601-302E - NSG 5500 User Manual english.indd
Contents
1. Control Pulse shape m generator Battery A DUT Battery switch Battery DUT Picture 3 26 Block diagram of the LD 5505 3 4 3 External output resistance LD 5505 only The circuitry used within the LD 5505 module to generate pulse types 5 and 7 uses a solid state active circuit Using the AutoStar control software the actual output current limit value can be set at between 1 and 120 Amps If the application requires that the actual output resistance is necessary the shorting plug on the Ri terminals of the LD 5505 module must be removed and connections made from these terminals to the optional output resistance unit INA 5025 or RM 5055 as shown below In this mode the output resistance unit is controlled by the control unit in the NSG 5500 mainframe system via the BUS EXP connector on the power entry module The AutoStar control software can set the output resistance in this unit to between 0 5 and 10 ohms in steps of 0 25 ohms This resistance appears in series with the output of the pulse generation circuit of the LD 5505 module When using the LD 5505 unit with the INA 5025 external resistance unit the output impedance of the LD 5505 itself is negligible LD 5505 INA 5025 LOAD DUMP GENERATOR OUTPUT RESISTANCE UNIT OUTPUT RESISTANCE UNIT LD 5505 LOAD DUMP GENERATOR INA 5025 Picture 3 27 LD 5505 in combination with the INA 5025 external resistance T3SEO Ad2. DIP switch for IEE 488 address Picture 3 8 Control unit of the NSG 5500 with connectors The optional Pulse 4 arbitrary waveform generator card may also be mounted within the control unit NOTE The pulse 4 control part is discontinued as of 2009 Due to a immitation related to command length in the IEEE 488 1 standard NSG 5500 2 systems should use only USB RS232 H NOTE Picture 3 9 RS 232 Remote control of the NSG 5500 NSG 5500 Automotive transient immunity generator Use of the IEEE 488 interface requires an interface to be fitted to the PC and the NSG 5500 chassis 41 IEEE Interface s Picture 3 10 IEEE remote control of the NSG 5500 The remote control command syntax is identical in both interface methods and is SCPI based NOTE The Windows based application program AutoStar allows full remote control and test sequences to be developed within the graphical Windows environment The generator supports either USB or RS 232 and GPIB communication The syntax of these commands is discussed in chapter 3 2 4 Remote programming However AutoStar is programmed with these commands and therefore detailed understanding of the syntax is unnecessary unless the system is to be integrated into another software package other than AutoStar 3 2 3 3 HV supply This u
3. u se amplitude mpedance se rise time tr se duration td rst frequency ses per burst rst repetition se modes 20 to 200 V in 0 5 V steps 15 to 100 V According to resistor installed the optional RM 5505 has available 0 5 to 100 in 0 25 Q steps 0 1 to 10 ms 30 to 700 ms in 1 ms steps 20 to 600 s in 0 1 s steps Single continuous programmed 1 to 99 999 20 to 200 V in 0 1 V steps 5 10 to 100 V 5 Pulse 5b overshoot typ 296 2V 0 5 to 100 in 0 250 steps 30 50 400 10 0 5 to 10 ms 10 0 5 ms 21096 5015 10 250 V pulse amplitude 20 50V pulse amplitude 15 to 600 s in 0 1 s steps pulse repetition depends on pulse energy Single continuous programmed 1 to 9 999 20 to 800 V in 1 V steps lower voltages are also programmable 500 5 ns 1 5 ns for td 150 ns lt 5 ns for td 100 ns 100 ns 10 20 and 150 ns 20 1 to 100 kHz in 0 1 kHz steps 1 to 200 90 ms to 999 s in 10 ms steps Single continuous programmed 1 to 99 999 2096 for pulse amplitudes 25 V 5 1 6 FT 5531 Fast transients generator for the ISO pulse 3a 3b and variants Pu im Pu Pu Bu Bu Pu Bu Pu Ise Amplitude pedance se Rise Time se Width rst Frequency rst Interval ses per Burst rst Repetition se Modes EUT Out 150 ns BNC Out 150 ns EUT Out 100 ns BNC Out 100 ns 50 800V 410 50 600V 410 50 600V 410 50 600V 215 500 5 ns 430 150 ns
4. Loaded Config COM Port Picture 2 14 Set GPIB address 001 recommended Select the desired address then Ok to confirm The address is immediately sent to the controller interface 2 9 2 Updating NSG 5500 firmware CAUTION HH Updating the firmware should only be done with direct assistance of your local support organization Incorrectly performed firmware downloads will result in an NSG 5500 that no longer boots and must be sent back for service TASEO Advanced Test Solutions for EMC 25 26 2 9 2 1 Updating the firmware CTR 5500 The firmware of the CTR 5500 can be updated from within AutoStar To update the CTR 5500 please see the applicable sections 2 9 2 2 Updating the firmware CTR 5501 The firmware of the CTR 5501 cannot be updated with AutoStar To update the CTR 5501 firmware please use the controller update tool found on the AutoStar CD Using the controller update tool cut exe found on the installation CD you can update the firmware The firmware is located in the same directory as the controller update too You may also choose the version to update if instructed to do so by service personnel CAUTION You should only perform this step with the assistance of one of our worldwide service representatives Incorrectly performed firmware downloads will result in an NSG 5500 that no longer boots and must be sent back for service 2 9 2 3 Installation No specific installation procedure is requir
5. NSG 5500 AUTOMOTIVE TRAN SIENT IMMUNITY GENERATOR HARDWARE GUIDE Advanced Test Solutions for EMC NSG 5500 AUTOMOTIVE TRAN SIENT IMMUNITY GENERATOR HARDWARE GUIDE CONTENTS 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 19 1 10 1 11 1 12 11 11 11 11 none WwW 24 22 29 24 2 4 1 2 5 2 6 2 6 1 2 6 2 2 7 2 7 1 2 7 2 2 8 2 8 1 2 8 2 29 2 9 1 2 9 1 1 2 9 1 2 29 2 2 9 2 1 29 22 2 9 2 3 2 9 2 4 2 9 2 5 2 9 2 6 2 9 2 7 2 9 2 8 Safety instructions Classification of dangers Warning symbols on the test system Excess voltage category Range of validity SYSTEM STOP button Safety of operation Personnel Responsibility for safety precaution Safety regulations Reduction of operational safety As agreed use General instructions nstallation Test execution Dangers concerning the generator Dangers concerning the DUT Installation Checking the shipment Delivery contents Operating position Line voltage connection and grounding ains voltage selector nstallation set up NSG 5500 nstallation set up FT 5531 Test set up Parameter references nstallation set up LD 5505 and LD 5550 Test set up Parameter references Installation set up MT 5511 Test set up Parameter references Installation set up control unit CTR Setting the IEEE address IEEE address setting CTR 5500 IEEE address setting CTR 5501 Updating NSG 5500 firmware Updating the firmware CTR 5500 Updatin
6. O Overvoltage Reservoir detect capacitor O HV Supply Pulse generator Polarity Coupling Measure and control circuit Battery Picture 3 21 Block diagram of the FT 5531 T3SEO Advanced Test Solutions for EMC 49 50 3 3 3 Tests with a coupling clamp A Capacitive coupling clamp is used when the bursts have to be injected into control and data lines The following diagram illustrates the arrangement of the test rig recommended by ISO and DIN Dimensions in millimetres A A 400 50 Picture 3 22 Arrangement of the test rig dimensions in millimetres Key Insulating support if device under test is not to be connected to ground in the vehicle Device under test Insulating supports for the test harness Peripheral items Such as sensors load accessories mounted as in the vehicle Ground plane Power supply 12 or 24 V AC power supply Battery Oscilloscope 10 50 attenuator 11 Coupling clamp 12 Test pulse generator so NSG 5500 Automotive transient immunity generator A standard conforming coupling clamp is available from Teseq under the type number CDN 500 The clamp has a 50 BNC connector at both sides The test circuit must be terminated with 50 on the side opposite to the generator The termination and attenuator type INA 500 can be used for this purpose FT 5531 Fast Transients A O EXTPULSE3
7. 22096 100ns 21096 1 100 kHz in 0 1 kHz steps 0 01 to 99 9 ms 1 200 90 ms 999 s in 10 ms steps Single continuous programmed Lower voltage also programmable System Requirements NSG 5500 with the new CTR 5501 AutoStar 6 2 Package Upgrades Available on Request NSG 5500 Automotive transient immunity generator 65 CAUTION HE The FT 5531 is only compatible with AutoStar 6 2 and above Failure to use AutoStar 6 2 and above may result in severe damage to the system 5 2 Measures and weight Dimensions NSG 5500 1 19 desktop housing rack mountable height 330 mm 13 depth 510 mm 20 NSG 5500 2 9 desktop housing rack mountable height 640 mm 25 2 depth 510 mm 20 Weight incl HV supply NSG 5500 1 36 kg CDN 5500 control unit NSG 5500 2 37 kg without additional modules MT 5511 FT 5530 LD 5505 5 3 Environmental Conditions Temperatur range Operation at 10 to 40 C Storage at 10 to 60 C Humidity 30 to 78 non condensing Air pressure 860 to 1060 hPa T3SEO Advanced Test Solutions for EMC 66 Headquarters Teseq AG 4542 Luterbach Switzerland T 41 32 681 40 40 F 41 32 681 40 48 sales 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
