Mtu Sam Manual

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 01

1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03

1.1 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03

1.2 Overview of device functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04

1.3 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07

1.4 CAN communication link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.5 Ethernet communication link (10/100BaseT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.6 RS422/RS232 communication link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.7 Binary inputs with common ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.8 Binary inputs via optocoupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.18 Fault display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.19 Control keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.20 Extendibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1.21 Self-diagnosis (ITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.22 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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02 Table of Contents

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Function 03

1 Function

1.1 UseThe 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 Function

1.2 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: 0.3A8 * 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 Item Designation

11 Flash ROM: 512Kbyte*32

12 Compact Flash Card: 32 or 64Mbyte

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 inthe course of SAM application engineering (project environment).

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Function 07

1.3 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 Value

Installation position As desired, however integral fault display shouldbe legible.

Operating voltage VDC 24 rated value (-50%; +30%)

Power consumption W Below 6 (0.25A at 24V) without additional loads

Degree of protection: IP 40 as per DIN 40 050

Shock:

Rail mounting 10g, 11ms

Fixed installation 30g, 11ms

Vibration:

Rail mounting Hz 2 - 12.8:Xpp < ± 3mm12.8 - 1000:a < 1g [rms]

Fixed installation Hz 2 - 12.8: Xpp < ± 3mm12.8 - 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 STANAG1008.Note: The processor is automatically reset if the voltagefalls below 7.

Power supply: W Below 7.Without activated loads at SAM outputsAdditional output current on positive or negative conductorshall 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 exceptionof certain electrically isolated channels.

• SAM electronics ground is not connected to housingground.

• Signal cable shields must be connected to housingground if applicable.

• Maximum direct current isolating voltage is 500unless otherwise stated.

Mechanical design

Term Unit Value

Installation position: • Horizontal (to facilitate legibility of fault display andinscriptions on SAM housing).

• Note that space is required to connect cabling at thetop and bottom when installing the SAM in controlcabinets.

• 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 theback wall of the SAM to the mounting frame. Do notallow neighboring devices to additionally heat up theSAM.

Signal connectionsThe SAM module is easily replaced. The input and output signal cables are equipped with modularconnectors. 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 withcoding pins to preclude polarity reversal.

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Function 11

Terminals

Term Unit Value

Terminal strip modules: 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 Function

1.4 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 eachother 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 optionusing an MCS5 extension module, e.g. a CCB2-02 module.One separate Y-connector plug “twin-wire connection” is provided for each CAN channel. Theterminal plug is equipped with the terminals described above. CAN bus communication should not bedisrupted if a connection on the SAM is disconnected. A terminator (120 ohm) must be installed atthe 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 andCAN_2 and an additional 24V power supply.

Pin assignment:

Designation PIN X6 X7 X8 X4

CAN1H 3 H

CAN1L 2 G

CAN_1

GND_CAN1 1 M

CAN2H 3 B

CAN2L 2 C

CAN_2

GND_CAN2 1 L

CAN3H 3

CAN3L 2

CAN_3

GND_CAN3 1

Lbatt+ (24V) EDialog

LGND K

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Function 13

1.5 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 converterand are thus electrically isolated from the SAM electronics.

1 Transmit2 Receive3 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).

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

Applications:

Connection to PC:Use crossed cable CAT5.

Designation Pin X5 EIA/TIA-T 568 A standard EIA/TIA- 568 B standard

Transmit data positive Tx (+) 1 white/green white/orange

Transmit data negative Tx (-) 2 green orange

Receive data positive Rx (+) 3 white/orange white/green

4

5

Receive data negative Rx (-) 6 orange green

7

8

Housing ground 9

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Function 15

1.6 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 configurationwith signals TxD, RxD and Signal_GND.

Pin assignment

Group Designation Pin X14

Tx 1

Rx 4

RS232_GND 5RS232

SAM_GND 6

O1 ( TxB [+] ) 1

O2 ( TxA [ -] ) 2

I1 ( RxB [+] ) 3

I2 ( RxA [ -] ) 4

RS422

RS422_GND 5

Serial link

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 Function

1.7 Binary inputs with common ground

Binary inputs with common groundThese 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 withoutconnection

V 3.8

Input impedance kohm ~6.9 to GND

Rated input current:

Switch for +UBatt mA 3.5 /24V

Switch for UBatt_GND µA -22 / 0V

Threshold voltage Measured at input terminal; Signal source impedance is less than10 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)

DC isolation None

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 VIN2 A/D converter

The input voltage is measured by an analog/digital converter (10 bit resolution). The switching thresholds are set bysoftware parameters. This also makes it possible to detect broken wires when the switch contacts are connectedin 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 frequencymeasuring 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

32 to 6 kHzFrequency: Hz

Usignal is the voltage at the SAM terminals.

