601-319B - AES 5501 User Manual english.indd
Contents
1. AES 5501 AUTOMOTIVE EMISSIONS SYSTEM USER MANUAL 601 3198 Advanced rest Solutions for EMC AES 5501 AUTOMOTIVE EMISSIONS SYSTEM USER MANUAL CONTENTS 6 2 6 3 6 4 6 5 6 6 10 11 12 13 13 1 13 2 13 2 1 13 2 2 14 15 16 Explanation of symbols used this manual Warning symbols on the test system Safety Installation Connecting the power cable Introduction to emissions in ISO 7637 2 The AES 5501 Automotive Emissions System The system controller Mechanical switch Artifical network amp shunt resistor Electronic switch Timing Trigger source The MS 5501 The AN 5501 The ES 5501 Electronic switch Operation Specifications Technical data Maintenance Cleaning Calibration Calibrating the AN 5501 Calibrating the ES 5501 The package contents Declaration of conformitiy CE Addresses 10 10 11 14 15 15 16 16 16 16 17 26 29 30 33 36 37 37 37 37 37 38 39 40 1 EXPLANATION OF THE SYMBOLS USED IN THIS MANUAL Please take note of the following explanations of the symbols used in order to achieve the optimum benefit from this manual and to ensure safety during operation of the equipment The following symbol draws your attention to a circumstance where failing to observe the warning could lead inconvenience or impairment in perfor mance Example This connection must not be confused with the main gt power in2. 1 X MS 5501 Mechanical switch 1 X ES 5501 Electronic switch 1 X SC 5501 System controller 3 x Control cables Calibration certificate Users guide this guide Oscilloscope probe compliant to ISO 7637 2 4 x Pin adapters for zero millimetres between devices 4 x 4 to 6 adapters 2 x Alternative relay PCB cable and hardware AES 5501 Automotive Emissions System 15 DECLARATION OF CONFORMITY 39 THSEO Advanced Test Solutions for EMC Teseq AG Nordstrasse 11F 4542 Luterbach Switzerland T 41 32 681 40 40 F 41 32 681 40 48 www teseq com Declaration of conformity Manufacturer Teseq AG Address Nordstrasse 11F 4542 Luterbach Switzerland declares that the following product Product AES 5501 Automotive Emission Switch Options all conforms to the following Directives and Regulations EMC Directive 2004 108 EEC LVD Directive 2006 95 EEC Generic standards EN61326 1 2005 EN61326 2 1 2005 EN61010 1 2001 The relevant technical file is available for inspection Technical file N EMC_AES5501_2009 LVD_AES5501_2009 Teseq AG CH 4542 Luterbach The purpose of this instrument is the generation of defined interference signals for EMI immunity testing Depending on the arrangement of the test rig the configuration the cabling and the properties of the EUT itself a significant amount of electromagnetic radiation may result that could also affect other equipment and systems The user himself or herself is ultimately
3. also has a place for connecting a resistor when using the external setting on the SC 5501 While most common impedances are included in the AN 5501 these banana connectors can be used for additional R shunt resistors The external jacks AES 5501 Automotive Emissions System 9 THE ES 5501 ELECTRONIC SWITCH 29 EINEN Tho ES 5501 is the container of the electronic switch with specifications outlined in ISO 7637 2 The ES 5501 The ES 5501 is a 100 A fast electronic switch Refer to chapter 6 for control Before using the ES 5501 you must connect the control cable from the ES 5501 to the SC 5550 The ES 5501 contains a BNC connector for ease of use TASEO Advanced Test Solutions for EMC 30 10 OPERATION mum every case it is important to consider where the input and outputs of the system are The input is always to the left of the various chassis and the output is on the right The cables are exchangeable as is the positions of the switches as long as the inputs and outputs are observed The AES 5501 Emissions system In the above example here shown with both switches the DC voltage battery comes in the left side and the DUT would be connected on the right AES 5501 Automotive Emissions System Carefully observe cable placement observing maximum cable lengths and 81 cable placing requirements of your standard ing the oscilloscope probe Most oscilloscope probes have a ground connection The AN 5501
4. change without notice Teseq is an ISO registered company Its products are designed and man ufactured under the strict quality and environmental requirements of the ISO 9001 This document has been carefully checked However Teseq does not assume any liability for errors or inaccuracies
5. is not isolated and failing to observe proper polarity can cause a short of the power supply to ground E It is important to observe proper polarity when connect Once all cables are in place and the various lengths of cables are observed provide the DC voltage to the DUT by switching both the Mechanical Switch and Electronic Switch to On The AES 5501 can also be used with the supplied pins The allows the user to effectively have zero distance between the AN and switches The AES 5501 being configured for zero cable length TASEO Advanced Test Solutions for EMC 32 Next select your RS by selecting the resistance value on the SC 5501 To per form the slow pulse for example select the Mechanical Switch gt Triggered and use either the Manual Single Internal fields to select the timing Any switch in the DC path must be selected ON or Triggered or DC will not pass to the DUT All switches in the DC path must be set to On or Trig HH 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 as is the cable height above the ground plane Observe m Cable lengths are strictly required by most standards these restrictions carefully for a compliant test After all of your cables are connected and the DUT is powered through the switch es then you are ready t