8. INA 500 50 Ohm Load Picture 3 23 Arrangement with the FT 5531 CDN 500 and the INA 500 as a 50 O termination FT 5531 Fast Transients Oscilloscope EXT PULSE 3 50 Ohm load 40 Attenuation Picture 3 24 Arrangement with the FT 5531 CDN 500 INA 500 as a 50 termination with integrated 40 dB attenuator and an oscilloscope In keeping with the specifications the following relationships result during calibration measurements Pulse at generator output 120 V Pulse at 50 connection 60 V W Pulse at the oscilloscope 0 6 V T3SEO Advanced Test Solutions for EMC 51 52 3 4 LD 5505 and LD 5550 Operation 3 4 1 Introduction The LD 5505 and LD 5505 LD Load Dump Generator are plug in high energy generator modules designed for use with the NSG 5500 mainframe system It is designed primarily to meet the specification requirements for the ISO 7637 standard for pulses 5 and 7 In many cases the specification of this generator exceeds those specified in the ISO 7637 standard When slotted into an NSG 5500 mainframe the LD module is fully programmable via USB or RS 232 and IEEE 488 interface Parameters such as amplitude pulse frequency pulse width are all under program control The LD 5550 and LD 5505 generates pulses of types 5 and 7 as specified in the ISO 7637 standard which defines how these pulses are generated in relation to the vehicle battery voltage When operating with a battery o
9. The NSG 5500 supports up to 100 A 250 A peak T3SEO Advanced Test Solutions for EMC 44 3 2 4 Remote programming A remote programming tools are available for advanced users who wish to program for their own special needs CAUTION These commands are for advanced users only The examples contained therein are generally for users who choose to write their own test software Teseq can not be held responsible for improper use of these commands and or syntax Please refer to the AutoStar communication logs during use for a complete under standing of the use of these commands 3 2 5 External trigger and control signals There are four input output signals available on the rear of the NSG 5500 mainframe that can be used for syncronization with external equipment The logic levels on these signals are as follows Fail signal CRO trigger Picture 3 14 Logic levels on the signals of the NSG 5500 NSG 5500 Automotive transient immunity generator 3 2 5 1 Start stop signal The signals are connected via a 9 pin D Sub connector labelled REMOTE in the CDN 5500 panel The pin assignment of this connector is as follows GND CRO Trigger reserved reserved Fail unused unused unused unused Picture 3 15 Pin assignment of the REMOTE connector on the rear side of the NSG 5500 when using the CTR 5500 unused GND reserved for future use reserved for future use Pause unused CRO T
10. 2 7 Installation set up LD 5505 and LD 5550 Check the instrument for any mechanical damage Report any damage found to the carrier immediately Both LD 5550 and LD 5505 modules are in usage The term LD Module is used to refer to either of these modules All of this information applies to both modules unless specifically refenced by module name Ensure that the power is turned off on the NSG 5500 mainframe and that the battery input is disconnected nsert the cassette in the right most slot and push in fully Screw in the four retaining screws fully f using the battery switch ensure this module is present and inserted fully in the rear of the NSG 5500 mainframe is vitally important that the unit is connected to a good protective earth Turn on the mains input power on the NSG 5500 mainframe After approximately a two second delay the power LED red on the LD module should light After a further two seconds of initialisation the unit is ready for operation The software communications will not start correctly until this initialization time is complete Now the scope test setup shown in picture 2 9 below 26 should be connected and the output pulses should be quickly checked to ensure that they are of the correct form and shape When pulses are being generated the relevant green LED 5 or 7 whichever is selected should flash as pulses are output When correct operation has been verified the DUT can be connected to the
11. NSG 5500 could be summarised as follows Modular construction pulse modules plug into main chassis Exceeds specifications set out in the ISO DIN and SAE standards Remote controllable via USB or RS 232 and IEEE 488 Internal multiplex bus system all pulses available from the front of the FT 5531 plug in Compact construction 12 inches high 30 cm 19 inch rack mountable Windows software program provided DUT FAIL START STOP TEST END AND CRO trig signals available for interfacing with other test equipment 3 2 2 Powering up the system Switch on the NSG 5500 by switching on the main switch on the rear side in the power entry unit CAUTION E The hardware requires at least 10 seconds to boot Reliable software communi cations can not be established until the system is completely booted DANGER When any Pulse 4 control is used the power amplifier battery simulator should always be turned on last to assure safe and reliable control of the power amplifier battery simulator Do not under any circumstances touch the outputs or connect any DUT to the outputs of the system during booting T3SEO Advanced Test Solutions for EMC 36 3 2 3 NSG 5500 System overview The NSG 5500 mainframe is designed to take the pulse plug in units from the front The system support electronics are plugged in from the rear ii iii iil umi 4 li i INPUT 9 Picture 3 3 NSG 5500 Rear v
12. and storing the device Protection Magnetic circuit breaker Fuses Declaration of conformity CE Technical Data Technical specifications NSG 5500 MT 5511 LD 5505 LD 5550 FT 5530 FT 5531 Measures and weight Environmental Conditions Addresses NSG 5500 Automotive transient immunity generator 33 33 34 34 35 36 37 40 41 42 43 44 44 45 46 46 47 47 48 48 49 50 52 52 53 53 54 54 56 56 57 57 57 58 58 59 62 63 63 63 63 64 64 64 64 65 65 66 1 SAFETY INSTRUCTIONS ES ES ES DANGER It is imperative that you read the following safety instructions and all safety ins tructions in the manuals of connected peripheral systems before installing and starting this test system for the first time DANGER The electrical and mechanical safety equipment must not be removed put out of operation or bypassed Handle all safety equipment with care If a safety device should be broken or is not working the system must be put out of operation until the safety device is repaired or exchanged and fully in working order again DANGER HAZARDOUS AREA Connectors on the test equipment must not be touched Only connect and disconnect the DUT and or fixture when the SYSTEM STOP button is pressed The equipment may only be operated within an area that is explicitly declared a Test Floor with appropriate signs and protected against improper access These operating instructions form an
13. be undertaken by a qualified specialist if specifi cally instructed to do so in the operating manual Since the equipment generally works with two independent power supplies for the generator and the DUT the instrument must first be disconnected from both sources before any changes are made Besides the mains supply itself certain instruments also operate at high voltages which are not provided with any internal form of extra protection against being touched Ensure that all unused slots are blanked off before powering up NSG 5500 Automotive transient immunity generator 1 14 Test execution The test area must be so organised that no unauthorised persons have access during execution of a test DUTs together with their accessories and cables are to be considered as being live during a test The test generator must be stopped and the DUT supply interrupted before any work is carried out on the DUT This can be implemented by pressing the SYSTEM STOP button DANGER The DUT is to be tested only in a protective cage or under a hood which provides protection against electric shock and all manner of other dangers pertaining to the particular DUT see Dangers concerning the DUT CAUTION The safety instructions concerning all the instruments and associated equipment involved in the test rig are to be observed CAUTION The configuration of the test rig is to be strictly in compliance with the methods described in the relevant standard to en
