Mtu Sam Manual

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Description

Technical Publication

SAM Functional Description E532187/00E

Printed in Germany © 2005 Copyright MTU Friedrichshafen GmbH Diese Veröffentlichung einschließlich aller ihrer Teile ist urheberrechtlich geschützt. Jede Verwertung oder Nutzung bedarf der vorherigen schriftlichen Zustimmung der MTU Friedrichshafen GmbH. Das gilt insbesondere für Vervielfältigung, Verbreitung, Bearbeitung, Übersetzung, Mikroverfilmungen und die Einspeicherung und / oder Verarbeitung in elektronischen Systemen, einschließlich Datenbanken und Online-Diensten. Das Handbuch ist zur Vermeidung von Störungen oder Schäden beim Betrieb zu beachten und daher vom Betreiber dem jeweiligen Wartungs- und Bedienungspersonal zur Verfügung zu stellen. Änderungen bleiben vorbehalten. Printed in Germany © 2005 Copyright MTU Friedrichshafen GmbH This Publication is protected by copyright and may not be used in any way whether in whole or in part without the prior written permission of MTU Friedrichshafen GmbH. This restriction also applies to copyright, distribution, translation, microfilming and storage or processing on electronic systems including data bases and online services. This handbook is provided for use by maintenance and operating personnel in order to avoid malfunctions or damage during operation. Subject to alterations and amendments. Imprimé en Allemagne © 2005 Copyright MTU Friedrichshafen GmbH Tout droit réservé pour cet ouvrage dans son intégralité. Toute utilisation ou exploitation requiert au préalable l’accord écrit de MTU Friedrichshafen GmbH. Ceci s’applique notamment à la reproduction, la diffusion, la modification, la traduction, l’archivage sur microfiches, la mémorisation et / ou le traitement sur des systèmes électroniques, y compris les bases de données et les services en ligne. Le manuel devra être observé en vue d’éviter des incidents ou des endommagements pendant le service. Aussi recommandons-nous à l’exploitant de le mettre à la disposition du personnel chargé de l’entretien et de la conduite. Modifications réservées. Impreso en Alemania © 2005 Copyright MTU Friedrichshafen GmbH Esta publicación se encuentra protegida, en toda su extensión, por los derechos de autor. Cualquier utilización de la misma, así como su reproducción, difusión, transformación, traducción, microfilmación, grabación y/o procesamiento en sistemas electrónicos, entre los que se incluyen bancos de datos y servicios en línea, precisa de la autorización previa de MTU Friedrichshafen GmbH. El manual debe tenerse presente para evitar fallos o daños durante el servicio, y, por dicho motivo, el usario debe ponerlo a disposición del personal de mantenimiento y de servicio. Nos reservamos el derecho de introducir modificaciones. Stampato in Germania © 2005 Copyright MTU Friedrichshafen GmbH Questa pubblicazione è protetta dal diritto d’autore in tutte le sue parti. Ciascun impiego o utilizzo, con particolare riguardo alla riproduzione, alla diffusione, alla modifica, alla traduzione, all’archiviazione in microfilm e alla memorizzazione o all’elaborazione in sistemi elettronici, comprese banche dati e servizi on line, deve essere espressamente autorizzato per iscritto dalla MTU Friedrichshafen GmbH. II manuale va consultato per evitare anomalie o guasti durante il servizio, per cui va messo a disposizione dall’utente al personale addetto alla manutenzione e alla condotta. Con riserva di modifiche. Impresso na Alemanha © 2005 Copyright MTU Friedrichshafen GmbH A presente publicação, inclusive todas as suas partes, está protegida pelo direito autoral. Qualquer aproveitamento ou uso exige a autorização prévia e por escrito da MTU Friedrichshafen GmbH. Isto diz respeito em particular à reprodução, divulgação, tratamento, tradução, microfilmagem, e a memorização e/ou processamento em sistemas eletrônicos, inclusive bancos de dados e serviços on-line. Para evitar falhas ou danos durante a operação, os dizeres do manual devem ser respeitados. Quem explora o equipamento economicamente consequentemente deve colocá-lo à disposição do respetivo pessoal da conservação, e à dispositção dos operadores. Salvo alterações.

Table of Contents

1

Function

01

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

03

1.1

Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

03

1.2

Overview of device functions

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

04

1.3

Ambient conditions

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

07

1.4

CAN communication link

1.5

Ethernet communication link (10/100BaseT)

1.6

RS422/RS232 communication link

1.7

Binary inputs with common ground

1.8

Binary inputs via optocoupler

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

12

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

13

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

15

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

16

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

19

1.9

Binary transistor outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

1.10

Binary outputs: Transistor switches

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

24

1.11

Binary outputs: Relay switches

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

27

1.12

Binary outputs: PWM outputs via Low switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

1.13

Signal outputs to control display instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

1.14

Interface for measuring sensor (analog IN)

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

33

1.15

Electrically isolated analog inputs

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

38

1.16

Frequency inputs

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

40

1.17

Removable memory

1.18

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

41

Fault display

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

42

1.19

Control keys

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

43

1.20

Extendibility

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

44

1.21

Self-diagnosis (ITS)

1.22

Index

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05-11

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

46

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

49

© MTU

02

E532187/00E

Table of Contents

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© MTU

Function

03

1

Function

1.1

Use

The SAM is primarily used for the following tasks: • Connection of additional peripheral engine sensors and actuators. • Conversion of CAN bus signals (data flow), e.g. ECU data and messages into separate signals. These signals are normally used to control measuring instruments or signal lamps in customer instrument panels. • Evaluation of discrete signals, e.g. binary switches or analog values (e.g. speed demand from customer control panels or plant computers). • Simple programmable logic for customer functions, e.g. speed regulation or power optimization for rail systems. • Display of fault messages for service personnel on a small display. • Adaptation of the MTU PCS5 bus to various customer bus systems. • Automatic backup of all ECU data and the ECU-FSW (Functional Software). • Upload and download of SAM data and ECU parameters via Ethernet 10BaseT using the TCP/IP protocol. The SAM must be installed in a protected and clean environment.

