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ECU Test SystemNI PRODUCTDESCRIPTIONTestStandIndustry-standard test management software for custom development and automated execution of testsequences.TestStand ECU ToolkitECUTS specific software that integrates the workflow between TestStand and InstrumentStudio.Switch ExecutiveSwitch management and routing application that accelerates development and simplifies maintenanceof switch systems.InstrumentStudioSoftware that provides interactive bring-up and debugging of instruments.ECU Test SystemMaintenance SoftwareECUTS specific software that lets you interactively visualize, diagnose, and test ECU Test Systemhardware components and perform continuity testing using the Field Diagnostic Tester.LabVIEW BaseGraphical programming environment that simplifies the programming of distributed test,measurement, and control systems.SystemLink ClientClient license for each test system connecting to the SystemLink Server.Test ExecutiveSignal RoutingTestStandSwitch ExecutiveThis industry-standard test management software functionsas the test executive and is ready to run.This intelligent switch management and routing applicationaccelerates development and simplifies maintenance ofswitch systems.JCreate, execute, and debug test sequencesReuse code developed in any programming languageJJGraphical and automatic routing optionsGenerate reports and integrate with databasesJJIntuitive channel aliases (“DMM HI” versus “r129”)Develop or connect to professional operator interfacesJJCustom naming for individual routes and route groupsIncrease throughput with parallel testing and auto schedulingJJTight integration with TestStandMeet custom requirements with an open andextensible frameworkJAPI for LabVIEW and LabWindows /CVI softwareJTestStand ECU ToolkitThis toolkit integrates the workflow between TestStand andInstrumentStudio to easily configure instruments within the ECUTS.JJJ08Controls instruments in TestStand based on configurationsdefined in InstrumentStudioDebugs instruments using InstrumentStudio while running atest sequence in TestStandWorks for measurement instruments supported only inthe ECUTSNI Switch Health CenterTo simplify relay maintenance and reliability in high-channel-countsystems, all NI SwitchBlock modules and PXI Matrix modulesare shipped with the NI Switch Health Center, which includesan integrated relay test and provides access to the relay-counttracking data stored on the NI switch hardware.Instrument Configuration and DebuggingInstrumentStudioThis application software helps you unify your display, exportinstrument configurations for a higher-level starting point, andmonitor and debug your automated test system.JConfigure hardware using familiar instrument front panelsJEasily navigate web browser-like user interfaceJExport data and screenshotsJExport instrument configurations to automation codeJEnjoy a simplified debug experience for automated test

ECU Test SystemECU Test System HardwareMonitorCore RackPXI InstrumentationMass InterconnectSLSC Load Switchingand ManagementOptional TrayPower SuppliesExternal Loads or eLoadsFIGURE 05Side View of the 24U ECU Test System (ECUTS-16000)HARDWARE SPECIFICATIONSCore RackESD (IEC 61340-5-1), RAL 7035 paint.24U (ECUTS-16000) and 40U (ECUTS-16001) form factors available.Power Input: 200–240 V (1-Phase, 50/60Hz) PDU DC Output: 12 V, 24 VPower Supply200 W (20/36/60 V), 400 W (20/36/60 V), and 800W (20/36/60 V)PXI InstrumentationHigh performance PXI chassis and quad-core controller.Configure up to 16 additional PXI instruments and I/O modules such as DMM, SMU, PSU, SCOPE,FGEN, Isolated AI/AO, and DIO.Automotive CommunicationsCAN, LIN, RS232, GPIB, Automotive EthernetPXI Pin Switch2-wire, support up to four each 4x64, 8x32, or 16x16 matrix modules, to create matricesof 4x256, 8x128, or 16x64 respectively.EMR, 60 V/2 A (60 W). 1-wire (64x1), 2-wire (32x1), or 4-wire (16x1). Multiplexeralso available.Load Switchingand Management8 A, up to 96-ch with current measurement.30 A, up to 24-ch with current measurement.5A, up to 192-ch with current measurement.LoadsSpace for either external load or electronic load (eLoad) 100 W (60 V/20 A) 8-chor 350 W (60 V/40 A) 4-chMass InterconnectVirginia Panel Corporation (VPC) 9025, 25 slotsOptional tray09