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18 Function

Pin assignment

Group 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

Binary inputs withcommon referenceground

Bin GND 8 12

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Function 19

1.8 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 linesand is isolated from all other channels.

Voltage range UBatt_GND to +UBatt

Initial voltagewithout connection

None

Input impedance kohm ~5.5 (load)

Rated input current:

Switch for +UBatt “ON” mA +4.0

Switch for UBatt_GND“OFF”

mA 0

Switching voltage Measured at input terminal

Vin >= 12 V mA Iin > = 1.6 -> High

Vin =< 9 V mA Iin < 1.3 -> Low

(typical value is 10.5Vthreshold 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 a33 resistor).

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20 Function

1 A/D converter2 Uin3 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 brokenwires when the switch contacts are connected in parallel to a 33kohm resistor.

Pin assignment

Group Designation Pin X2 X3 X11 X12

OKI_switch B_IN1_H 1B_OKI_CH1

B_IN1_L 2

B_IN2_H 3B_OKI_CH2

B_IN2_L 4

B_IN3_H 5B_OKI_CH3

B_IN3_L 6

B_IN4_H 7B_OKI_CH4

B_IN4_L 8

B_IN5_H 9B_OKI_CH5

B_IN5_L 10

B_IN6_H 11B_OKI_CH6

B_IN6_L 12

B_IN7_H 1B_OKI_CH7

B_IN7_L 2

B_IN8_H 3B_OKI_CH8

B_IN8_L 4

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Function 21

Group Designation Pin X2 X3 X11 X12

B_IN9_H 5B_OKI_CH9

B_IN9_L 6

B_IN10_H 7B_OKI_CH10

B_IN10_L 8


B_IN11_L 10


B_IN12_L 12


B_IN13_L 2


B_IN14_L 4


B_IN15_L 6


B_IN16_L 8


B_IN17_L 10


B_IN18_L 12


B_IN19_L 2


B_IN20_L 4

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22 Function

1.9 Binary transistor outputs

Binary transistor outputsThe High switches and the Low switches are connected internally on the SAM. Activation as High or Lowswitch 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 clampdiode, 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


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

BIN_OUT_CH11 1

BIN_OUT_CH12 2

BIN_OUT_CH13 3

BIN_OUT_CH14 4

BIN_OUT_CH15 5

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Function 23


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

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24 Function

1.10 Binary outputs: Transistor switches

Binary outputs: Transistor High switches

Term Unit Value

Number of channels 20 Transistor High switchesNote: These channels are used in commonwith the transistor Low switches.

Reference voltage Two terminals are provided separatelyfor supply voltage +UBatt and UBatt_GND(use wire cross-section AWG 15 mm2 or1.5 mm2).

Voltage range V +UBatt (12 - 45)


V 2.3 - 3.7

Impedance in ON state mΩ Less than 320 per channel

Output current

ON state A Less than or equal to - 0.5

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

DC isolation None

Switching cycle Hz The switching rate is determined by thesoftware:Less than 10 admissible

Signal filter nF Capacitor with 100 to UBatt_GND (EMI/EMC)

Short circuit A Self-protection commencing at 0.7 andreaching to 1.9.

Online self-diagnosis Yes, Note*

Note*: Minimum load current must exceed 500µA to avoid associated fault messages. Thismeans 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

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

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

Voltage range V +UBatt (up to 12 - 45)


V 2.3 - 3.7

Impedance in ON state

Low current Ω 1.3 per channel

High current Ω 0.2 per channel

Output current in ON state

Low currentBT_OUT1…..BT_OUT6 andBT_OUT11…BT_OUT16

A Rated value less than or equal to 0.3 per channel

High currentBT_OUT7…BT_OUT10BT_OUT17…BT_OUT20

A Rated value less than or equal to 1.0 per channel

Output current in OFF state

Low current µA Max. - or + (50 - 150)

High current µA Max. - or + (100 - 300)

DC isolation None

Switching cycle Hz The switching rate is determined by the software: Lessthan 10 admissible

Signal filter nF Capacitor with 100 to UBatt_GND

Short circuit Self-protection commences at:

A 1 to 2 for low current

A 6 to 12 for high current

Online self-diagnosis Yes, Note*

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

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26 Function

BenefitsThe outputs offer the following benefits:

• Overload protection with thermal breaking• Overvoltage protection (Load Dump Protection)

The outputs BT_OUT9 and BT_OUT10 may also be used as PWM outputs.