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04

1.2

Function

Overview of device functions

View of SAM

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Function

05

Graphic representation of functional units

Legend for graphic Item

Designation

Item

Designation

1

Switching input (referenced to ground)

13

LCD display: 2 lines of 16 characters

2

Switching input (optocoupler input)

14

Connector for MCS5 I/O module signals

3

2* active: Frequency input active transmitter

16

20 * TOHI: 0.5A

5

2* passive: Frequency input inductive transmitter

17

17 12 * TOLO: 0.3A 8 * TOLO: 1.0A

6

Alternatively: Serial interface RS422 or RS232

18

PWM 1.5A TLOLOP: Ri=01Ω

7

Ethernet interface

19

NO/NC relay 1A

9

PPC: Central processor

20

8 * (0 - 10V)

10

SRAM: 512Kbyte*16

21

Alternatively: 4 * (4 - 20mA) 4 * (0 - 10V)

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06

Function

Item

Designation

11

Flash ROM: 512Kbyte*32

12

Compact Flash Card: 32 or 64Mbyte

Item

Designation

Explanation of abbreviations Abbreviation

Description

TOHI

Transistor Output High (Source 0.5A from UBatt).

TOLO

Transistor Output Low (Drain 0.3A to UBatt_GND).

TOLOP

Transistor Output Low Power (Drain 1.5A to UBatt_GND).

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

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Function

1.3

07

Ambient conditions

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

Technical data of SAM Term

Unit

Installation position

Value As desired, however integral fault display should be legible.

Operating voltage

VDC

24 rated value (-50%; +30%)

Power consumption

W

Below 6 (0.25A at 24V) without additional loads IP 40 as per DIN 40 050

Degree of protection: Shock: Rail mounting

10g, 11ms

Fixed installation

30g, 11ms

Vibration: Rail mounting

Hz

2 - 12.8:Xpp < ± 3mm 12.8 - 1000:a < 1g [rms]

Fixed installation

Hz

2 - 12.8: Xpp < ± 3mm 12.8 - 100:a < 4g [rms]

Ambient temperature:

°C

-40 - +70 with circulating ambient air

Storage temperature:

°C

-40 - +100

Relative humidity

%

5 - 97, non-condensing

Color:

Blue (RAL5015)

Material:

%

Polycarbonate reinforced with 10% fiberglass

Dimensions:

mm

L x W x H (295 x 151 x 75)

Weight:

kg

Approx. 1.6

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

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08

Function

EMI/EMC - Electromagnetic interference (general) The SAM has been tested according to the following standards and meets the relevant limit values: Standard

Testing

EN 55011

(Conducted Emission) 10 kHz - 30 MHz Class A

EN 55011

(Radiated Emission) 30 MHz - 1 GHz

IEC-60533:1999

(Conducted Emission) 10 kHz - 30 MHz (type test)

EC-60533:1999

(Radiated Emission) 150 kHz - 2 GHz (type test)

EN 61000-4-2

(ESD interference immunity) ±8kV

EN 61000-4-3

(Radiated interference immunity) 80MHz - – 2GHz

EN 61000-4-4

(Burst interference immunity) ±2kV

EN 61000-4-5

(Surge interference immunity) ±1kV/±2kV

EN 50155

(Surge interference immunity) ±1.8kV

EN 61000-4-17

(LF conducted interference) 0.03 – 10 kHz / 3Veff

EN 61000-4-29

(Mains fluctuation / STANAG 1008)

IEC 60092-504

(Dielectric strength) 550VAC / 10mA

EN 50155

(Isolation) 500V / 10MOhm

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Function

09

Special application (automotive industry) Standard

Testing

EN 55025:2003

(Conducted) Class 1

EN 55025:2003

(Emission) Class 1

EN 13309:2000

(Emission) EUB limit value

ISO 11452-2:2000

(Radiated) 1 MHz – 18 GHz 50V/m

ISO7637-2.2:2002

Pulse 1 - 600V / 50.0 / 5000 pulses level 4 Pulse 2a +50V / 2.0 / 5000 pulses level 4 Pulse 2b +20V / 0.05 / 10 pulses level 4 Pulse 3a - 200V / 50.0 / 1 hour level 4 Pulse 3b +200V / 50.0 / 1 hour level 4 Pulse 4 - 20V / 0.01 / 5 pulses level 4 Pulse 5a +73V / 2.0 / 1 pulses level 2

ISO 7637-3:1999

Pulse 3a - 500V / 50.0 / 10 minutes per cable Pulse 3b - +500V / 50.0 / 10 minutes per cable

ISO 10605:2001

ESD operating test level 2 ESD packing and transport test level 1

Requirements for fulfillment of EMI/EMC limit values are as follows: • The housing of the SAM must be connected to housing ground e.g. by a cable with a minimum cross-section of 2.5 mm2. Cable length shall not exceed 10 cm. • Twisted-conductor cables only shall be used to connect sensors and actuators. Maximum length of shall not exceed 5 m for unshielded cables and 50 m for shielded cables (providing that cable harness impedance allows).

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10

Function

Electrical requirements Term

Unit

Value

Operating voltage:

V

24, -50% to +30% (+12 - +32) Admissible residual ripple less than 5% as per STANAG 1008. Note: The processor is automatically reset if the voltage falls below 7.

Power supply:

W

Below 7. Without activated loads at SAM outputs Additional output current on positive or negative conductor shall not exceed 10 A DC in total.

Current terminals:

mm

5.08 terminals (spring-cage terminals) • Wire diameter AWG14 (US) or 2.5 mm2 recommended.