ECU Test System10PXI Instrumentation OptionsCombined with a chassis and controller, PXI systems feature high-throughput data movement using PCI Express bus interfaces andsubnanosecond synchronization with integrated timing and triggering. Select up to 16 PXI modules from the standard options listed belowto create the ideal I/O set to meet your ECU test requirements.PXIe-40817 1/2-DIGIT, 1000 V/3 ADIGITAL MULTIMETERPXIe-2737100 V/2 A EMR, 4X642-WIRE MATRIX SWITCHPXIe-85106-PORTCAN/LIN INTERFACEPXIe-84030/88-PORTRS232 SERIAL INTERFACEPXIe-41308-CH 60 VDC 400 KHZCH-CH ISOLATED, ANALOG INPUTSPXIe-51058-CH 30 VPP 60 MHZ12-BIT OSCILLOSCOPEPXIe-43228-CH 16 VDC 250 KHZCH-CH ISOLATED, ANALOG OUTPUTSPXIe-54132-CH 24 VPP 20 MHZFUNCTION GENERATORPXIe-41391-CH, 60 V/3 A/20 WSOURCE MEASUREMENT UNITPXIe-41122-CH, 60 V/1 A/60 WPROGRAMMABLE POWER SUPPLYPXI-256416-CHANNEL, 5 ASPST RELAYPXI-6515 30 VDC 32 SINK/SOURCE INPUTS,32 SINK OUTPUTSINSTRUMENTMAX. PER SYSTEMDESCRIPTIONDigital Multimeter (DMM)4PXIe-4081 DMM (DC current, DC voltage, resistance)Source Measurement Unit (SMU)4PXIe-4139 1-ch, 60 V, 3 AProgrammable Power Supply (PSU)4PXIe-4112 2-ch, 60 V, 1 AScope2PXIe-5105 8-ch, 60 MHz, 12-bit, 15 VAnalog Input (AI)4PXIe-4310 8-ch isolated, 400 kS/s/ch, 60 VFunction Generator2PXIe-5413 2-ch, 20 MHz, 16-bit, 24 VppAnalog Output (AO)8PXIe-4322 8-ch isolated, 250 kS/s/ch, 16 VDigital Input (DI)1PXI-6515 32-ch sink/source, 30 VDC, bank-isolatedDigital Output (DO)1PXI-6515 32-ch sink, 30 VDC, bank-isolatedRelay1PXI-2564 16-ch, 5 A and PXI-2520 80-ch, 2 A SPST relay

ECU Test System11Switch Load and Signal ConditioningNI Switch Load and Signal Conditioning (SLSC) hardware extends the PXI platform with front-end modules for load switching andmanagement. With standardized connectivity and form factor, it eliminates the fault-prone process of point-to-point wiring, simplifyingthe overall system by handling small to medium loads on a simple circuit card. The ECUTS leverages the SLSC hardware below, whichenables larger switches for fault insertion, adds custom signal conditioning, and reduces signal routing complexity.SLSC-1200112-SLOT, 650 W DISSIPATIONSLSC MAINFRAMEINSTRUMENTSLSC-1225116-CH, 100 V/8 A FETFIU WITH CURRENT SENSESLSC-122528-CH, 100 V/30 A FETFIU WITH CURRENT SENSEDESCRIPTIONChassis for SLSCSLSC-1200112-slot chassis provides power, active cooling, triggering, and a communication interfaceto SLSC modules8 A Fault Insertion Unit (FIU)SLSC-12251Provides 16 channels for 8 A continuous RMS maximum current for load switch routes withcurrent measurement30 A Fault Insertion Unit (FIU)SLSC-12252Provides 8 channels for 30 A continuous RMS maximum current for load switch routes withcurrent measurementThe SLSC-12251/2 can present the DUT with the following errors: open circuit, pin shorted to two different potentials (for example, Vbatt orGND), and short to another pin. These modules provide current sensing on each channel when coupled with a measurement module in adata acquisition system. This functionality can be used to measure current profiles; for example, measuring the profile of a solenoid injector.