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Function 27

1.11 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 linesand is isolated from all other channels.

Voltage range Less than 36VDC

Contacts Switching contacts (connected as NO contact or NCcontact)

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 liesabove the contacts.

DC isolation Isolation less than 300V DC

Switching cycle The switching rate is determined by the software: Lessthan 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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28 Function

Online self-diagnosis Yes

Offline diagnosis Yes

Pin assignment


BIN_OUT_Rel1 COM1 1

NC1 2

NO1 3

BIN_OUT_Rel2 COM2 4

NC2 5

NO2 6

BIN_OUT_Rel3 COM3 7

NC3 8

NO3 9

BIN_OUT_Rel4 COM4 10

NC4 11

Relay outputs

NO4 12

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Function 29

1.12 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 circuitTwo terminals are provided separately for thesupply voltage +UBatt and Switch LGND (usewire cross-section AWG 15 mm2 or 1.5 mm2).

Voltage range + UBatt


Impedance in ON state mΩ 150 - 250 per channel

Output current in ON state

ON state A Less than or equal to 1.5 per channel

OFF state µA Max. +/-100

DC isolation None

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 reachingto 6.For switching transistor and supply line.


The 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 theprocessor via an A/D converter. The processor software corrects the PWM output ratio on the basis of the desiredcoil 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 currentis measured by a 100 mΩ measuring resistor.Precise current regulation in the closed-loop control circuit only applies to the outputfrequency range of 100Hz to 200Hz.Attainable settling accuracy is = < 0.3 % at 1A current.

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30 Function

1 Measuring resistor2 LBatt+, short-circuit-proof3 PWM – control signal

Pin assignment


PWM1_L 10PWM_CH1

PWM1_H 9

PWM2_L 12

PWMcontrol

PWM_CH2PWM2_H 11

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Function 31

1.13 Signal outputs to control display instruments

Signal outputs to control display instrumentsThese outputs are used to control display instruments or other measuring instruments. 8 channels are providedto 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.

GeneralSignal 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%


V_OUT1 1

V_OUT2 2

V_OUT3 3

V_OUT4 4

V_OUT5 5

V_OUT6 9

V_OUT7 10

Volt_outvoltage output

V_OUT8 11

Common GND AGND 12

Curr_out C_OUT1 6

C_OUT2 7

C_OUT3 8

Current output

C_OUT4 9

Instrument control

Common GND AGND 10

Lbatt+ 11Auxiliary voltage 24V/-1A

LGND 12

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32 Function

Voltage outputs

Term Unit Value

Number of channels 8 voltage inputs with commonUBatt_GND reference potential

Reference voltage UBatt_GND (AGND)

Voltage range V +0 – +10

Accuracy % 0.3 of measuring range**

Initial voltage withoutconnection

V 0 - 10

Impedance in ON state Ω 0

Output current mA Less than or equal to 8 admissible

DC isolation None

Settling time ms Less than 60.

Short-circuit protection mA The output voltage is automaticallyreduced when current intensityexceeds 20 - 30.Short-circuit proof to +UBatt andUBatt_GND.

** The value indicates accuracy in the temperature range –20 °C to 75 °C and for an operating period of one yearafter 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 commonUBatt_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) Ω Less than 400.

Max. output voltage VDC Less than 10.

DC isolation None

Settling time ms Less than 60.

Short-circuit protection Short-circuit proof to +UBatt andUBatt_GND

** The value indicates accuracy in the temperature range –20 °C to 75 °C and for an operating period of one yearafter 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 flowsvia an external instrument to UBatt_GND.