Electrical isolation:

V

• Supply ground is common reference potential (Common Ground) for all SAM electronics. This applies to the entire I/O range with the exception of certain electrically isolated channels. • SAM electronics ground is not connected to housing ground. • Signal cable shields must be connected to housing ground if applicable. • Maximum direct current isolating voltage is 500 unless otherwise stated.

Mechanical design Term

Unit

Installation position:

Value • Horizontal (to facilitate legibility of fault display and inscriptions on SAM housing). • Note that space is required to connect cabling at the top and bottom when installing the SAM in control cabinets. • The device heats up as a result of power dissipation. Heat from the SAM dissipates through the back wall. Ensure that heat can be conducted away from the back wall of the SAM to the mounting frame. Do not allow neighboring devices to additionally heat up the SAM.

Signal connections The SAM module is easily replaced. The input and output signal cables are equipped with modular connectors. Common function channels are combined in groups. The wires are connected using spring-cage terminal technology. Two wires may be connected to one terminal when the wires are crimped in a double-wire ferrule. For example, a Phoenix AL-TWIN 2* 0.75-10 may be used. Connector modules are plugged together. The connector modules are equipped with coding pins to preclude polarity reversal.

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Function

11

Terminals Term

Unit

Terminal strip modules:

Value WAGO spring-cage terminals

Current-carrying capacity (at 70 °C):

A

10 per contact

Measuring voltage:

V

250

Measuring surge voltage:

V

2500

Wire cross-sections:

mm2

Up to 1.5 or AWG15

Clamping range:

mm2

0.08 – 1.5 or AWG15

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

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12

1.4

Function

CAN communication link

CAN communication link Number of channels:

3 CAN interfaces; electrically isolated

CAN interface hardware conforms with the definition in ISO11998. The controller supports CAN version 2.0B/ (11/29 bit coding). All interfaces are electrically isolated from each other and from the SAM electronics. The interface operates with a 5V voltage level. 3 CAN channels are provided on the board. Additional channels can be realized as an option using an MCS5 extension module, e.g. a CCB2-02 module. One separate Y-connector plug “twin-wire connection” is provided for each CAN channel. The terminal plug is equipped with the terminals described above. CAN bus communication should not be disrupted if a connection on the SAM is disconnected. A terminator (120 ohm) must be installed at the connector plug when the SAM is used as a bus terminator device. Note: The connection (X4) for the MTU dialog unit features the signal lines for CAN_1 and CAN_2 and an additional 24V power supply.

Pin assignment: Designation

PIN

CAN_1

CAN1H

3

H

CAN1L

2

G

GND_CAN1

1

M

CAN_2

CAN_3

Dialog

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X6

X7

X8

X4

CAN2H

3

B

CAN2L

2

C

GND_CAN2

1

L

CAN3H

3

CAN3L

2

GND_CAN3

1

Lbatt+ (24V)

E

LGND

K

© MTU

Function

1.5

13

Ethernet communication link (10/100BaseT)

Communication link (10/100BaseT) Number of channels:

1 Ethernet interface; electrically isolated

Ethernet interface hardware conforms with the definition in IEEE802.3. A standard RJ-45 connector (Western connector) is provided on the board. The bus lines are coupled via a signal converter and are thus electrically isolated from the SAM electronics.

1 Transmit 2 Receive 3 RJ-45 connection

The operating status of the interface is indicated by a yellow and red LED on the board. • Link red LED; connection established to LAN device.

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14

Function

• Bsy yellow LED; communication in progress. Interface:

10/100Base_T (10/100Mbit/s, twisted conductor pairs).

Applications:

Connection to HUB: Use patch cable CAT5 (1:1). Connection to PC: Use crossed cable CAT5.

Designation

Pin

Transmit data positive

Tx (+)

Transmit data negative Receive data positive

X5

EIA/TIA-T 568 A standard

EIA/TIA- 568 B standard

1

white/green

white/orange

Tx (-)

2

green

orange

Rx (+)

3

white/orange

white/green

orange

green

4 5 Receive data negative

Rx (-)

6 7 8

Housing ground

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9

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Function

1.6

15

RS422/RS232 communication link

RS422/RS232 communication link Number of channels:

1 serial interface; electrically isolated

Connection as per RS422, with one pair of transmit lines and one pair of receive lines. Channel may also be used as an RS232 communication link for minimum configuration with signals TxD, RxD and Signal_GND.

Pin assignment Group

Designation

RS232

Serial link RS422

Pin

X14

Tx

1

Rx

4

RS232_GND

5

SAM_GND

6

O1 ( TxB [+] )

1

O2 ( TxA [ -] )

2

I1 ( RxB [+] )

3

I2 ( RxA [ -] )

4

RS422_GND

5

SAM_GND

6

Standard configuration: Baud rate:

1.2 to 19.2 kbaud

Data

8 bits

Parity

N

Stop bits

1

Data flow control

Xon/Xoff

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16

1.7

Function

Binary inputs with common ground

Binary inputs with common ground These channels may, for example, be connected by a line to a switch connecting +UBatt or Ubatt_GND to the input channel. Term

Unit

Value

Number of channels

8 binary inputs with common UBatt_GND reference potential

Voltage range

UBatt_GND to +UBatt

Initial voltage without connection

V

3.8

Input impedance

kohm

~6.9 to GND

Switch for +UBatt

mA

3.5 /24V

Switch for UBatt_GND

µA

-22 / 0V

Rated input current:

Threshold voltage

Measured at input terminal; Signal source impedance is less than 10 ohm

Switch for +UBatt

V

Vin > 10 -> Contact closed (logic high) Vin < 9 -> Contact open (logic low) For Open-Load detection: (33 kohm contact parallel resistor) 9 > Vin > 4.2 -> Contact open (logic low) Vin < 4.2 -> Contact open (Open Load)