6. two short battery cables and a six pin cable The six pin cable provides the necessary drive voltages to the relay Take care when installing this cable The two red battery cables should be connected from the battery studs to the common and normally open connections as shown TASEO Advanced Test Solutions for EMC 24 Next you will need to select the voltage for your specific relay The included Bosch relay is part number 0 332 019 151 and uses a 12 V drive voltage The AES 5501 system was designed to include 12 24 and 42 36 volt drive voltages to the relay The voltage for the relay comes over the short six pin cable and is selected as shown in the following picture Selecting the drive voltage AES 5501 Automotive Emissions System before connecting the drive cable to the MS 5501 Degradation in performance or damage may result in incorrectly selected drive voltages Carefully select the drive voltage of the relay installed 25 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 The MS 5501 may be closed again using a reverse process of that given above and reconnecting the six screws and the drive cable from the SC 5501 Mind the polarity of the diode when exchanging Please note that the coil suppression diode is required relays TASEO Advanced Test Solutions for EMC 26 8 THE AN 5501
7. F performance All tolerances 1096 unless otherwise noted 1 Active temperature dependant cooling The ES 5501 is depending on duty cycle approximately 3 minutes at 100 A with 10096 duty cycle before the switch will be deactivated for cooling See derating below 2 With supplied relay or Electronic Switch 3 With test load defined in ISO 7627 2 Purely resistive loads display typically in the range of a few microseconds i i Measure P1fall lv C2 P2 min C2 P3falliglv C2 P4 fall lv C3 P5 period C1 P6 max C1 value 303 774ns 466 V status v ES 5501 switching curve with test load AES 5501 Automotive Emissions System 60 50 40 30 20 0 0 1 1 10 100 f MHz Impedance curve of the AN 5501 Derateing ES 5501 100 a 90 85 80 75 70 lon 100 Duty Cycle 25 C A 65 60 0 10 20 30 40 50 60 ON Time min Current capability of ES 5501 TASEO Advanced Test Solutions for EMC 35 36 12 TECHNICAL DATA mmmm Mains voltage 85 264 VAC Power max 100W Fuse 2X T BAVA Environmental conditions Temperature range Operation at 10 to 40 C Storage at 10 to 60 C Humidity 30 to 7896 non condensing Air pressure 860 to 1060 hPa Dimensions and weights Phy
8. e Trigger in Trigger out Connectors on the SC 5501 TASEO Advanced Test Solutions for EMC 18 7 The MS 5501 The MS 5501 is the container of the mechanical switch relay The MS 5501 The MS 5501 is delivered with a 100 A relay Refer to section 6 for control The 100 A relay may be exchanged using the supplied PCB for other relays that use the industry standard footprint Before using the MS 5501 you must connect the control cable from the MS 5501 to the SC 5501 The relay control voltage is provided from the SC 5501 as well as all timing functions The MS 5501 contains an counter and BNC con nector for ease of use The counter will indicate the number of pulses that have been sent from the SC 5501 Note that even if the repetition frequency is too fast for the mechanical Switch to react the counter will still count the pulses the SC 5501 even if the timings are too fast for the The counter counts the control pulses that are sent from electromechanical switch to react Resetting the counter may be performed by pressing the provided button in side the MS 5501 Normally this is done when replacing the relay AES 5501 Automotive Emissions System Resetting the counter The MS 5501 is provided with a 100 A relay installed by default The PCB adapt er with a selection of industry standard footprints may also be installed by performing the following steps Opening the housing should be achieved by remov
9. ing the four thumb screws indicated in the following picture and gently lifting the handles outwards and upwards Opening the housing TASEO Advanced Test Solutions for EMC 20 Removing the housing cover The old relay must be removed Start by removing the cables connecting the relay to the input and output posts high side only using a 10 mm wrench This will be performed two times on the input and output sides of the MS 5501 AES 5501 Automotive Emissions System The system should appear as in the following picture when the relay is 21 removed Uninstalled 100 A relay TASEO Advanced Test Solutions for EMC 22 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 Reinstalling the 100 A relay may be achieved by reversing the above steps Installing the included PCB with standard relay footprints may be installed us ing the following process Install the supplied studs and the PCB using the supplied hardware a screw driver with T25 bit nstall the relay PCB The studs will require the use of washers included between the base of the ES 5501 and the stud AES 5501 Automotive Emissions System The PCB containing the relay sockets uses two studs 23 2 included with the AES 5501 system Next connect the included cabling This includes two sets