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Function 33

1.14 Interface for measuring sensor (analog IN)

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

Pin assignment


A_Supp_CH1 1

A_In_CH1 2

AN_CH1

A_GND 3

A_Supp_CH2 4

A_In_CH2 5

AN_CH2

A_GND 6

A_Supp_CH3 7

A_In_CH3 8

AN_CH3

A_GND 9

A_Supp_CH4 10

A_In_CH4 11

AN_CH4

A_GND 12

A_Supp_CH5 1

A_In_CH5 2

AN_CH5

A_GND 3

A_Supp_CH6 4

A_In_CH6 5

AN_CH6

A_GND 6

A_Supp_CH7 7

A_In_CH7 8

AN_CH7

A_GND 9

A_Supp_CH8 10

A_In_CH8 11

Analog multi-purpose inputs

AN_CH8

A_GND 12

Temperature sensorsUsed for:

• PT1000, Ni1000 temperature sensors• PT100, Ni100 temperature sensors

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34 Function

• NTC temperature sensors, e.g. Bosch NTC284 509 049 (71Ω - 45k Ω)

Temperature inputs

Term Unit Value

Number of channels 8 commonly used with voltage inputs.

Voltage range V +5; AGND

Measuring current:

PT1000 mA 2.5

PT100 mA 4.5

NTC mA 2 - 5

Input impedance kohm 1

Accuracy of electronics:

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)

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.


** The values indicate accuracy in the temperature range –20 °C to 75 °C and for an operating period of one yearafter 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 impedanceof 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 channel2 IN: PT1000, PT100, NTC

Analog inputs for voltage/currentUsed 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 channel2 Potentiometer or 5V pressure sensor

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36 Function

Example: Voltage measuring 5V or 10V

1 A/D channel2 0 - 5V or 0 - 10V3 IN: 0 - 10V

Example: Current measuring

1 A/D channel2 Sensor 0 - 20mA3 IN: 0 - 20mA

Term Unit Value

Number of channels 8 commonly used with temperatureinputs

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 Ω 150

Accuracy of electronics % 0.2 of measuring range**

Sensor supply

Voltage V 5; 0.1 %**

Current intensity mA 0 - 20 DC (current intensity limitedinternally)

Potentiometer supply

Voltage V 5; 0.1 %**

Current intensity mA 0 - 20 DC (current intensity limitedinternally)

Pin assignment

A_SUPPx V 5 potentiometer/sensor supply

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)

DC isolation None

Sampling rate Hz The sampling rate is determined bythe software: E.g. 100

Signal filter Hz HW low-pass filter: f g = 20

Online self-diagnosis Yes (monitoring of range violationsadjustable by software)

** The value indicates accuracy in the temperature range –20 °C to 75 °C and for an operating period of one yearafter 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 Function

1.15 Electrically isolated analog inputs

Electrically isolated analog inputsUsed 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 commonreference potential (Common GND),which is electrically isolated fromUBatt_GND of the SAM electronics.

Voltage measuring

Voltage range V 0 - +5; 0 - +10

Impedance kΩ 47

Current measuring

Current range mA 0 - 24

Load Ω 150

Accuracy of electronics % 0.3 of measuring range**

Pin assignment

+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

A/D_OPT_+5V Supplies Vpp (5.0V/10mA) to controlan 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 bythe software: E.g. 100

Signal filter Hz HW low-pass filter: f = 20

Online self-diagnosis Yes (monitoring of range violationsadjustable by software)

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

Configuration: Input adjustable between 5V, 10V and 20mA measuringin the application engineering phase.

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Function 39

1 A/D converter optocoupler2 Voltage measuring3 Current measuring

Pin assignment


A/D_OPT_+5V 5

+IN_V_CH1 6

+IN_I_CH1 7

O-AN_CH1

A/D_OPT_GND 8

A/D_OPT_+5V 9

+IN_V_CH2 10

+IN_I_CH2 11

OKI_Analog

O-AN_CH2

A/D_OPT_GND 12

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40 Function

1.16 Frequency inputs

Frequency inputsNormal 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

Signal filter kHz HW low-pass filter: fg = 15

Online self-diagnosis Yes (monitoring of range violations adjustable bysoftware).