14. case of doubt the tests should be carried out a Faraday cage European representative Teseq GmbH Landsberger Str 255 12623 Berlin Germany Place and Date Luterbach December 12 2006 Johannes Schmid President NSG 5500 Automotive transient immunity generator 5 TECHNICAL DATA 5 1 Technical specifications 5 1 1 NSG 5500 Instrument power supply 100 to 120 VAC 10 47 63 HZ 220 to 240 VAC 10 47 63 HZ DUT supply From an external source e g battery or PA 5840 power amplifier battery simulator Computer interface IEEE 488 recommended USB or RS 232 Auxiliary input signals DUT FAIL START STOP CRO TRIG TEST END Input DC voltage range 60 V max DC current 100 A 250 A for 200 ms Voltage drop of battery 2V Q 100A Switch 1 5V 25A for positive serial coupled pulses in battery mode upc under program control 3 5 V 100 A Battery switch on off time 2 us 10 load Protection class IP20 5 1 2 MT 5511 Micro transient generator for the pulses 1 2 6 and variants Voltage range Rise tim Pulse Internal Repetition rate Polarity Ext Ri Pulse v width Ri Q t1 s available Pulse 1 0 330 1 V steps 1 us 2 us 3us 2 ms 6ms 40 10 20 10 5 60 0 01 steps 30 50 90 Neg Pos NO 0 200 1 V steps 1 us 2ms 10 0 5 60 0 01 steps Neg Pos NO 0 600 1 V steps 1 us 3 us 1ms 20 50 0 5 60 0 01 steps Neg Pos BNC Yes Pul
15. first five switches correspond to the binary weighted address values 1 2 4 8 and 16 The total sum of the values corresponding to the switches in the ON position is the IEEE address For example in the illustration below the address set is 1 2 8 11 Picture 2 13 DIP switch array to set the NSG 5500 IEEE address NOTE The address is read only at power on Therefore after changing the address setting the NSG 5500 must be powered off and then on to accept the new setting The hardware is set at the factory to address 1 This is also reflected in the Auto Star setup NSG 5500 Automotive transient immunity generator 2 9 1 2 IEEE address setting CTR 5501 The CTR 5501 address can only be set with the tool supplied on the AutoStar CD using a USB 2 0 Cable To set the GPIB address it is first necessary to establish a connection using USB Please see the section on installing the driver To choose the GPIB address of the CTR 5501 use the Flash Loader Tool found on the AutoStar CD Once communications is established click Set to the right of the GPIB address field to bring up this setting dialog CTR5501 Flash Loader Tool Version V1 3 Connected Y Check interface Interface FW Version 1 01 0 GPIB Id 001 Y Check Controller Controller FW Version 8 01 00 UPDATE MAIN CONTROLLER Update Interface Get File Info Embedded Version Module Name Description Read Firmware File Path Download to Controller
16. 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 T3SEO Advanced Test Solutions for EMC 1 1 Classification of dangers The safety instructions in this manual are classified in different levels The table below shows a survey over the relation of symbols ideograms and signal words to the specific risk and the possible consequences Warning symbol Signal word Definition Possibly dangerous situation that may cause damage DANGER to persons or heavy damage to the tester and or the equipment Situation that may cause damage to the tester and or CAUTION the equipment User tips and other important or useful information and NOTE comments 1 2 Warning symbols on the test system Different warning symbo sare placed on the test system The following table shows the assignment of symbols and signal words to the specific risk Warning symbol Signal word Definition Warning of voltages that might involve the risk of I DANGER electric shock CAUTION Warning of a danger spot refer to the documentation Caution symbol Definition Warning of voltages that might involve the risk of electric shock Warning of a danger spot refer to the documentation NSG 5500 Automotive transient immunity generator 1 3 Excess voltage category The test system NS
17. singaporesales Taiwan Teseq Ltd T 886 2 2917 8080 F 886 2 2917 2626 taiwansales 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 withinTeseq s global network please go to www teseq com October 2013 Teseq 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 33 139 47 42 21 F 33 139 47 40 92 francesales teseq com Japan Teseq K K T 81 3 5725 9460 F 81 3 5725 9461 japansales teseq 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 teseg com Specifications subject to change without notice Teseq is an ISO registered company Its products are designed and manufactured 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
18. G 5500 as described in this manual is related to the excess voltage category Il according IEC 60664 1 4 Range of validity These instructions are valid for the complete installation Further safety regulations for components installed in this test system or additional installed devices are not suspended by these instructions 1 5 SYSTEM STOP button Pressing the SYSTEM STOP button on the front panel of the FT 5531 or opening another safety circuit cuts the voltages that may involve electrical shock by touch DANGER The SYSTEM STOP button does not disconnect the test system from the line voltage If a danger for life machine or the product occurs the SYSTEM STOP button must be pressed Thereby the test voltage in the DUT is disconnected NOTE Hn After resetting the SYSTEM STOP button the test system must be restarted before continuing operation is possible T3SEO Advanced Test Solutions for EMC 1 6 Safety of operation Reliable function and safe operation of the test equipment are ensured only if the relevant general precautions as well as all safety instructions given in this manual are observed In particular observe the following Connect the generator only to line voltage that confirms to the power specification given on the type label on the back of the test system Do not touch any conductive parts at the test point connectors the fixture and the test object during a test run Never apply external voltag
19. OUTPUT terminals at the front of the unit and the required tests can be carried out 2 7 1 Test set up The following set up can be used to check the integrity of the output pulses The scope probe should be in conformance with the specifications outlined in ISO 7637 2 High impedance Oscilloscope probe NSG 5500 output in module FT 5531 Ground plane Picture 2 9 Test set up with the LD 5505 or LD 5550 and scope NSG 5500 Automotive transient immunity generator 2 7 2 Parameter references The following diagrams show the reference points for parameter specifications on the module 1 1 4 h __________ V 1 1 i p gt t 1 1 Picture 2 10 Reference points for pulse 5 upper diagram and pulse 7 lower diagram T3SEO Advanced Test Solutions for EMC 21 22 2 8 Installation set up MT 5511 Check the instrument for any mechanical damage Report any damage found to the carrier immediately Ensure that the power is turned off on the NSG 5500 mainframe and that the battery input is disconnected Insert the cassette in the most left slot and push in fully Screw in the four retaining screws fully The battery switch is required ensure that this module is present and inserted fully in the rear of the NSG 5500 main frame It is vitally important that the unit mains power is connected to protective earth Turn on the mains input
20. e specifications of the magnetic circuit breaker are as follows 100 A 300 A 200 ms peak Picture 4 1 The magnetic circuit breaker in the CDN 5500 unit NSG 5500 Automotive transient immunity generator 4 3 2 Fuses The fuses are placed in the mains voltage selector To exchange a fuse proceed as follows DANGER The NSG 5500 must be disconnected from the mains by disconnecting the power cord before working on the mains voltage selector Carefully loosen the drawer from the input connector assembly using a screwdriver and turning it slightly in both directions as shown in the picture below REMOTE d m ee SENSE Picture 4 2 Loosen the drawer using screwdriver Pull out the drawer from the input connector assembly Picture 4 3 Pull out the drawer T3SEO Advanced Test Solutions for EMC 59 60 Remove the defect fuse s Picture 4 4 The Fuses are placed on the sides of the drawer probably carefully using a small screwdriver Picture 4 5 Remove defect fuses NSG 5500 Automotive transient immunity generator W The defect fuse on the side of the drawer Remove the defect fuse s CAUTION Use the following fuse types for the appropriate voltage ranges 110 120 V 5x20mm 6 3 A time lag 220 240 V 5 20 mm 3 15 A time lag Take care to install the drawer to the correct voltage range when reinstalling the draw