Switch for UBatt_GND

V

Vin < 1.9 -> Contact closed (logic high) Vin > 1.9 -> Contact open (logic low) For Open-Load detection: (33.2k contact parallel resistor) 1.9 < Vin < 3.5 -> Contact open (logic low) Vin > 3.5 -> Contact open (Open Load) None

DC isolation Sampling rate

Hz

The sampling rate is determined by the software: E.g. 100

Signal filter

Hz

HW low-pass filter: fg = 500 *Note1

Contact bounce

ms

Masking by software e.g. 50 signal holding

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Function

17

1 VIN 2 A/D converter

The input voltage is measured by an analog/digital converter (10 bit resolution). The switching thresholds are set by software parameters. This also makes it possible to detect broken wires when the switch contacts are connected in parallel to a 33k resistor. The inputs may be switched to positive voltage (+UBatt) or ground potential . The P-IN1 and P_IN2 channels are additionally connected to the TPU channels of the MPC565. This makes frequency measuring possible at these inputs. The HW low-pass filter cut-off frequency for these two channels is fg = 10kHz.

Frequency measuring requirements: Term

Unit

Value

Switch-on threshold, HV threshold voltage (w.c.)

V

Usignal > 11.1

Switch-off threshold, LV threshold voltage (w.c.)

V

Usignal < 3.2

Switching hysteresis:

V

Uhyst 2.7 to 4.1

Frequency:

Hz

32 to 6 kHz Usignal is the voltage at the SAM terminals.

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18

Function

Pin assignment Group

Binary inputs with common reference ground

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Designation

Pin

X14

X19

Bin/pulse

P_IN1

5

Bin/pulse

P_IN2

6

Bin

P_IN3

7

Bin

P_IN4

8

Bin

P_IN5

9

Bin

P_IN6

10

Bin

P_IN7

11

Bin

P_IN8

7

Bin

GND

8

12

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Function

1.8

19

Binary inputs via optocoupler

Binary inputs via optocoupler Term

Unit

Value

Number of channels

20 electrically isolated binary inputs

Reference voltage

None: Each channel must be connected with two lines and is isolated from all other channels.

Voltage range

UBatt_GND to +UBatt

Initial voltage without connection

None

Input impedance

kohm

~5.5 (load)

Switch for +UBatt “ON”

mA

+4.0

Switch for UBatt_GND “OFF”

mA

0

Rated input current:

Measured at input terminal

Switching voltage Vin >= 12 V

mA

Iin > = 1.6 -> High

Vin =< 9 V

mA

Iin < 1.3 -> Low

(typical value is 10.5V threshold voltage)

V

For Open-Load detection: (33.2k contact parallel resistor) Vin < 9.0 -> Contact open (logic low). 9.0 > Vin > 2.1-> Contact open (Open Load).

DC isolation

VDC

> = 500

Sampling rate

Hz

The sampling rate is determined by the software: E.g. 100.

Signal filter

Hz

HW low-pass filter: fg = 500

Contact bounce

ms

by software e.g. 50 signal holding.

Online self-diagnosis

kohm

Yes: Wire break (when switch is connected in parallel with a 33 resistor).

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20

Function

1 A/D converter 2 Uin 3 Iin

The secondary voltage of the optocoupler is measured by an analog/digital converter (10 bit resolution). The switching thresholds are set by software parameters. This also makes it possible to detect broken wires when the switch contacts are connected in parallel to a 33kohm resistor.

Pin assignment Group

Designation

Pin

OKI_switch

B_OKI_CH1

B_IN1_H

1

B_IN1_L

2

B_IN2_H

3

B_IN2_L

4

B_IN3_H

5

B_IN3_L

6

B_IN4_H

7

B_IN4_L

8

B_IN5_H

9

B_IN5_L

10

B_IN6_H

11

B_IN6_L

12

B_OKI_CH2

B_OKI_CH3

B_OKI_CH4

B_OKI_CH5

B_OKI_CH6

B_OKI_CH7

B_OKI_CH8

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X2

X3

X11

X12

B_IN7_H

1

B_IN7_L

2

B_IN8_H

3

B_IN8_L

4

© MTU

Function

21

Group

Designation

Pin

B_OKI_CH9

B_IN9_H

5

B_IN9_L

6

B_IN10_H

7

B_IN10_L

8

B_IN11_H

9

B_IN11_L

10

B_IN12_H

11

B_IN12_L

12

B_OKI_CH10

B_OKI_CH11

B_OKI_CH12

B_OKI_CH13

B_OKI_CH14

B_OKI_CH15

B_OKI_CH16

B_OKI_CH17

B_OKI_CH18

B_OKI_CH19

B_OKI_CH20

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X2

B_IN13_H

1

B_IN13_L

2

B_IN14_H

3

B_IN14_L

4

B_IN15_H

5

B_IN15_L

6

B_IN16_H

7

B_IN16_L

8

B_IN17_H

9

B_IN17_L

10

B_IN18_H

11

B_IN18_L

12

X3

X11

B_IN19_H

1

B_IN19_L

2

B_IN20_H

3

B_IN20_L

4

X12

© MTU

22

Function

1.9

Binary transistor outputs

Binary transistor outputs The High switches and the Low switches are connected internally on the SAM. Activation as High or Low switch is set by the software. The two output types are determined in the project application environment. The substrate diodes of the output transistors operate like clamp diodes. An additional external clamp diode, as normally used for inductive loads (relays, valve coils), is superfluous. Combination of High switches and Low switches:

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

Group

Designation

Pin

Power activation

Transistor outputs

BIN_OUT_CH1

3

BIN_OUT_CH2

4

BIN_OUT_CH3

5

BIN_OUT_CH4

6

BIN_OUT_CH5

7

BIN_OUT_CH6

8

BIN_OUT_CH7

9

BIN_OUT_CH8

10

BIN_OUT_CH9

11

BIN_OUT_CH10

12

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X17

X18

BIN_OUT_CH11

1

BIN_OUT_CH12

2

BIN_OUT_CH13

3

BIN_OUT_CH14

4

BIN_OUT_CH15

5

© MTU

Function

23

Designation

Group

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Pin

X17

X18

BIN_OUT_CH16

6

BIN_OUT_CH17

7

BIN_OUT_CH18

8

BIN_OUT_CH19

9

BIN_OUT_CH20

10

Load supply voltage

+LBatt

2

12

Reference ground for load

LGND

1

11

© MTU

24

1.10

Function

Binary outputs: Transistor switches

Binary outputs: Transistor High switches Term

Unit

Value

Number of channels

20 Transistor High switches Note: These channels are used in common with the transistor Low switches.

Reference voltage

Two terminals are provided separately for supply voltage +UBatt and UBatt_GND (use wire cross-section AWG 15 mm2 or 1.5 mm2).

Voltage range

V

+UBatt (12 - 45)

Initial voltage without connection

V

2.3 - 3.7

Impedance in ON state

mΩ

Less than 320 per channel

ON state

A

Less than or equal to - 0.5

OFF state

µA

Less than or equal to + or – (50 - 150)

Output current

None

DC isolation Switching cycle

Hz

The switching rate is determined by the software: Less than 10 admissible

Signal filter

nF

Capacitor with 100 to UBatt_GND (EMI/EMC)

Short circuit

A

Self-protection commencing at 0.7 and reaching to 1.9.

Online self-diagnosis

Yes, Note*

Note*: Minimum load current must exceed 500µA to avoid associated fault messages. This means that load impedance should be less than 30 kohm. The outputs offer the following benefits: • Overload protection with thermal breaking • Overvoltage protection (Load Dump Protection) • Possibility of switching inductive loads: (1 joule per channel when the channels are switched simultaneously, otherwise 10 joules per channel)

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Function

25

Binary outputs: Transistor Low switches Term

Unit

Value 20 transistor Low switches Note: These channels are used together with the transistor High switches (see above). The number of Low transistors is divided into 12 low-current and 8 high-current outputs.

Number of channels

Reference voltage

mm2

Two terminals are provided separately for supply voltage +UBatt and UBatt_GND (use wire cross-section AWG 15 or 1.5).

Voltage range

V

+UBatt (up to 12 - 45)

Initial voltage without connection

V

2.3 - 3.7

Low current



1.3 per channel

High current



0.2 per channel

Low current BT_OUT1…..BT_OUT6 and BT_OUT11…BT_OUT16

A

Rated value less than or equal to 0.3 per channel

High current BT_OUT7…BT_OUT10 BT_OUT17…BT_OUT20

A

Rated value less than or equal to 1.0 per channel

Low current

µA

Max. - or + (50 - 150)

High current

µA

Max. - or + (100 - 300)

Impedance in ON state

Output current in ON state

Output current in OFF state

None

DC isolation Switching cycle

Hz

The switching rate is determined by the software: Less than 10 admissible

Signal filter

nF

Capacitor with 100 to UBatt_GND

Short circuit

Self-protection commences at:

Online self-diagnosis

A

1 to 2 for low current

A

6 to 12 for high current Yes, Note*

Note*: Minimum load current must exceed 1mA to avoid associated fault messages. This means that load impedance should be less than 11 kohm.

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26

Function

Benefits The • • The

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

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Function

1.11

27

Binary outputs: Relay switches

Binary outputs: Relay switches Number of channels

4 monostable relays with switching contacts

Reference voltage

None: Each channel must be connected with two lines and is isolated from all other channels.

Voltage range

Less than 36VDC

Contacts

Switching contacts (connected as NO contact or NC contact)

Impedance in ON state

Less than 20 mΩ

Output current ON state

Less than 1.0 A per channel

OFF state

Less than or equal to 100 µA per channel; a varistor lies above the contacts.

DC isolation

Isolation less than 300V DC

Switching cycle

The switching rate is determined by the software: Less than 1Hz

Switching cycles at 10W

106 (resistive load) max.

1W

107 (resistive load) max.

Self-protection

Overcurrent protection by multifuse (nom. 1A) Overvoltage protection by varistor (nom. 36V)

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Function

Online self-diagnosis

Yes

Offline diagnosis

Yes

Pin assignment Group

Designation

Pin

Relay outputs

BIN_OUT_Rel1

COM1

1

NC1

2

NO1

3

COM2

4

NC2

5

NO2

6

COM3

7

NC3

8

NO3

9

COM4

10

NC4

11

NO4

12

BIN_OUT_Rel2

BIN_OUT_Rel3

BIN_OUT_Rel4

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Function

1.12

29

Binary outputs: PWM outputs via Low switches

Binary outputs: PWM outputs via Low switches Term

Unit

Value

Number of channels

2 transistor Low switches

Reference voltage

UBatt_GND circuit Two terminals are provided separately for the supply voltage +UBatt and Switch LGND (use wire cross-section AWG 15 mm2 or 1.5 mm2).

Voltage range

+ UBatt

Initial voltage without connection mΩ

150 - 250 per channel

ON state

A

Less than or equal to 1.5 per channel

OFF state

µA

Max. +/-100

Impedance in ON state Output current in ON state

None

DC isolation Output signal Frequency

Hz

5 to 500 adjustable by software

ON/OFF ratio

%

1 - 100 ; 0: Off

Accuracy (PWM)

%

0.3 of measuring range 60 - 200 Hz

Signal filter

nF

Capacitor with 30 to UBatt_GND

Short circuit

A

Self-protection commencing at 3 and reaching to 6. For switching transistor and supply line.