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

Pin assignmentPin assignment


F_IN1H 1SPEED_CH1

F_IN1L 2

F_IN2H 3

Frequency inputs

SPEED_CH2

F_IN2L 4

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Function 41

1.17 Removable memory

Removable memoryThe need for a removable storage medium (i.e. Compact Flash) primarily results from theconditions 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 variousI/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 Function

1.18 Fault display

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

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Function 43

1.19 Control keys

Control keysFour 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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44 Function

1.20 Extendibility

ExtendibilityI/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 frequencymeasuring modules, e.g. MFB1, these must be inserted in slot 1 and/or slot 2.

Pin assignment

Group Designation Corresponding PIM PIN Module Pin X10 X21 X22 X23

MCS–5I/O moduleextension

Slot_1 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

Slot_2 n01 PIN_1 5

n02 PIN_2 6

n03 PIN_3 7

n04 PIN_4 8

n05 PIN_5 9

n06 PIN_6 10

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Function 45

Group Designation 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

Slot_3 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

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46 Function

1.21 Self-diagnosis (ITS)

Self-diagnosis (ITS)The SAM features self-monitoring where appropriate from the technical viewpoint. The followingtests 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 diagnosisA straightforward diagnostic method allows service personnel to perform troubleshootingquickly 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 secondsand observe the display for approximately 10 seconds. Any faulty channels are displayed.

Supported MCS5 I/O modules

Designation Board no. Drawing /documentation

Use in SAMslot 1

Use in SAMslot 2

Use in SAMslot 3

AIB 1-02Analog InputBoard

529 530 93 12 529 539 83 02529 531 57 91

x x x


529 530 39 12 529 539 40 02529 531 29 91

x x x


529 530 38 12 529 539 39 02529 531 28 91

x x x


529 530 49 12 529 539 50 02529 531 34 91

x x x

BIB 1-02Binary InputBoard

529 530 88 12 529 539 79 02529 531 53 91

x x x

BIB 2-01Binary InputBoard

504 530 08 97 504 539 66 03504 531 01 90

x x x

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Function 47

Designation Board no. Drawing /documentation

Use in SAMslot 1

Use in SAMslot 2

Use in SAMslot 3

BOB 1-02Binary OutputBoard

529 530 86 12 529 539 77 02529 531 51 91

x x x

BOB 1-02/ABinary OutputBoard

529 530 95 12 529 539 85 02529 531 51 91

x x x


529 530 87 12 529 539 78 02529 531 52 91

x x x


504 530 39 97 504 539 78 03504 531 10 90

x x x

EGB 1-01Exhaust GasBoard

504 530 74 92 504 539 54 03504 531 91 93

x x x

IIB 1-01Instrument InputBoard

504 530 98 92 504 539 64 03504 531 99 93

x x x

INB 2-01InstrumentBoard

504 530 54 97 504 539 84 03504 531 15 90

x x x

MFB1_01Multi-FunctionBoard

504 530 76 92 504 539 56 03 x x —

CCB2_02MultiCommunicationBoard

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 Modules2 Module3 Software

4 Housing5 Board6 Board

7 Cap8 Screws9 Lock

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Function 49

1.22 Index

AAmbient conditions . . . . . . . . . . . . . . . . . . . . . 07

BBinary inputs via optocoupler . . . . . . . . . . . . . 19Binary inputs with common ground . . . . . . . . . 16Binary outputs: PWM outputs via Lowswitches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Binary outputs: Relay switches . . . . . . . . . . . . 27Binary outputs: Transistor switches . . . . . . . . 24Binary transistor outputs . . . . . . . . . . . . . . . . . 22

CCAN communication link . . . . . . . . . . . . . . . . . 12Control keys . . . . . . . . . . . . . . . . . . . . . . . . . . 43

EElectrically isolated analog inputs . . . . . . . . . . 38Ethernet communication link(10/100BaseT) . . . . . . . . . . . . . . . . . . . . . . . . 13Extendibility . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

FFault display . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Frequency inputs . . . . . . . . . . . . . . . . . . . . . . 40

IIndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Interface for measuring sensor (analog IN) . . . 33

OOverview of device functions . . . . . . . . . . . . . 04

RRemovable memory . . . . . . . . . . . . . . . . . . . . 41RS422/RS232 communication link . . . . . . . . . 15

SSelf-diagnosis (ITS) . . . . . . . . . . . . . . . . . . . . 46Signal outputs to control displayinstruments . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

UUse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03

E532187/00E 05-11 © MTU

Documents

Mtu Sam Manual