware Configuratio
10. ing station and DAS is initially powered all sensor excitation sources signal conditioning 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 per forming tasks When the user runs a test set up the software automatically energizes the excitation sources and other circuits The current draw will increase to as much as 1 4 amps when the system is fully armed and powering 32 full bridge loads During data collection 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 complete the system de energizes several circuits to minimize power consumption It takes a maximum of 125 seconds after the end of the data storage window for the system to return to the idle state which then allows communication and download TDAS G5 Docking Station Internal Battery Each TDAS G5 Docking Station contains a 2 1 AHr NiMH battery This battery can function as the primary power source or as a back up power source when using external power The system ensures a smooth transition from external to internal power if the external power source is disconnected or shorted during data collection Charging the Battery The two most reliable ways to fully charge the TDAS G5 Docking Station s internal battery ar
11. ion to an on board docking station for maximum flexibility of data acquisition resources Docking stations may be interconnected in a chain to create higher channel count systems they may also be interconnected with TDAS PRO racks This manual discusses the features and options available with the TDAS G5 Docking Station To identify the specific hardware included with your system please see your packing list Overview of TDAS G5 Docking Station Features Built and tested for 100 G dynamic testing environments 32 fully programmable sensor input channels Internal battery with a capacity of up to one hour Smart Charge circuit helps ensure that the battery receives the proper charge LED indicator for power and battery status Power input is protected against reverse current over current and transient over voltage conditions 2 volt and 5 volt excitation sources Ethernet 10 100BaseT Tx communications allow interconnection with TDAS G5 Docking Stations or TDAS PRO racks Contact closure event input with 1000 volt isolation Rugged time constant momentary power switch prevents inadvertent turn off 16 isolated and protected multi purpose digital inputs Integral threaded mounting holes 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 rated common mode voltage range is 0 3 to 4 7 volts Excitation S
12. marked SLAVE connected the other COM port will remain open Do not connect your PC to the last docking station in the chain Note You may use the open COM port to connect your event input TDAS PLUS Visual Status Indicator or other device if desired Note that TDAS G5 Docking Stations may also be interconnected in this manner with TDAS PRO racks Auxiliary Signals Additional auxiliary signals are available on either of the 19 pin COM connectors Please see Appendix A for the connector specifics and pin assignments These signals are e Start record input optically coupled 0 5 volt signal e Status output 0 5 volt 20 mA output Start Record Input The start record input used only in recorder mode is used to send a signal to the system to begin recording data independent of any event signal The desired length of recording time is entered into the TDAS Control software Once the start record signal is received by the system data is recorded only for the length of time specified An event signal can be used separately to facilitate post processing of the data Care should be taken when using this feature so that the desired event is captured within the data window See the TDAS Control software manual for additional information Please contact DTS for additional information on how this may be useful in your application Status Output Signal The status output signal is available for use as an indicator of system status A ty
13. n Specifications es 17 support dtsweb com ii Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 DTS Support TDAS systems are designed to be reliable and simple to operate Should you need assistance DTS has support engineers worldwide 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 supporti dtsweb com Your e mail is immediately forwarded to all DTS support engineers worldwide and is typically the fastest way to get a response particularly if you need assistance outside of normal business hours For assistance by telephone please go to http www dtsweb com support html to find the phone number appropriate for your region of the world support dtsweb com 3 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 Introducing the TDAS G5 Docking Station The TDAS G5 Docking Station allows for easy installation of a TDAS G5 Data Acquisi tion System DAS into a rugged enclosure for on board testing applications Power communication and event signals are easily accessible via 2B LEMO connectors on the control panel Sensors are easily connected via a compact sensor connector panel that can accommodate a variety of user specified connectors and pin assignments including 1B LEMO and Tajimi A TDAS G5 DAS can be moved easily from an in dummy applicat
14. ocking Station Battery Charger e g high quality 5 A unit 12 V SLA Battery rugged on board This configuration can also be used during pre test set up and check out to keep both the external and internal battery continually charged DTS supplied power supplies and distribution units are designed to meet all criteria for proper charging and operation If you need help determining which set up is best for your application or if a power supply or charger will meet the power demands please contact DTS LED Indicator The TDAS G5 Docking Station has one LED red yellow green that provides ongoing battery status in three ways 1 Charging when docking station is off blinking LED 2 Charging when the docking station is on solid LED 3 Discharging when the docking station is on blinking LED When discharging i e drawing power from the internal battery battery status is determined dynamically during use Please pay close attention to the LED as it will indicate if the battery status is acceptable green low yellow or at a critical level red WARNING Do not perform any critical tests when the LED indicator is yellow battery low or red battery critical support dtsweb com 9 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 Charging when Off Charging when On blinking LED rate solid LED 0 4 Hz s1nou OT sanoq OT Insufficient external power to charge Critical