ECU Test System12Mass InterconnectNI partnered with the Virginia Panel Corporation(VPC) to provide a mass interconnect that enablesrapid system changeover through a standardizedapproach that minimizes downtime and reducesmaintenance with reliable long-term operation.This mass interconnect receiver arrangement isstandardized across all ECU Test Systems, whichallows for easy pin testing with the Field DiagnosticTester (FDT). The layout was designed to avoidcable crossovers with symmetry, keep cables asstraight as possible, and leave blank spaces forfuture expansion or customization.Both the VPC 9025 position modular massinterconnect and VPC 9025TR (tray option) areavailable with the ECUTS.FIGURE 06Mass Interconnect Example PinoutFIGURE 07VPC 9025 TR with Fixture and DUTsDC Power SuppliesThe ECUTS includes options to include 2U, 1/6 rack-width, single-channel, and rack mount DC programmable power supplies. Based on yourrequirements, you can choose options such as:RMX-4101 comes in four versions and offers up to 216 W of power with options that support up to 100 VDC or 10 A.RMX-4102 offers up to 432 W of power with options that support up to 100 VDC or 20 A.RMX-4101 (20 V VERSION)1-CH, 20 V/10 A/200 WDC POWER SUPPLYRMX-4101 (36 V VERSION)1-CH, 36 V/12 A/400 WDC POWER SUPPLYRMX-4101 (60 V VERSION)1-CH, 60 V/3.5 A/200 WDC POWER SUPPLYRMX-41021-CH, 20 V/20 A/400 WDC POWER SUPPLY

ECU Test System13Electronic LoadsBuilt for automated test and measurement, electronic loaddevices can sink power at various current and voltage levels forpower supply design, quality inspection, and functional tests.Their modular design and multiple operating modes help themsimulate the real load that a power source handles in its actualapplication. They also feature buttons and knobs for interactiveRMX-40024-SLOT ELECTRONIC LOADMAINFRAMELOAD MODULE MODELuse, as well as USB or RS232 interface options for automation.You can connect multiple loads in parallel to increase yoursystem’s overall power capacity.Instead of the RMX electronic loads, you can also choose touse an external load box with dimensions 5U (200 mm) height,530 mm depth, and 480 mm width.RMX-40032-CH, 80 V/20 A/100 WELECTRONIC LOADRMX-40051-CH, 80 V/70 A/350 WELECTRONIC LOADCHANNELSMAX. POWERMAX. VOLTAGEMAX. CURRENTRMX-40032100 W/100 W80 V/80 V20 A/20 ARMX-40051350 W80 V70 ATopology OptionsThere are several topology options you can select for testingDUTs in parallel based on your desired throughput, DUTcomplexity, and budget requirements.A NEST refers to the place a DUT connects to a test fixture; eachNEST has dedicated instrumentation and test pins for paralleltest execution. One NEST can hold several DUTs, and those DUTswill share instrumentation. Parallel testing can result in a 10–40percent reduction in test time compared to previous testers.NEST 1NEST 2NEST 1NEST 2NEST 3NEST 4NEST 3NEST 44 NESTs with 2 DUTs EachFIGURE 08Selection of ECUTS Topology Options4 NESTs with 1 DUT EachNEST 1NEST 22 NESTs with 2 DUTs Each