21. e to the sytem s output connectors Disconnect the generator f rom the mains before opening the casing for maintenance or repair During operating the generator always observe the relevant rules of ESD Electro Static Discharge protection To guarantee the EMC features of the NSG 5500 the control computer must meet the requirements of the EN 50082 55011 61000 standard The operation of radio equipment or other high frequency emitting devices near the DUT or adaptation cables may possibly lead to wrong test results while HF energy is emitted Observe the environmental conditions as described in chapter 5 3 Environmental conditions 1 7 Personnel The generator may be operated by qualified personnel only It may be opened for adjustment maintenance or repair by authorized staff only Teseq or its representative may not be held responsible for service not performed by Teseg personnel 1 8 Responsibility for safety precaution The owner operation supervisor and or operator of the equipment are responsible for safety The owner operation supervisor and or operator are in charge of any safety measures that do not directly concern the generator itself For details see the relevant accident prevention regulations See also the safety instructions in the manufacturer s manual included with any additional instrument or device you intend to use with your Teseq equipment Neither Teseq AG nor any of the sales organisations can accept an
22. ed Just copy the exe file into the desired working directory 2 9 2 4 Starting the loader After starting the application the following screen appears During the initialization period of about one second the buttons for interacting with the controller are disabled NSG 5500 Automotive transient immunity generator 27 CTR5501 Flash Loader Tool Version V1 3 Connected Check Interface Interface Fw Version GPIB Id Set Check Controller Controller PW Version UPDATE MAIN CONTROLLER Update Interface Get File Info Embedded Version Module Name Description Read Firmware File Download to Controller Loaded COM Config COM Port 9600 Picture 2 15 Starting the flash loader The Flash Loader automatically retrieves basic configuration information from the connected controller and displays them in the first three text fields J CTR5501 Flash Loader Tool Version V1 3 Connected Y Check Interface Interface FW Version 1 01 0 GPIB Id 001 Set Y Check Controller Controller FW Version ao 00 Picture 2 16 The flash loader tool TASEO Advanced Test Solutions for EMC 28 2 9 2 5 Startup error In case the INI file refers to a non existent COM port the following error message appears and the connection status is set to Off Line Error on connect CTR5501 Flash Loader Version V1 2 Your INI file references an invalid COM port Please select another one P
23. en on the type label If the grounding is interrupted inside or outside of the equipment the NSG 5500 will become a source of danger Additionally the output of the device may not conform with the relevant test standards when the grounding of the power plug is interrupted Carefully observe grounding precautions The plug on the power cord may be replaced by qualified personnel only The power input of the tester is located on the rear side of the NSG 5500 see picture 3 4 The power input is secured by two 3 15 A time lag fuses 220 240 V range or two 6 3 A time lag fuses 110 120 V range For details refer to chapter 4 3 Protection The power plug and outlet must have grounding contacts When the NSG 5500 is brought from cold to warm environment the ensuing condensation may bring about dangerous conditions DANGER The NSG 5500 may only be switched on after all parts have acclimatized T3SEO Advanced Test Solutions for EMC 2 4 1 Mains voltage selector The mains voltage selector is a small drawer placed in the mains input main switch module The user can select the regional input voltage range 110 120 V or 220 240 V by pulling out the selector using a small screwdriver and turning it The selected voltage range is marked by the small arrow on the module that points to the white mark at the input connector assembly rr The small bar indicates the voltage range selected 220 240 V selec
24. enerator b Erasing the flash contents on the controller and writing the new firmware Picture 2 23 Downloading the firmware to the controller After a successful download a brief sound is played and a message is shown Information i Download A Please restart controller Picture 2 24 Download complete It is now required to restart the controller by switching off the NSG 5500 2 9 2 8 Recovery If a communication error occurs or the download procedure is aborted for any reason the firmware will not be successfully loaded Information Error during download Communication error with CTR5501 Page 623 4064 12 will now abort load process Picture 2 25 Error during download In this case the controller will restart into a failsafe recovery mode upon startup In other words the controller s boot loader detects an incorrect bootup and falls back into the failsafe boot loader listening mode There is no way to delete overwrite or update the failsafe boot loader TASEO Advanced Test Solutions for EMC 31 32 When a controller who s update has failed or contains corrupted firmware the following dialog is brought up Confirmation xi No response from 5501 Do you want to attempt a recovery A If yes please restart controller Picture 2 26 Fialsafe recovery You will then be guided through the recovery process identical to the update process and may continue to use
25. er into the input connector assembly Picture 4 6 Push the drawer back in until it is fixed to the input connector assembly again Picture 4 7 Fix the drawer to the input connector assembly B Now reconnect the NSG 5500 to the mains T3SEO Advanced Test Solutions for EMC 61 4 4 Declaration of conformity CE TASEO 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 NSG 5500 Automotive Transient Immunity Generator 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_NSG5500_2006 LVD_NSG5500_2006 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 responsible for the correct and controlled operation of the rig In
26. erator 2 8 2 Parameter references The following diagrams show the reference points that are used for parameter specifications on the MT 5511 Pulse 2a Pulse 6 Picture 2 12 Reference points for pulses 1 2 and 6 T3SEO Advanced Test Solutions for EMC 23 24 2 9 Installation set up control unit CTR There are two controllers in circulation The CTR 5500 and CTR 5501 The CTR 5501 has some small changes it Supports a new USB connection and has a new method of updating the firmware CAUTION The IEEE Bus has proven to be a very reliable control method in industrial environ ments However the CTR 5501 supports also USB control Please note that USB can be affected by disturbances in typical EMC laboratories For this reason please use only the supplied USB cable Only cables confirming to the USB 2 0 standard and above are supported Even so in very noisy environments the IEEE 488 2 connection is recommended 2 9 1 Setting the IEEE address 2 9 1 1 IEEE address setting CTR 5500 When communicating with the NSG 5500 via the IEEE 488 Interface it is necessary that the address set in the AutoStar comm setup screen corresponds with the IEEE 488 address set on the control unit A DIP switch array on the front panel of the control unit is used to set the NSG 5500 IEEE address There may be five or six switches on this DIP switch depending on the hardware version Only the first five switches are used These
27. esult in the interference voltage or the DUT supply voltage being present on the DUT s housing CAUTION Electrical breakdown or arcing from and in plugged connections that are over stressed voltage wise during the test DANGER Explosion of electronic components with fire or fragmentation as a result of the energy dissipated e g from the resultant supply current or ignition of vaporised plastics materials CAUTION Faulty behaviour by the DUT e g robot device strikes out temperature controller fails etc NSG 5500 Automotive transient immunity generator 2 INSTALLATION 13 E 2 1 Checking the shipment Upon receiving the shipment first check the packaging and outer equipment cover for visible damage Also check packaging and casings of peripherals if you ordered any Record in writing any defects which were possibly caused in transit If the shipment shows damage or is not complete immediately advise the shipping agency and or your dealer 2 2 Delivery contents The standard delivery contains the NSG 5500 with connection cables and the instruction manual Optional modules are installed in the NSG 5500 if ordered Possibly there is also optional equipment e g computer or printer 2 3 Operating position The NSG 5500 must be placed in upright position firmly and securely during operation 2 4 Line voltage connection and grounding DANGER Connect the NSG 5500 only to line voltage conforming to the power specification giv