Online self-diagnosis The • • •

Yes

outputs offer the following benefits: Overload protection with thermal breaking Operation automatically restored after fault rectification A free-wheeling diode on the +UBatt supply rail allows switching of inductive loads.

Integral current regulation: Current measuring for operation of linear magnets is envisaged. The coil current is measured and signaled to the processor via an A/D converter. The processor software corrects the PWM output ratio on the basis of the desired coil current. This is a closed-loop control circuit the dynamic parameters of which can be set by the software. The supply of the coil LBatt+ is protected against short-circuit. The response time of the current regulator is approx.: Settling time =< 200ms. The coil current is measured by a 100 mΩ measuring resistor. Precise current regulation in the closed-loop control circuit only applies to the output frequency range of 100Hz to 200Hz. Attainable settling accuracy is = < 0.3 % at 1A current.

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30

Function

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

Pin assignment Designation

Group

PWM_CH1 PWM control PWM_CH2

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Pin

X14

PWM1_L

10

PWM1_H

9

PWM2_L

12

PWM2_H

11

© MTU

Function

1.13

31

Signal outputs to control display instruments

Signal outputs to control display instruments These outputs are used to control display instruments or other measuring instruments. 8 channels are provided to control instruments with a 0 - +10 V voltage input. Four of these channels are prepared for additional 0 20 mA current signals. The external load of the current channels must be less than 400 ohm. The choice of voltage or current channels for the respective application is made in the application engineering phase.

General Signal scaling: Scaling parameters can be set by the software. The DC output voltage or current is generated by PWM processor channels. The processor PWM signal is buffered, routed via a low-pass filter and finally amplified. PWM frequency

1710 Hz

PWM ratio

0 - 100%

Group

Designation

Pin

Instrument control

Volt_out voltage output

V_OUT1

1

V_OUT2

2

V_OUT3

3

V_OUT4

4

V_OUT5

5

Auxiliary voltage

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X1

X10

V_OUT6

9

V_OUT7

10

V_OUT8

11

Common GND

AGND

12

Curr_out

C_OUT1

6

Current output

C_OUT2

7

C_OUT3

8

C_OUT4

9

Common GND

AGND

10

24V/-1A

Lbatt+

11

LGND

12

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32

Function

Voltage outputs Term

Unit

Value

Number of channels

8 voltage inputs with common UBatt_GND reference potential

Reference voltage

UBatt_GND (AGND)

Voltage range

V

+0 – +10

Accuracy

%

0.3 of measuring range**

Initial voltage without connection

V

0 - 10

Impedance in ON state



0

Output current

mA

Less than or equal to 8 admissible None

DC isolation Settling time

ms

Less than 60.

Short-circuit protection

mA

The output voltage is automatically reduced when current intensity exceeds 20 - 30. Short-circuit proof to +UBatt and UBatt_GND.

** The value indicates accuracy in the temperature range –20 °C to 75 °C and for an operating period of one year after device manufacture. A factor of 0.05% p.a. must be allowed when determining long-term accuracy.

Current outputs Term

Unit

Value

Number of channels

4 current outputs with common UBatt_GND reference potential

Current

Source to UBatt_GND

Current intensity range

mA DC

0 - 20

Accuracy

%

0.3 of measuring range**

Max. load impedance (load)



Less than 400.

Max. output voltage

VDC

Less than 10. None

DC isolation ms

Settling time Short-circuit protection

Less than 60. Short-circuit proof to +UBatt and UBatt_GND

** The value indicates accuracy in the temperature range –20 °C to 75 °C and for an operating period of one year after device manufacture. A factor of 0.05% p.a. must be allowed when determining long-term accuracy. Note: These outputs supply current. This means that the current from SAM flows via an external instrument to UBatt_GND.

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Function

1.14

33

Interface for measuring sensor (analog IN)

Interface for measuring sensor (analog IN) The eight analog multi-purpose measuring inputs facilitate alternative measuring of temperatures or voltages and currents.

Pin assignment Group

Designation

Pin

Analog multipurpose inputs

AN_CH1

A_Supp_CH1

1

A_In_CH1

2

A_GND

3

A_Supp_CH2

4

A_In_CH2

5

A_GND

6

A_Supp_CH3

7

A_In_CH3

8

A_GND

9

A_Supp_CH4

10

A_In_CH4

11

A_GND

12

AN_CH2

AN_CH3

AN_CH4

AN_CH5

AN_CH6

AN_CH7

AN_CH8

X16

A_Supp_CH5

1

A_In_CH5

2

A_GND

3

A_Supp_CH6

4

A_In_CH6

5

A_GND

6

A_Supp_CH7

7

A_In_CH7

8

A_GND

9

A_Supp_CH8

10

A_In_CH8

11

A_GND

12

X20

Temperature sensors Used for: • PT1000, Ni1000 temperature sensors • PT100, Ni100 temperature sensors E532187/00E

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Function

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

Temperature inputs Term

Unit

8 commonly used with voltage inputs.

Number of channels Voltage range

Value

V

+5; AGND

PT1000

mA

2.5

PT100

mA

4.5

NTC

mA

2-5

Input impedance

kohm

1

PT1000

K

± 0.4 (measuring range: -20°C - 120°C)

PT100

K

± 5 (measuring range: -20°C - 650°C)

NTC

K

± 4 (measuring range: -20°C - 120°C)

Measuring current:

Accuracy of electronics:

Short-circuit protection

Yes

DC isolation

None

Sampling rate

Hz

The sampling rate is determined by the software: E.g. 100.

Signal filter

Hz

HW low-pass filter: f < 20.

Online self-diagnosis

Yes

** The values indicate accuracy in the temperature range –20 °C to 75 °C and for an operating period of one year after device manufacture. A factor of 0.05% p.a. must be allowed when determining long-term accuracy.