ECU Test System144-NEST2-NESTSingle NESTFlashDMM or SMU—1ch2-wire 2 A Matrix—1 module400 W PS—1 supply200 W PS—4 supplies350 W eLoad—1 moduleCAN/LIN—up to 12 ports8 A Load Switch—16chRS232—8 ports30 A Load Switch—8chDIO—32ch In, 32ch OutScope or Isolated AI—8chSPST Relay—16ch, 5AIsolated AO—8chDMM or SMU—1chDMM or SMU—2ch2-wire 2 A Matrix—2 modules2-wire 2 A Matrix—1 module400 W Power Supply—2 supplies400 W PS—1 supply350 W eLoad—2 modules350 W eLoad—1 module8 A Load Switch—16ch8 A Load Switch—8ch30 A Load Switch—8chScope or Isolated AI—8ch Single NESTIsolated AO—8ch 2-NEST FlashFIGURE 09Example Hardware Configurations for Different TopologiesSimplified Hardware MaintenanceBecause system uptime and reliability are essential in aproduction test environment, the ECUTS includes optionsto simplify servicing and maintenance: the ECU Test SystemMaintenance Software (included in the ECUTS Software Suite)and the Field Diagnostics Tester (optional hardware add-on)for automated pin continuity checking. With these tools, if justone pin breaks in this complex system, it can be identified inminutes rather than hours.FIGURE 08Exterior View of a Field Diagnostics Tester

ECU Test SystemField Diagnostic TesterYou have the option of including a FieldDiagnostics Tester (FDT) with the ECUTSfor higher maintenance and serviceabilityof the system. This tool performscontinuity testing to the mass terminationand is housed in the 15-inch deep ITAenclosure compatible with the VPC 9025rack-mount receiver. Diagnostics testsare performed using the ECU Test SystemMaintenance Software. Because the massinterconnect layout is standard on allECU Test Systems, one FDT can servicemultiple test systems.Note: The FDT works only for pre-definedslots and pins. It does not cover open slots(J3, J11, J13, J15, J17, and J25).When paired with an FDT, the ECU TestSystem Maintenance Software providesa report of components expected in thesystem and performs a continuity checkon all pre-defined slots and pins.15ECU Test System Maintenance Software ReportGENERAL INFORMATIONReport start date and time (YYYY-MM-DD, hh:mm)2020-04-20, 04:28Report end date and time (YYYY-MM-DD, hh:mm)2020-04-20, 04:32Model NameECUTS-16000Configuration NameHard namePart NumberHard numberSerial Number1EC91E9System Configuration Verification SummaryComponents Expected and FoundMODEL NAMERESOURCE NAME, ALIAS,OR OTHER UNIQUE IDNI PXIe-8861PART NUMBERLOCATION WITHIN SYSTEM200519A-01PXIChassis1, Slot 1TRC-8543CAN1200429A-01PXIChassis1, Slot 18, Port 1NI PXIe-8510CAN1, CAN2, CAN3,CAN4, LIN5, LIN6200414A-01PXIChassis1, Slot 18TRC-8543CAN2200429A-01PXIChassis1, Slot 18, Port 2TRC-8543CAN3200429A-01PXIChassis1, Slot 18, Port 3TRC-8543CAN4200429A-01PXIChassis1, Slot 18, Port 4TRC-8543CAN7200429A-01PXIChassis1, Slot 17, Port 1NI PXIe-8510CAN7, CAN8, CAN9,CAN10, LIN11, LIN12200414A-01PXIChassis1, Slot 17TRC-8543CAN8200429A-01PXIChassis1, Slot 17, Port 2TRC-8543CAN9200429A-01PXIChassis1, Slot 17, Port 3TRC-8543CAN10200429A-01PXIChassis1, Slot 17, Port 4NI PXIe-6375FIU MIO 1200427A-01PXIChassis1, Slot 13NI PXIe-6363(MassTermination)FIU MIO 2200513A-01N/AFIGURE 11Example First Page of an ECUTS Maintenance Report