28. g the firmware CTR 5501 Installation Starting the loader Startup error Download operation Downloading Recovery Oo 0 2 NO NO NO NO NJ AAA 3 lt 0 T3SEO Advanced Test Solutions for EMC 3 1 3 2 3 2 1 3 2 2 3 2 3 3 2 3 1 3 2 3 2 3 2 3 3 3 2 3 4 3 2 3 5 3 2 4 3 2 5 3 2 5 1 3 2 5 2 3 2 5 3 3 2 6 3 2 6 1 3 3 3 3 1 3 32 3 3 3 3 4 3 4 1 3 4 2 3 4 3 3 5 3 5 1 3 5 2 3 5 3 4 1 4 2 4 3 4 3 1 4 3 2 4 4 5 1 5 1 1 5 1 2 5 1 3 5 1 4 5 1 5 5 1 6 5 2 5 3 Operation General system overview NSG 5500 Operation Introduction Powering up the system NSG 5500 System overview CDN 5500 Power entry and battery switch Control unit HV supply System block diagram External connection of pulse 4 amplifiers Remote programming External trigger and control signals Start stop signal DUT FAIL signal CRO trigger RS 232 wiring diagram Optical interface FT 5531 Operation ntroduction Block diagram Tests with a coupling clamp LD 5505 and LD 5550 Operation ntroduction Block diagram External output resistance LD 5505 only T 5511 Operation ntroduction Block diagram Transient diagram Maintenance Cleaning the equipment Moving
29. gacy system interface Interface For updating communications like the USB and GPIB features NSI new system interface Main Controller The main firmware for updating firmware that determines how the NSG 5500 operates TASEO Advanced Test Solutions for EMC 30 Now select the desired file and click Open In a first step the Flash Loader reads the metadata in the file header and displays them Embedded Version This parameter has been embedded into the firmware file during the file creation process The Flash Loader checks it against the version information read back from the controller Module Name A string describing the target module this firmware is intended for The Flash Loader checks it against the fixed string CTR5501 Description Describes and further qualifies the firmware file e g Release Beta Test etc The Flash Loader now brings up the following dialog containing the above information and requests a con firmation for download Confirmation 3 Do you want to load this file CTRSSO1 Release 09 01 00 1 Estimated download duration 3min Os Picture 2 21 Loading the firmware file 2 9 2 7 Downloading This involves two steps 8 Reading the complete firmware file and converting it into an appropriate format for downloading to the controller This is performed automatically on load by the tool Picture 2 22 Reading the firmware file NSG 5500 Automotive transient immunity g
30. harness is as follows 9 Pin connector 25 Pin connector 2 2 RX 3 3 TX 5 7 Gnd PC serial output NSG 5500 Picture 3 19 Wiring diagram for the RS 232 interface cable 3 2 6 1 Optical interface Because the primary function of the NSG 5500 Instrument is to generate interference pulses the interference pulses may effect the communication link between the instrument and the PC and corrupt the data being transferred For this reason it is recommended when using the RS 232 link to protect this link using two optically isolated interfaces one at each end of the connecting cable These interfaces available from Teseq will prevent corruption of the data by the interference pulses generated T3SEO Advanced Test Solutions for EMC 47 48 3 3 FT 5531 Operation 3 3 1 Introduction The FT 5531 FT Fast Transients is a plug in burst generator designed for use with the NSG 5500 mainframe system This generator is designed primarily to meet the specification requirements for the ISO 7637 standard for pulses 3a and 3b In many cases the specification of this generator exceeds those specified in the ISO 7637 standard When slotted into an NSG 5500 mainframe the FT 5531 burst generator is fully programmable via USB or RS 232 or IEEE 488 interface Parameters such as amplitude burst frequency pulse frequency number of pulses in the burst number of bursts are all under program control This allows flexible test patterns to be ge
31. icture 2 17 Unable to connect Click Config COM Port at the bottom of the main window to select the working COM port Custom s E 5 Noe F Picture 2 18 Choose the COM port USB In this dialog only select Port the other parameters are not relevant The new port is now stored in an INI file NSG 5500 Automotive transient immunity generator 2 9 2 6 Download operation 29 Click the UPDATE MAIN CONTROLLER or Update Inteface button First the firmware versions of the interface and the main controller are retrieved The Flash Loader uses this information in the subsequent step UPDATE MAIN CONTROLLER Update Interface Get File Info Embedded Version Module Name Description en naw Picture 2 19 Updating the controller Following this the file selection dialog is brought up Select Firmware Image File 2 xi Suchen in Current E3 Fe Zuletzt verwendete D 6 Desktop Corrupt NSI 09 01 00 motx NSI_09_00 motx gt NSI_09_01_00 motx S mcr Eigene Dateien LUTPCO36 LI hernias Dateiname X ffnen Dateityp Firmware Files Abbrechen Picture 2 20 Choose firmware file to Use Navigate to the directory where the firmware files are stored The listing is filtered to display only the files with compatible extensions motx You will find two different types of MOTX files LSI le
32. iew These rear plug in units are not generally removed by the user These units have a modular construction to facilitate easy maintenance and to allow for future upgrades to the NSG 5500 system The plug in units in question are HV supply this is a solid state high voltage programmable power supply that provides the required charging voltage to the pulse generators Power entry this unit facilitates the connection of the mains input to the system and the connection o the battery supply to the power bus In addition it also provides the input output connections for the external control signals DUT FAIL START STOP TEST END and CRO TRIG Battery switch this unit contains a solid state switch and timing electronics which are used for precise timing control of the ON and OFF periods of the battery power supplied to the device under test DUT This is required to meet some of the timing requirements specified in the standards particularly for negative pulses NOTE The power entry and battery switch is one functional unit plugin module W Control unit this unit contains the processor board that controls the complete system The remote control interfaces USB or RS 232 and IEEE 488 are also available via this unit as well as the optional pulse 4 4c control board NSG 5500 Automotive transient immunity generator 3 2 3 1 CDN 5500 Power entry and battery switch 37 This unit is used to bring mains input int
33. ld really be determined by the voltage level of the pulse Once it has decayed to a point of zero volts the battery power must be turned on rapidly and with minimal discontinuities A general block diagram of the CDN 5500 unit for the NSG 5500 system could be represented as follows Switch Battery 4 Timer Switch Voltage Optional most control control sense newer standards Battery 4 Picture 3 7 Block diagram of the CDN 5500 battery switch unit The switch has facilities for being controlled by a voltage sense circuit or a timer circuit While it is obvious that the control of the battery switch to the required specification requires complicated timing and monitoring controls all of this activity is generally transparent to the user The control unit in the NSG 5500 manages all of these requirements internally and automatically as required during pulse generation T3SEO Advanced Test Solutions for EMC 39 40 3 2 3 2 Control unit The control unit houses the processor board which controls the complete NSG 5500 system The remote control interfaces are also mounted on this unit The USB or RS 232 and IEEE 488 interfaces are supplied as standard on all NSG 5500 systems IOo jA O ma e o m USB port GPIB IEEE PORT IEEE 488 port IEEE 488 port W BNC Output PULSE 4 CONTROL RORA Control connector to pulse 4 chassis optional RS232C PORT W RS 232 Interface IEEE 488 ADDRESS
34. lexi analysis of susceptibility limits of a device unde The output pulses of the generator are availab frame The MT 5511 allows selection of different inter ble test patterns to be generated which can facilitate rapid r test e on two 6 mm sockets on the front of the NSG 5500 main nal output resistances under software control If enabled in AutoStar the Ri jacks will not internally be bypassed This will allow to add an additional resistance to the selected internal pulse output resistor NOTE d The AutoStar software program available from Teseq is a Windows based graphi cal program that allows full control of all programmable features via an intuitive graphical windows front panel NSG 5500 Automotive transient immunity generator System requirement Min version no NSG 5500 Auto Star 4 0 Firmware 7 0 55 Table 3 1 Minimum system requirements for use with the MT 5511 MT 551 1 MICRO TRANSIENTS BW Indicates power ON W Flashes when unit addressed Error indicator E Positive pulses indicator Flashes when pulse is generated Picture 3 28 MT 5511 Front panel layout BI Negative pulse indicator Ri optional BNC optional TASEO Advanced Test Solutions for EMC 56 3 5 2 Block diagram Charge switch Discharge switch Pulse width capacitor Meas amp control Overvoltage protect HV supply i