Measuring method: A 5V reference voltage is applied to the sensor resistor. The measuring current is generated from the temperature impedance and the inherent impedance of the measuring channel (conductors and contacts). The temperature-dependent voltage is decoupled by an amplifier and supplied to the 12-bit analog/digital converter.

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Function

35

1 A/D channel 2 IN: PT1000, PT100, NTC

Analog inputs for voltage/current Used for: • Voltage measuring 0 - 5V or 0 - 10V • Current measuring 0 - 24mA • Operation of 8 external measuring sensors with 5V supply Example: Potentiometer or measuring sensor with 5V supply

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

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Function

Example: Voltage measuring 5V or 10V

1 A/D channel 2 0 - 5V or 0 - 10V 3 IN: 0 - 10V

Example: Current measuring

1 A/D channel 2 Sensor 0 - 20mA 3 IN: 0 - 20mA

Term

Unit

Value

Number of channels

8 commonly used with temperature inputs

Reference potential

UBatt_GND (AGND)

Voltage measuring Voltage range

V

0 - +5; 0 - +10

Impedance

kΩ

100

Current measuring

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Function

37

Term

Unit

Value

Current range

mA

0 - 30

Load



150

Accuracy of electronics

%

0.2 of measuring range**

Voltage

V

5; 0.1 %**

Current intensity

mA

0 - 20 DC (current intensity limited internally)

Voltage

V

5; 0.1 %**

Current intensity

mA

0 - 20 DC (current intensity limited internally)

V

5 potentiometer/sensor supply

Sensor supply

Potentiometer supply

Pin assignment A_SUPPx A_IN1

Measuring voltage/current input

A_GND

Measuring ground

Short-circuit protection A_SUPPx ->(VBatt+; VBatt-)

Yes

A_IN1 ->(VBatt+; VBatt-)

Yes

A_GND ->(VBatt+; VBatt-)

A

Yes (SAM device fuse 15) None

DC isolation Sampling rate

Hz

The sampling rate is determined by the software: E.g. 100

Signal filter

Hz

HW low-pass filter: f g = 20

Online self-diagnosis

Yes (monitoring of range violations adjustable by software)

** The value indicates accuracy in the temperature range –20 °C to 75 °C and for an operating period of one year after device manufacture. A factor of 0.05% p.a. must be allowed when determining long-term accuracy. Input function can be selected between 5V, 10V and 20mA measuring in the application engineering phase.

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38

1.15

Function

Electrically isolated analog inputs

Electrically isolated analog inputs Used for: • Voltage measuring 0 - 5V or 0 - 10V • Current measuring 0 - 20mA Term

Unit

Value

Number of channels

2 multi-purpose inputs

Reference potential

Both channels have a common reference potential (Common GND), which is electrically isolated from UBatt_GND of the SAM electronics.

Voltage measuring Voltage range

V

0 - +5; 0 - +10

Impedance

kΩ

47

Current range

mA

0 - 24

Load



150

Accuracy of electronics

%

0.3 of measuring range**

+IN_V_CHx -> A/D_OPT_GND

V

Measuring voltage 0 - 10 or 0 - 5

+IN_I_CHx -> A/D_OPT_GND

mA

Measuring current input 0 - 20

Current measuring

Pin assignment

A/D_OPT_+5V

Supplies Vpp (5.0V/10mA) to control an external potentiometer.

Short-circuit protection All poles to UBatt_GND

Yes

All poles to +UBatt

Yes

DC isolation

Yes

Sampling rate

Hz

The sampling rate is determined by the software: E.g. 100

Signal filter

Hz

HW low-pass filter: f = 20

Online self-diagnosis

Yes (monitoring of range violations adjustable by software)

** The value indicates accuracy in the temperature range –20 °C to 75 °C and for an operating period of one year after device manufacture. A factor of 0.05% p.a. must be allowed when determining long-term accuracy. Input adjustable between 5V, 10V and 20mA measuring in the application engineering phase.

Configuration:

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Function

39

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

Pin assignment Group

Designation

Pin

OKI_Analog

O-AN_CH1

A/D_OPT_+5V

5

+IN_V_CH1

6

+IN_I_CH1

7

A/D_OPT_GND

8

A/D_OPT_+5V

9

+IN_V_CH2

10

+IN_I_CH2

11

A/D_OPT_GND

12

O-AN_CH2

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40

1.16

Function

Frequency inputs

Frequency inputs Normal use: Speed measuring via a gear and an inductive sensor (without auxiliary voltage). Term

Unit

Value

Number of channels

2 x 2-pole differential inputs

Reference potential

Differential input

Signal measuring Maximum signal

1.2 Vpp < U input < 100Vpp

Hysteresis

V

Positive threshold at 0, negative threshold at -620mV.

Impedance

kΩ

Ri =2 x 24

Frequency range

Hz

5 to 10kHz

Accuracy of electronics

%

0.1 (frequency measuring range)**.

Configuration Short-circuit protection

Yes

DC isolation

None kHz

Signal filter Online self-diagnosis

HW low-pass filter: fg = 15 Yes (monitoring of range violations adjustable by software).

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

Pin assignment Pin assignment Group

Designation

Pin

Frequency inputs

SPEED_CH1

F_IN1H

1

F_IN1L

2

F_IN2H

3

F_IN2L

4

SPEED_CH2

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X19

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Function

1.17

41

Removable memory

Removable memory The need for a removable storage medium (i.e. Compact Flash) primarily results from the conditions of use and maintenance of the ADEC governor. Compact-Flash (CF)

32Mb 3.3 V supply voltage Block erasing and block programming

Using the Compact Flash CF memory card facilitates future use of higher storage capacity cards e.g. 64 MB or 256 MB. The Compact Flash operates with a file management system. Application engineering data and backup data incl. (FSW_SW) of the ADEC governor are stored on the CF. Following device manufacture and testing, the SAM incorporates firmware which includes the various I/O channel drivers and the initial program loader software. User-related software (application software) is first transmitted when the CF is installed in the SAM. Note: The CF shall only be installed and removed when the SAM is de-energized.