10. mmm The AN 5501 contains the artificial network rated to 100 A the necessary select able impedance an extra banana connector for external impedances and an output connector for monitoring if necessary The AN 5501 The AN 5501 shall be connected to the SC 5501 using the supplied control cable As in any of these external chassis it is not important which cable is connected any of the three available may be used To select the RS resistor choose the appropriate resistance value on the SC 5501 If an external resistor shall be used selecting off external on the SC 5501 Will activate the Ext R connector Pay attention that a resistor of sufficient power is used based on your battery voltage using the following formula P U R AES 5501 Automotive Emissions System Where P is the resistor power U is the battery voltage and R is the resistor 27 value in Ohms select a resistor value of sufficient power to withstand When an external resistor is used care shall be taken to the battery voltage The AN 5501 contains a jumper for connecting the negative battery input ter minal to ground This should be left connected usually and is required for conformance to ISO 7637 The output side of the AN also contains a special connection for the calibration adapter This can be ignored during daily use The ground jumper Mating surface for the calibration adapter TASEO Advanced Test Solutions for EMC 28 The AN 5501
11. ng the power cable For further information on cabeling and setup please see the section Opera tion AES 5501 Automotive Emissions System 5 INTRODUCTION TO EMISSIONS IN ISO 7637 2 mE The AES 5501 is designed in accordance to ISO 7637 2 and may be used with confidence for many manufacturer standards This guide gives a good overview of ISO 7637 2 Carefully consult the relevant manufacturer standard and ISO 7637 2 before operating the AES 5501 system ISO 7637 2 2004 describes a method of measuring transient returns from a DUT when the battery is switched on or off This standard is an important part of automotive EMC testing This standard describes two methods of switching the DUT with a mechanical Switch recommended the actual switch built into the vehicle or a fast electronic Switch Refer to the applicable annex of ISO 7637 2 for guidance gt in measuring the returned effects and limits have strict cable length requirements The most Pay special attention to cable lengths The standards common are provided with the AES 5501 system ISO 7637 2 recommends two setups The switch can be before or after the AN as seen in the following diagrams Refer to ISO 7637 2 for more information TASEO Advanced Test Solutions for EMC 12 Oscilloscope Artificial Network Simulates Wiring Harness Switch Impedance Slow pulses ms range or slower Application for Slow
12. o create a dropout Note that the worst emis sions returns usually occur at the time of switching the voltage off due to in ductive kickback AES 5501 Automotive Emissions System 11 SPECIFICATIONS 33 EEEEN Complete system Battery current 100 A Inrush current 300 A for 200 ms Battery voltage 0 to 60 VDC Shunt resistor R 10 20 40 120 O Ext Trigger modes External internal single manual Battery off time 10 ms 10 s 10 10 ms Battery on time T 0 5 10 5 10 10 ms Mains input voltage 85 264 VAC 47 63 Hz Available relay 12 24 36V for 42 V voltage applications Electronic Switching time Ats 300 ns 2096 Voltage drop lt 1V 25A lt 21 V 100A Transient voltage 440V protection Mechanical switch Type Automotive relay Contacts High purity AgNi with no suppression across contacts Voltage rating gt 400 V Artificial network Inductance 5 UH Capacitance 0 1 UF Resistance 500 Impedance AS per ISO 7637 2 see above impedance curve Connectors 100A MC type countersunk 50 mm above ground plane Housing Stainless steel unpainted underside screw terminal and earth connections TASEO Advanced Test Solutions for EMC 34 Indicators Counter on relay LED indicator on controller for mechanical and electronic switchs Measurement MS 5501 ES 5501 directly connected to output Ports AN 5501 5 6 k output impedance to output connector necessary for improved R