35. lii Pulse shaping network Ri Jack Picture 3 29 Block diagram of the MT 5511 3 5 3 Transient diagram HV supply Picture 3 30 Block diagram of the MT 5511 NSG 5500 Automotive transient immunity generator 4 MAINTENANCE 57 mem Under normal conditions it does not take much effort to keep your test equipment in good working order CAUTION Hg Protect the equipment against moisture heat and dust 4 1 Cleaning the equipment To clean the equipment use a dry clean cloth Never use water any other liquid or detergent 4 2 Moving and storing the device The device must be installed uninstalled only by qualified personnel Before moving the equipment even over a short distance you must first turn it off and disconnect it from the mains Remove any fixturing devices and or test objects Also disconnect the equipment from any peripherals For longer transit protect the equipment against humidity dust and shock by proper packaging The equipment must be stored in upright working position Make sure the equipment is protected against humidity dust and dirt Observe the environmental conditions specified in chapter 5 3 Environmental conditions T3SEO Advanced Test Solutions for EMC 58 4 3 Protection 4 3 1 Magnetic circuit breaker The NSG 5500 Main battery source Input is protected with a magnetic circuit breaker The element is a slow breaker to allow high inrush currents Th
36. lot from left and push in fully Screw in the four retaining screws fully Turn on the mains input power on the NSG 5500 mainframe After approximately a two second delay the power LED red on the FT 5531 generator should light Now the scope calibration setup shown in picture 2 7 should be connected and the output pulses should be quickly checked to ensure that they are of the correct form and shape When pulses are generated the green LED 3a or 3b whichever is selected flashes as pulses are output 2 6 1 Test set up The following set up can be used to check the integrity of the output pulses Due to the high frequency nature of the 3a and 3b pulses it is critically important that cable lengths are kept to a minimum and that the test set up is rigorously adhered to The attenuator used in this test set up is a series combination of two attenuators The oscilloscope used needs to a have a high sampling rate and bandwidth Refer to ISO 7637 2 for details 50 Ohm coax Scope Cable 50 cm 20 dB 20 dB Attenuators FT 5531 a output Ground plane Picture 2 7 Test set up with the FT 5531 and scope NSG 5500 Automotive transient immunity generator 2 6 2 Parameter references The following diagram shows the reference points used for parameter specifications on the FT 5531 t4 t5 E 1096 Picture 2 8 Reference points of the FT 5531 T3SEO Advanced Test Solutions for EMC 19 20
37. nerated which can facilitate rapid analysis of susceptibility limits of a device under test The FT 5531 is designed using state of the art semi conductor technology This means repeatable performance and maintenance free operation It also means that test results can be repeated accurately The output pulses of the generator are available on two connectors a 50 Ohm BNC connector and a pair of 6 mm sockets The 6 mm socket output has the added advantage in that it forms part of the multiplexed power bus within the NSG 5500 system This means that output pulses for other plug in units are also available on the socket output of the FT 5531 module This can simplify fixturing to the device under test NOTE H The AutoStar program available from Teseq is a Windows based graphical program which allows full control of all programmable features via an intuitive graphical windows front panel The BNC output connector must be chosen from AutoStar NO CD is present at this connector and it is meant for pulse 3 only X 5530 FAST TRANSIENTS Indicates power ON amp amp Flashes when unit addressed Flashes when pulses generated Flashes when pulses generated Indicates an error condition System stop button BNC output 6 mm output sockets Picture 3 20 FT 5530 Front panel layout NSG 5500 Automotive transient immunity generator 3 3 2 Block diagram HV Supply
38. nit is used to charge the pulse generators It is a solid state electronic power supply that is capable of supplying the necessary high energy bursts of power required to charge all of the pulse generator capacitors used in modules contained in the NSG 5500 mainframe system The HV supply is fully programmable and is controlled on the internal bus by the control unit Picture 3 11 HV supply of the NSG 5500 TASEO Advanced Test Solutions for EMC 42 3 2 3 4 System block diagram Connections to possible l expansion chassis HV SUPPLY CDN 5500 BNC OUT Polarity KH EXT PULSE 3 DUT Remote BAT CONTROL l UNIT l L Connections to possible DC power train expansion chassis Signal pulse line Picture 3 12 System block diagram of the NSG 5500 NSG 5500 Automotive transient immunity generator 3 2 3 5 External connection of pulse 4 amplifiers 43 The Pulse 4 and 2b amplifiers if Supplied with the system are housed in an external chassis This external device is controlled by the NSG 5500 or NSG 5600 The diagram below shows in conceptual form how the two units are connected and interact NSG 5500 PA 5740 PA 5840 75 150 300 v m 5 w TOULNOD 60V 10A 50A 100A Picture 3 13 Interaction of the NSG 5500 and power amplifiers NOTE H A complete range of Teseq power amplifiers are available
39. o the system and to connect the battery input to the system power bus Rae x O CDN 5500 POWER ENTRY BATTERY SWITCH e 2 I sje Bus expansion HIE BUS connector E rg REMOTE ll Remote interface bn ll Battery terminals sense W Thermal circuit breaker n Mains input Battery terminals with fuses FORCE W Auxiliary source Optional reserved for future use Picture 3 4 CDN 5500 If a DC source with remote sense is being used to simulate the battery input i e supply power to the DUT then the sense inputs can be used to ensure that the voltage at the main source Input is accurate by compensating for voltage drops in the lines If a pulse 4 2b amplifier is supplied with the test system then this can also be used as the battery input for all the other pulses The mains Input unit is fitted with two 3 15 A 6 3 A time lag fuses This is intended to protect the internal power bus in the case of an overload condition T3SEO Advanced Test Solutions for EMC 38 Mains input power is brought into the system via the power entry module The power entry module has a mains input power filter socket that allows for adjustment between 110 120 VAC and 220 240 VAC operation This filter socket contains the two 3 15 6 3 A fuses E On off switch Mains input connector Rotate this Insert to change voltage selection W This indicator dete
40. or testing automotive electronic components and parts Automo tive EMC test requirements are covered primarily in ISO 7637 2 This standard outlines five basic pulse types that are used for automotive EMC testing The NSG 5500 system is a modular instrument that can generate all of the pulses described in the ISO standard and in many cases to a higher specification than that specified in the standard The NSG 5500 is a modular instrument where the pulse generators are designed as plug in modules that fit into the NSG 5500 mainframe g Q NSG 5500 MT 5511 FT 5531 LD 5550 or LD 5505 Picture 3 2 NSG 5500 mainframe with module and pulse assignment NSG 5500 Automotive transient immunity generator Due to the modular structure of the NSG 5500 you may configure a test system that provides only the 35 pulse requirements that are required for your application by removing and installing additional modules as needed NOTE i Pulses of similar specification and energy requirements are usually housed in the same plug in unit For example the ISO pulses 2a and 6 are all supplied within the same plug in The NSG 5500 is fully programmable over USB or RS 232 and IEEE 488 interface bus A Windows program AutoStar is available to provide full remote control via a PC computer This program allows you to generate pulse sequences including dynamic ramping and to generate hardcopy printouts of the test results The main features of the