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42

1.18

Function

Fault display

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

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Function

1.19

43

Control keys

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

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1.20

Function

Extendibility

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

Pin assignment Group

Designation

MCS–5 I/O module extension

Slot_1

Slot_2

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Corresponding PIM PIN

Module Pin

X10

X21

X22

n01

PIN_1

1

n02

PIN_2

2

n03

PIN_3

3

n04

PIN_4

4

n05

PIN_5

5

n06

PIN_6

6

n07

PIN_7

7

n08

PIN_8

8

n09

PIN_9

9

n10

PIN_10

10

n11

PIN_11

11

n12

PIN_12

12

n13

PIN_13

1

n15

PIN_14

2

n14

PIN_15

3

n16

PIN_16

4

n01

PIN_1

5

n02

PIN_2

6

n03

PIN_3

7

n04

PIN_4

8

n05

PIN_5

9

n06

PIN_6

10

X23

© MTU

Function

Group

45

Designation

Slot_3

E532187/00E

05-11

Corresponding PIM PIN

Module Pin

X10

X21

X22

X23

n07

PIN_7

11

n08

PIN_8

12

n09

PIN_9

1

n10

PIN_10

2

n11

PIN_11

3

n12

PIN_12

4

n13

PIN_13

5

n14

PIN_14

6

n15

PIN_15

7

n16

PIN_16

8

n01

PIN_1

1

n02

PIN_2

2

n03

PIN_3

3

n04

PIN_4

4

n05

PIN_5

5

n06

PIN_6

6

n07

PIN_7

7

n08

PIN_8

8

n09

PIN_9

9

n10

PIN_10

10

n11

PIN_11

11

n12

PIN_12

12

n13

PIN_13

13

n14

PIN_14

14

n15

PIN_15

15

n16

PIN_16

16

© MTU

46

Function

1.21

Self-diagnosis (ITS)

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

SAM in order

Flashing

SAM faulty

Dark

SAM power supply missing

The function of this LED is the same as the DILA in ECU 7. Offline diagnosis A straightforward diagnostic method allows service personnel to perform troubleshooting quickly and easily in case of a fault in the SAM. Proceed as follows: Place the SAM device on a table leaving only the power supply lines connected. Press the “▼” and “Enter” keys simultaneously and switch on the power supply at the same time. Release the keys after a few seconds and observe the display for approximately 10 seconds. Any faulty channels are displayed. Supported MCS5 I/O modules Designation

Board no.

Drawing / documentation

Use in SAM slot 1

Use in SAM slot 2

Use in SAM slot 3

AIB 1-02 Analog Input Board

529 530 93 12

529 539 83 02 529 531 57 91

x

x

x

AIB 2-02 Analog Input Board

529 530 39 12

529 539 40 02 529 531 29 91

x

x

x

AIB 3-02 Analog Input Board

529 530 38 12

529 539 39 02 529 531 28 91

x

x

x

AIB 4-01 Analog Input Board

529 530 49 12

529 539 50 02 529 531 34 91

x

x

x

BIB 1-02 Binary Input Board

529 530 88 12

529 539 79 02 529 531 53 91

x

x

x

BIB 2-01 Binary Input Board

504 530 08 97

504 539 66 03 504 531 01 90

x

x

x

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Function

47

Designation

Board no.

Drawing / documentation

Use in SAM slot 1

Use in SAM slot 2

Use in SAM slot 3

BOB 1-02 Binary Output Board

529 530 86 12

529 539 77 02 529 531 51 91

x

x

x

BOB 1-02/A Binary Output Board

529 530 95 12

529 539 85 02 529 531 51 91

x

x

x

BOB 2-02 Binary Output Board

529 530 87 12

529 539 78 02 529 531 52 91

x

x

x

BOB 3-01 Binary Output Board

504 530 39 97

504 539 78 03 504 531 10 90

x

x

x

EGB 1-01 Exhaust Gas Board

504 530 74 92

504 539 54 03 504 531 91 93

x

x

x

IIB 1-01 Instrument Input Board

504 530 98 92

504 539 64 03 504 531 99 93

x

x

x

INB 2-01 Instrument Board

504 530 54 97

504 539 84 03 504 531 15 90

x

x

x

MFB1_01 Multi-Function Board

504 530 76 92

504 539 56 03

x

x



CCB2_02 Multi Communication Board

X 000 134 34

X 000 134 35





x

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

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48

Function

Design of the SAM (all parts illustrated)

1 Modules 2 Module 3 Software

E532187/00E

4 Housing 5 Board 6 Board

05-11

7 Cap 8 Screws 9 Lock

© MTU

Function

1.22

49

Index A

Ambient conditions

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

Frequency inputs

I 19 16

49 33

O Overview of device functions

12 43

S

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

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface for measuring sensor (analog IN) . . .

29 27 24 22

C CAN communication link . . . . . . . . . . . . . . . . . Control keys . . . . . . . . . . . . . . . . . . . . . . . . . .

40

07

B Binary inputs via optocoupler . . . . . . . . . . . . . Binary inputs with common ground . . . . . . . . . Binary outputs: PWM outputs via Low switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Binary outputs: Relay switches . . . . . . . . . . . . Binary outputs: Transistor switches . . . . . . . . Binary transistor outputs . . . . . . . . . . . . . . . . .

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

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

04

Removable memory . . . . . . . . . . . . . . . . . . . . RS422/RS232 communication link . . . . . . . . .

41 15

R

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

46 31

38 13 44

U Use

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

03

F Fault display

E532187/00E

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

05-11

42

© MTU

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