13. pulse showing most of the wiring harness impedance between the switch and DUT AES 5501 Automotive Emissions System Application for Fast pulse showing most of the wiring harness impedance between the battery and switch Oscilloscope Artificial Network Simulates Wiring Harness Impedance Switch Fast pulses ns to us range TASEO Advanced Test Solutions for EMC 13 14 6 THE AES 5501 AUTOMOTIVE EMIS SIONS SYSTEM mE The AES 5501 is a system of electronic and mechanical switches an artificial network and a unique control station designed for emissions testing to ISO 7637 2 Consisting of a four part solution the user has complete control over where when and how the switches can be placed and controlled including the necessary drive voltages for the relays The 100 A connectors are carefully placed and countersunk to allow precise cabling between the switches the artificial network and test bench and allows for the electronic or mechanic Switches to be placed at any point before or after the artificial network This careful attention to switch placement and cable length means that the numer ous manufacturer standards can also be met The AES 5501 features a rugged construction with unpainted underside for good earth contact precise switch ing control and monitoring functions A counter for the relay and LED indica tors for both electronic and mechanical electronic switches are p
14. put The following symbol draws your attention to a circumstance where failing to observe the warning could lead to component damage or danger to the operating personnel Caution sign A situation that may cause damage to the equipment Example EH Connect the system only to rated mains power TASEO Advanced Test Solutions for EMC 5 banger sign Possibly dangerous situation that may cause damage to persons or heavy damage to the test equipment or DUT Example It is dangerous to fail to observe safety warnings AES 5501 Automotive Emissions System 2 WARNING SYMBOLS ON THE TEST 7 SYSTEM CAUTION Warning of a danger spot refer to the docu mentation TASEO Advanced Test Solutions for EMC 3 SAFETY The AES 5501 system itself contains no dangerous voltages or currents however the application requires an external power source and can use up to 100 A for DUT power Up to 100 A may be switched using the AES 5501 Care should be taken in connecting and operating the DUT The AES 5501 system is used to measure emissions from the DUT These emis Sions may be high voltages caused by inductive kickbacks Care should be used when powering the DUT through the AES 5501 system Refer to engineering or product documentation for your specific DUT cables leading to and from the DUT Take care and follow all applicable safety guidelines given for your specific DUT Potentially dangerous voltage may be p
15. r source fields below TASEO Advanced Test Solutions for EMC 6 3 Artifical network amp shunt resistor This field allows the user to select the impedance of the artificial network Selecting the resistance here will set the resistor on the left input side of the artificial network to the selected value as shown on the AN 5501 Selecting the Off Exernal option will connect the resistor to the banana jacks on the left input side of the AN 5501 For more details consult section 8 6 4 Electronic switch The electronic switch field is used to control the ES 5501 and contains three input elements buttons named Triggered Off and On In Off mode th switch is turned completely off thus blocking any DC voltage to the DUT On mode the switch is turned on thus providing any DC voltage availab at the input of the mechanical switch to the DUT Trigger mode is the mod by which the user has the ability to control the timing of the switch using th fields timing and trigger source This field also has an LED display that show the status of the switch The LED will indicate green when it is on and unlit when off and red indicating an error condition Pressing the unlit indicator will select the mode Refer to the descriptions of the timing field and trigger source fields below ooo D gt n 6 5 Timing The timing field is used to select the battery off and battery on times The battery on time is only valid when the t
16. resent at the General warnings safety instructions and all safety instructions in the manuals of the connected peripheral systems before installing and starting this test system for the first time DANGER It is imperative that you read the following AES 5501 Automotive Emissions System 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 The electrical and mechanical safety equip 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 The operating instructions form an integral part of the equipment and must be available to the operating personnel at all times All the safety instructions and advice notes are to be observed TASEO Advanced Test Solutions for EMC 10 4 INSTALLATION E 4 1 Connecting the power cable The power supply is an auto ranging type For exact specifications see the section technical specifications Please only use power cables that are certified for use in your location Connecti