41. power on the NSG 5500 mainframe After approximately a two second delay the power LED red on the MT 5511 generator should light After a further two second initialisation period the unit is ready for operation The software communications will not start until this initialization time is complete The scope test set up shown in picture 2 11 should be connected and the output pulses should be quickly checked to ensure that they are of the correct form and shape As pulses are generated the Fire LED should light briefly The MT 5511 should be then verified in accordance with appendix D of ISO DIS 7637 2 2004 or similar section of the applicable standard When correct operation has been verified the DUT can be connected to the OUTPUT terminals at the front of the unit and the required tests can be carried out 2 8 1 Test set up The following set up may be used to check the integrity of the output pulses The scope probe should be in conformance with the specifications outlined in ISO 7637 2 CAUTION it is critical to compensate the probe in advance Because of the exponential shape of the transients an uncompensated probe will cause errors on rise time and voltage measurement and an incorrect pulse shape High impedance Oscilloscope probe NSG 5500 m output in module FT 5531 LB Ground plane Picture 2 11 Test set up with the MT 5511 and scope NSG 5500 Automotive transient immunity gen
42. r you must mark or label the equipment appropriately so it will not inadvertently be put into operation again You should then call authorized service personnel for assistance 1 11 As agreed use The tester may be used exclusively for simulation of automotive EMC events 1 12 General instructions CAUTION Use of the generator is restricted to authorised and trained specialists DANGER Output connections must not be handled while pulses are being generated During pulse generation high voltages and currents are present at the output terminals BNC output connectors are accessible and can have hazardous live voltages present while in operation The generator is to be used only for the purposes set down by the manufacturer It is the user s responsibility to ensure that the test set up does not emit excessive radiation that may effect other equipment The instru ment itself does not produce excessive radiation However applying interference pulses to an DUT may cause that DUT and its cables to start radiating EMI The method recommended by standards bodies to prevent unwanted emission is to operate the test set up in a Faraday cage DANGER The construction of the unit renders it unsuitable for use in an explosive atmos phere DANGER Persons fitted with a heart pacemaker must not operate the instrument nor approach the test rig while it is in operation Only approved accessory items connectors adapters etc are to be used to ensu
43. r battery simulator connected to the NSG 5500 mainframe the CDN 5500 battery switch module should also be mounted in the rear of the NSG 5500 chassis This module provides the necessary switching on and off of the battery voltage according to the standard The module is designed using state of the art active pulse shaping technology This means repeatable perfor mance and maintenance free operation It also means that test results can be repeated accurately The output pulses of the generator are available on two 6 mm sockets on the front of the NSG 5500 instru ment NOTE fie The AutoStar program available from Teseq is a Windows based graphical program which allows full control of all programmable features via an intuitive graphical windows front panel NOTE Test files made with AutoStar are only compatible with the module they were written for LD 5550 or LD 5550 El Indicates power ON BW Flashes when unit addressed E Flashes when pulse 5 generated W indicates an error condition Flashes when pulse 7 generated Ri resistor connector LD 5505 only Picture 3 25 LD 5505 Front panel layout NSG 5500 Automotive transient immunity generator 3 4 2 Block diagram HV Supply Overvoltage Charge 77 Reservoir Active detect control capacitor pulse shaping network 4 HV Supply Coupling _ Polarity Ri
44. re safe operation T3SEO Advanced Test Solutions for EMC 10 1 13 Installation The instrument conforms to protection class 1 Local installation regulations must be respected to ensure the safe flow of leakage currents DANGER Persons fitted with a heart pacemaker must not operate the instrument nor approach the test rig while it is in operation Two independent protective earth connections are necessary instrument and DUT supply connected back to the local permanent installation or to a fixed permanent protective earth conductor Operate the equipment only in dry surroundings Any condensation that occurs must be allowed to evaporate before putting the equipment into operation Do not exceed the permissible ambient temperature humidity or altitude This equipment must not be used in an enclosed space that would restrict the air flow through the instrument Use only legally approved connectors and accessory items The instrument must be powered from a mains supply that provides a properly earthed mains socket Before the unit is powered up check that the voltage selector on the instrument is set to the correct position Ensure that a reliable return path for the interference current is provided between the DUT and the generator The reference ground plane and the earth connections to the instruments as described in the relevant test standard serve this purpose well The instruments must not in principle be opened This may only
45. rigger reserved for future use unused Picture 3 16 Pin assignment of the REMOTE connector on the rear side of the NSG 5500 when using the CTR 5501 T3SEO Advanced Test Solutions for EMC 45 46 3 2 5 2 DUT FAIL signal This is an input signal It can be used to indicate that a DUT failure has occured Once this signal input is pulled low the present pulse generation pattern will be aborted and testing will end The AutoStar software can automatically detect the state of the DUT FAIL signal input and will stop the program execution automatically if it detects a low signal The DUT FAIL input signal is optically isolated The schematic for this input is as follows Picture 3 17 Schematic for the DUT FAIL signal input 3 2 5 3 CRO trigger This is an output signal Its main purpose is for triggering an oscilloscope The CRO trigger output will go low at the start of a pulse or burst of pulses If a burst of pulses is being generated with the 3a or 3b generators the trigger output will stay low for the duration of the burst The CRO trigger is an optically isolated output and the schematic for this output is as follows Optically isolated Control internal Picture 3 18 Schematic for the CRO trigger output signal NSG 5500 Automotive transient immunity generator 3 2 6 RS 232 wiring diagram An RS 232 interface cable may be supplied as standard with the NSG 5500 system The relevant wiring diagram for this
46. rmines voltage selected Picture 3 5 Power entry module of the NSG 5500 located in the CDN 5500 The battery switch unit is an electronic solid state switch that allows flexible control of the power bus output during the generation of interference pulses 1 2 6 and 7 ref ISO standard 7637 The requirement for sophisticated switch control when generating ISO 7637 pulses is not immediately apparent However upon deeper examination it will become clear that the requirement for turning ON and OFF the battery power can only be met with a complicated solid state switch arrangement This is because high power current needs to be switched over very short periods of time and by different control mechanisms Take for example pulse 1 of the ISO 7637 1 specification lt 100 uSec gt j e ISO 7637 Pulse 1 Battery OFF here Battery ON here Picture 3 6 Pulse 1 of the ISO 7637 1 specification NSG 5500 Automotive transient immunity generator The voltage drop of the switch is minimal see chapter 5 1 Technical specifications The sense inputs are terminated at the switch except in pulse 4 applications where the 4 continue through the output connector on the front panel of the FT 5531 Upon detailed analysis of this pulse requirement it becomes clear that there is an implied requirement for the battery power to switch ON and OFF during pulse generation The point at which the battery power is turned ON shou
47. se 1 0 600 1 V steps 1 us 3 us 2ms 2 3ms 10 20 30 0 5 60 0 01 steps 24 V 50 Neg Pos BNC Yes 0 330 1 V steps 1 us 50 us 2 4 10 0 5 60 0 01 steps Pulse 2a 20 50 90 Neg Pos BNC Yes Pulse 6 0 330 1 V steps 60 us 300 us 30 0 5 60 0 01 steps Neg Pos BNC Yes Others 0 330 1 V steps 1 us SOUS 35 2 50 0 5 60 0 01 steps Neg Pos BNC Yes 0 330 1 V steps 1 us 50 us 150 us 40 10 30 0 5 60 0 01 steps 2000 350 us Neg Pos BNC Yes 0 330 1 V steps 2 us 50 us 10 0 5 60 0 01 steps Neg Pos BNC Yes Table 5 1 Technical specifications MT 5511 Note Repetition rate of 0 2 are only valid for negative pulses or positive pulses with batter ON Note Pulse 1 and pulse 2a are used here for easy reference All pulses from the MT 5511 can be both positive or negative T3SEO Advanced Test Solutions for EMC 64 5 1 3 LD 5505 Load dump generator for pulse 5 and clamped load dump pulse 5b Pulse amplitude Clamping Impedance Pulse rise time Pulse duration Pulse repetition Pulse modes 5 1 4 LD 5550 Load dump generator for pulse 5 and clamped load dump pulse 5b Pulse amplitude Clamping Impedance Ri Pulse rise time Pulse repetition Pulse modes 5 1 5 FT 5530 Fast transients generator for the ISO pulse 3a 3b and variants u u u u u me s gg 3s 38