15. ol panel on the TDAS G5 Docking Station allows you to connect external power a contact closure event signal digital inputs and communication signals to your PC and other TDAS G5 Docking Stations or TDAS PRO racks Please see Appendix A for the connector specifics and pin assignments support dtsweb com 5 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 Main Power Input e 13 15 VDC Digital Inputs e 16 digital inputs Momentary AN do e Event input Power Switch j LED Communication Connectors identical Indicator Ethernet 10 100BaseT Tx Status output Status input Start record input Event input TDAS G5 Docking Station Control Panel Basic Care and Handling TDAS G5 Docking Stations are precision devices designed to operate reliably in dynamic testing environments Though resistant to many 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 as 10 000 Gs Under these conditions damage to the exterior and or interior of the unit is likely When transporting the unit treat it as you might a laptop computer and you should have no problems If a TDAS G5 DAS is not installed in the docking station we strongly recommend reattaching the clear plastic cap to cover the opening and protect the connector interface on
16. ources TDAS G5 Docking Stations provide adjustable excitation under software control Standard excitation voltages are 2 volt and 5 0 volt Other factory options are available Excitation sources for each channel are individually regulated and current support dtsweb com 4 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 limited 20 mA per channel to ensure reliable operation even with shorted cables Recovery time is 1 msec Excitation sources are not turned on until the software initializes the system during the Real Time or Collect Data modes Sensor Connectors DTS supplies TDAS G5 Docking Stations with a variety of connectors and pin assign ments All docking stations have sensor connections as shown below Please see Appendix C for the specific connectors and pin assignments for your equipment 16 contact closure inputs on Excitation 26 pin LEMO Check ADC Shunt Check A Driver Gain t Calibration Differential Le Instrumentation p Le ID digital Amplifier pe Shield Fre Bid 44 pin TDAS G5 DAS connector connector Digital Inputs Di Ss ID Diversified Technical Systems Inc 2003 nterface All Rights Reserved Sensor Connections Digital Inputs Sixteen isolated protected and self powered contact closure digital inputs are available via the 26 pin LEMO connector on the control panel See Appendix A for connector information and pin assignments Control Panel The contr
17. pical application would be in an environment where operators may be a substantial distance away from the test equipment in a control room or other remote location and desire confirmation from the system that it is armed and healthy prior to testing The table below describes this function support dtsweb com 12 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 Status Output Functional Description When the docking station is not armed the status output is always low near O V regardless of signals on the event input The status output will be high near 5 V ONLY when 1 The docking station is armed AND 2 The docking station is ready to record data is in circular buffer mode or has received a start signal in recorder mode AND 3 The docking station has not received an event signal AND 4 The docking station s power status is within acceptable levels In circular buffer mode the status output will go high as you arm the system It will go low when the docking station receives an event signal any A D circuit stops functioning or if the system s power is outside of acceptable limits In recorder mode the status output will remain low until the system is actually recording data The status output will go high when the docking station receives a start record signal and all other diagnostic checks are within acceptable limits It will go low when the docking station receives an event signal the end of the
18. recording time window is reached any A D circuit stops functioning or if the system s power is outside of acceptable limits Using the Event Input The TDAS G5 Docking Station contains an isolated ESD protected contact closure EVENT input The EVENT input is available through both of the 19 pin connectors and the 26 pin connector The specific connector pin assignments can be found in Appendix A This input provides a way to use a closure switch in harsh or noisy environments without negatively affecting the data acquisition system A software trigger can also be used please see your TDAS Control software manual for informa tion on how to set a software level trigger The EVENT input may be used in either of two ways e In circular buffer mode this input actually triggers data collection and is used to mark zero time T 0 e In recorder mode this input is used to mark T 0 only WARNING Do not apply external voltages to the event communication status or control output and inputs this could result in damage to the unit support dtsweb com 13 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 Appendix A Control Panel Connector Information 19 pin COM Connectors EEG 2B 319 CLL panel view Suggested cable connector P N FGG 2B 319 CLADxx Internal function only Internal function only Shield Start recording input optically coupled apply 5 V with respect to pin 16
19. tion is only possible when the docking station contains a TDAS G5 DAS Communication is enabled after the power up sequence has completed 20 seconds Using Multiple TDAS G5 Docking Stations TDAS G5 Docking Stations can be interconnected in a chain to create higher channel count systems In this way one docking station can act as the main terminal point for a multiple docking station system Docking station to docking station communica tions are accomplished by using a control cable RDC xx xxxx The procedure for the making the proper connections is outlined below e Using either COM port on the first docking station connect your PC to the docking station using the Ethernet communication cable REC xx xxxx provided with your system support dtsweb com 11 Rev 2 TDAS G5 Docking Station Hardware User s Manual December 2004 e Then using a control cable RDC xx xxxx connect the end marked MASTER to the first docking station and the end marked SLAVE to either COM port on the second docking station e Using a second control cable connect the end marked MASTER to the open COM port on the second docking station connect the end marked SLAVE to either COM port on the third docking station e Continue connecting the control cables in this manner so that each docking station in the middle of the chain has both a MASTER and SLAVE cable end connected The last docking station in the chain will have only the cable end
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