17. responsible for the correct and controlled operation of the rig In case of doubt the tests should be carried out ina Faraday cage Place and Date Luterbach November 3 2009 puo am Johannes Schmid President TASEO Advanced Test Solutions for EMC Headquarters Teseq AG 4542 Luterbach Switzerland T 41 32 681 40 40 F 41 32 681 40 48 sales teseq com www teseq com China Teseq Company Limited T 86 10 8460 8080 F 86 10 8460 8078 chinasales teseg com Germany Teseq GmbH T 49 30 5659 8835 F 49 30 5659 8834 desales teseq com Singapore Teseq Pte Ltd T 65 6846 2488 F 65 6841 4282 singaporesales teseg com Taiwan Teseq Ltd T 4 886 2 2917 8080 F 886 2 2917 2626 taiwansales Q9 teseq com USA Teseq Inc T 1 732 417 0501 F 1 732 417 0511 Toll free 1 888 417 0501 usasales teseq com To find your local partner within Teseq s global network please go to www teseq com Manufacturer Teseq AG 4542 Luterbach Switzerland T 41 32 681 40 40 F 41 32 681 40 48 sales teseq com France Teseq Sarl T 33 1 39 47 42 21 33 1 39 47 40 92 francesales teseq com Japan Teseq K K T 81 3 5725 9460 F 81 3 5725 9461 japansales Qt eseq com Switzerland Teseq AG T 41 32 681 40 50 F 41 32 681 40 48 sales teseq com UK Teseq Ltd T 44 845 074 0660 F 44 845 074 0656 uksales teseq com December 2010 Teseq Specifications sub ect to
18. rigger source is set to Internal The battery off time is used only when trigger source mode is internal or single Both the battery off and battery on times may be set using the included dials between approximately 10 ms and 10 s See specifications for exact timings 6 6 Trigger source The trigger source is used to select the source and mode of the switching timing In internal mode the timing of both repetition and disconnection is selected with the dials provided in the timing field of the SC 5501 AES 5501 Automotive Emissions System In single mode the timing of the pulse will be selected by the battery off dial in the timing field of the SC 5501 There will be no repetition in single mode To activate a pulse press the trigger button under the single button when selected In manual mode the timing is dependant on how long the trigger is de pressed To start a pulse battery voltage off depress the trigger button un der the manual button with manual selected To end the pulse allow battery voltage to the DUT release the trigger button In external mode the user supplies a TTL signal on the BNC located at the back side of the SC 5501 The battery output will follow the signal A high input to the trigger in BNC will result in battery voltage available to the DUT selected switch ON The input signal may be between 4 5 and 12 V and is a differential input Control cables Interchangeabl
19. rovided The ES 5501 has temperature controlled fans for quiet operation and a thermal shutdown feature The AES 5501 AES 5501 Automotive Emissions System 6 1 The system controller The system controller SC 5501 is used to control timing and provide the neces sary voltages for the AES 5501 system and provide a convenient method of selecting the various functions The SC 5501 The SC 5501 is broken into several fields depending on their functions Mechani cal switch artificial network amp shunt resistor electronic switch trigger source and timings The following sections will provide details about these various control ele ments 6 2 Mechanical switch The mechanical switch field is used to control the MS 5501 and contains three input elements buttons named triggered Off and On In Off mode the Switch is turned completely off thus blocking any DC voltage to the DUT In On mode the switch is turned on thus providing any DC voltage available at the input of the mechanical switch to the DUT Trigger mode is the mode by which the user has the ability to control the timing of the switch using the fields timing and trigger source This field also has an LED display that shows the status of the switch The switch will indicate green when it is on conducting and unlit when off red indicates an error condition Pressing the unlit indicator will select the mode Refer to the descriptions of the timing field and trigge
20. sical Dimensions L x W x H ES 5501 125 x 125 x 125 mm MS 5501 125 x 125 x 125 mm AN 5501 340 x 270 x 205 mm Weight ES 5501 3 4 kg MS 24 kg SC 5501 29 kg AN 5501 10 kg AES 5501 Automotive Emissions System 13 MAINTENANCE Except for the relay in the MS 5501 there are no user serviceable parts inside For fuse selection please see the section on technical data 13 1 Cleaning Cleaning the AES 5501 should be performed using only a clean dry cloth No detergents of any kind are recommended 13 2 Calibration The AES 5501 has two parts requiring calibration The ES 5501 and AN 5501 13 2 1 Calibrating the AN 5501 Calibration of the AN 5501 is performed using the calibration kit INA 5500 CK which provides a shorting connector for the input side and a MC to N Type connector for the output side where the network analyzer is connected The grounding plug must be in place during calibration For more details on calibration see the calibration procedure and documen tation included in the INA 5500 CK 13 2 1 Calibrating the ES 5501 Calibration of the ES 5501 is performed using the test load defined in ISO 7637 2 This is available under model number INA 5500 TL The switching time of 300 ns is only valid using this load Resistive loads and open circuit mea surement will be different TASEO Advanced Test Solutions for EMC 38 14 THE PACKAGE CONTENTS mem inside the packaging you will find the following items
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