48. sure that the test is executed in a standard conforming manner 1 15 Dangers concerning the generator m DANGER Dangers from a disrupted DUT DANGER Local burning arcing ignition of explosive gases DANGER Danger from the resultant DUT supply current caused by a flashover or breakdown resulting from the superimposed high voltage effects DANGER Disturbance of unrelated electronics telecommunications navigational systems and heart pacemakers through unnoticed radiation of high frequency energy In most test rigs the interference voltage is superimposed on the protective earth conductor of the DUT in accordance with the requirements of the test standard Earth contacts or pins e g in German and French connectors as well as the DUT earth can hence be at a dangerous to touch voltage The screws too in certain connectors are also linked to the protective earth conductor T3SEO Advanced Test Solutions for EMC 1 16 Dangers concerning the DUT DUTs are often simply functional samples that have not previously been subjected to any safety tests It can therefore happen that in some cases that the DUT is quickly damaged by internal overloads caused by the control electronics being disrupted or it may even start to burn m m BH CAUTION AS soon as the DUT shows signs of being disrupted the test must be stopped and the power to the DUT switched off DANGER Internal disruption of the electronics can r
49. the system as normal after restarting NSG 5500 Automotive transient immunity generator 3 OPERATION 3 1 General system overview 55311 Battery simulator PA 5840 option connected to MAIN source terminals in battery switch unit Non optional module front side FT 5531 Fast transients generator Optional internal modules single width 1 MT 5511 Micro transients generator NT 5512 Nissan transients generator JT 5510 Jaso transients generator ect Optional external couplers supression networks CDN 500 CDN 5050 INA 220 etc NSG 5500 1 NSG 5500 2 INA 5025 Option Connected to 4 INA 5026 EXP connector in power entry unit DUT and or external couplers Suppression networks etc P1 P2 Pulses connected to EUT terminals P3 Pulses connected to EXT PULSE BNC connector Non optional module rear side HV supply CDN 5500 Power entry Battery switch Control unit Optional internal modules Double width 2 y LD 5505 Load dump generator RM 5055 Resistance module JT 5550 Jaso transients generator etc Optional external output resistor units INA 5025 INA 5026 ect Optional external battery simulators PA 5840 etc Picture 3 1 System interconnection diagram with optional modules and units T3SEO Advanced Test Solutions for EMC 34 3 2 NSG 5500 Operation 3 2 1 Introduction The NSG 5500 EMC test system is designed f
50. tion shown Picture 2 1 Mains voltage selector 220 240 V range selected in the picture NSG 5500 Automotive transient immunity generator To select the other voltage range procceed as follows DANGER The NSG 5500 must be disconnected from the mains before working on the mains voltage selector by disconnecting the power cord Carefully loosen the drawer from the input connector assembly using a screwdriver and turning it slightly in both directions as shown in the picture below REMOTE Wwe B ee ee SENSE Picture 2 2 Loosen the drawer using a screwdriver Pull out the drawer from the input connector assembly a Picture 2 3 Pull out the drawer T3SEO Advanced Test Solutions for EMC 15 16 Turn the drawer until the text of the desired voltage range and its arrow is on the bottom of the drawer Picture 2 4 Turn the drawer B Push the drawer back in SENSE MAINS Picture 2 5 Push the drawer back in NSG 5500 Automotive transient immunity generator until it is fixed to the input connector assembly again Picture 2 6 Fix the drawer to the input connector assembly B Now reconnect the NSG 5500 to the mains 2 5 Installation set up NSG 5500 This section outlines a brief checklist of items that should be done before the unit is powered up and put into service The NSG 5500 may be set up by qualified personnel only It is imperative
51. to observe the safety instructions at the beginning of this manual Check that all items and accessories ordered have been delivered Inspec immed Carefu t the equipment for damage during transit Any damage found should be reported to the carrier iately ly study the documentation and operating instructions supplied The mains voltage selector on the rear of the instrument must agree with the local mains voltage mains frequency 47 63 Hz Connect the mains cable to a mains outlet that has a good earth connection Ensure that all modules are inserted correctly and screwed home tightly Observe and adhere to the polarity of all input and output connections Power up and operate according to the instructions supplied NOTE The three modules contained herein are simply the most commonly required transient generators Additional generators are available for use in the NSG 5500 These additional generators will be supplied with their own user s guide T3SEO Advanced Test Solutions for EMC 17 2 6 Installation set up FT 5531 Check the instrument for any mechanical damage Report any damage found to the carrier immediately NOTE The FT 5530 and FT 5531 are functionally identical and may be used interchargeably in this guide Differences are noted where necessary Ensure that the power is turned off on the NSG 5500 mainframe and that the battery input is disconnected Insert the cassette in the second s
52. vanced Test Solutions for EMC 53 54 CAUTION d When no external resistor or shorting connector must be i Teseq output resistance unit is used the provided nstalled le The difference between the INA 5025 and the NOTE The RM 5055 is also availab RM 5055 is that the INA 5025 is an external unit while the RM 5055 is meant to be installed into the NSG 550 chassis 3 5 MT 5511 Operation 3 5 1 Introduction The MT 5511 MT Micro Transients is a plug i 0 The INA 5025 is installed in the external INA 5026 n transient generator module designed for use with the NSG 5500 mainframe system This generator is designed to meet the specification requirements for the ISO 7637 standard for pulses 1 2a 6 and similar In ma ny cases the specification of this generator exceeds those specified in the applicable standard The MT 5511 complies with ISO 7637 2 2004 with previous versions of the standard and also meets many proprietary automobile manufacturer standards The MT 5511 generates pulses of types 1 2a and 6 as specified in the ISO SAE and Ford standards This standard defines how these pulses are generated in relation to the vehicle battery voltage When slotted into an NSG 5500 mainframe the MT 5511 Micro transient generator is fully programmable either via USB or RS 232 and the IEEE 488 interface Parameters such as amplitude pulse width and pulse rise time are all under program control This allows f
53. y responsibility for personal material or consequential injury loss or damage that results from improper use of the equipment and accessories 1 9 Safety regulations According to the EN 50191 standard this equipment may involve the risk of electric shock The owner opera tion supervisor and or operator are responsible to build up and operate the equipment according to the EN 50191 standard Conductive parts must not be touched and the test station must have appropriate warning labels and signs In general observe the industrial health and safety standards pertaining to electrical test installations in your country The construction of the equipment conforms to the safety requirements of IEC 348 and provides all the prerequisites for safe and reliable operation Development and manufacture is in compliance with ISO 9001 The equipment conforms to the safety requirements of IEC 1010 1 EN 61010 1 safety requirements for electri cal equipment for measurement control and laboratory use The switching power supply conforms to IEC 950 NSG 5500 Automotive transient immunity generator All mains driven types of generators are equipped for high voltage working safety in accordance with VDE 0104 The EMC compatibility has been tested with EN 61326 version 03 2002 1 10 Reduction of operational safety If you have any reasons to suppose that the test equipment is not completely safe you must shut it down and put it out of operation Moreove
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