ECU Test System16Services and SupportYou expect NI systems to help you solve some of the most challenging engineering problems; expect the same levelof capability in our services. With every ECU Test System (ECUTS) deployment, we partner with you to determine thelevel of service that best meets your application needs and ensures long-term success.Receive Basic Support: Obtain peace of mind through support from ECUTS experts to accompany your in-housemaintenance operations. One year of our Basic Service Program is included with every ECUTS.Maximize Production Uptime: Maximize uptime of your ECUTS with faster turnaround times from NI when hardwarefails or expert support is needed. NI has the global infrastructure and resources to help you manage a tiered sparingmodel across your ECUTS installed base. We provide flexible service options from a regional inventory of spares thatcan be delivered in less than 24 hours to an on-site spares inventory.Optimize Tester Performance: With more than 10 years’ experience calibrating PXI instruments and more than20 years working with calibrating precision instrumentation, we’re well equipped to provide on-site and laboratorycalibration options that meet your needs.Maximize Efficiency: To help you quickly develop and deploy testers, NI offers a variety of options for engineeringservices, such as test program development, custom operator interface (OI) development, test cell integration, andtester migration. We also deliver a spectrum of services to help integrate ECUTS into your factory and train yourengineers, technicians, and operators.Achieve Longevity: NI knows every application has different requirements for support and longevity, so we’re committedto providing the life-cycle support you need for your applications. We offer consultative engagements on the life-cyclestatus of products, recommended updates, and planning related to sustaining engineering.ECU Test System Service OfferingsAvailability of service programs varies by region. Contact your account manager for more information.BASICSoftware SupportFULLAccess to SW UpdatesAccess to SW Updates3–5 Days Replacement 24 Hour ReplacementTechnical Support 8x5Technical Support 8x5CUSTOMAccess updates and bug fixesRepair and ReplacementMinimize downtimeTechnical SupportResolve issues quicklyField and Remote ServicesTroubleshooting and SupportFixed maintenance costLife-Cycle ManagementMitigate obsolescence riskTrainingIncrease productivityStandard ProductNotificationsStandard ProductNotificationsOnline Operator andMaintenance TrainingOnline Operator andMaintenance TrainingScope to be defined tailoredto your specific needs anddeployment goals

ECU Test System17Additional Services AvailableCalibrationLaboratory CalibrationQuality measurementsand traceabilityOn-site CalibrationBring-Up AssistanceOn-site or Remote Tester Bring-UpCalibration ReplacementHassle-free commissioningTrainingReduce development timeInstructor-Led, On-Site and/or Customized Training Operator and/or Maintenance TrainingTest Engineer TrainingProfessional ServicesIntegration Engineering ServicesMethodology Consulting ServicesResident Engineering ServicesCalibration Levels OfferedCALIBRATION STANDARDSNI CALIBRATION LEVELINDUSTRY REQUIREMENTSTYPICAL INDUSTRIESNo Industry Standard(ISO 9001 umbrellamay be used)TraceableVerification and adjustment of measurementperformance using calibration procedures andmeasurement standards traceable to SI units (NISTtraceable). Includes “As Found” and “As Left” data.AllISO/IEC 17025AccreditedTraceable calibration level plus detailedmeasurement uncertainty for each test point.Includes the official logo of the accreditationbody Performed at an ISO ve IATF16949), MedicalANSI/NCSLI Z540.1-1994CompliantTraceable calibration level plus a measurementuncertainty evaluation; identify test points whereratio is less than specified (NI uses 4:1 ratio).Defense, AerospaceNI Traceable and Compliant calibrations are performed in an ISO 17025 Lab even though it’s not required. NI Calibration Labs areaccredited by A2LA. (NI China Calibration Lab accreditation in progress.) NI-manufactured products that do not have accredited serviceavailability can be covered under IATF 16949 for a specific customer in some cases.Methodology Consulting ServicesWith more than 40 years’ test experience, NI is an expert in test-related processes and strategies. We provide a framework to help youevaluate your people, processes, and technology to recommend a test strategy appropriately customized to your business. Let’s worktogether to solidify a business case that articulates your future state and expected program ROI to secure the funding you need.Planning and project management consulting helps build a project execution plan that keeps teams on track to achieve major developmentmilestones. Together, we can help you establish priorities, identify the right resources, and make trade-offs to optimize cost withoutputting projects at risk.Integration Engineering ServicesWith global solution centers and engineers in more than 40 countries supported by more than 900 NI Partner companies, NI offersdesign and development assistance in every region and industry. Our engineers help you mitigate risk, develop faster, and reduce coststhrough project management, architecture development, and system documentation to deliver an integrated solution.

ECU Test System18Education ServicesNI Education Services helps ensure testcustomers realize the full potential of NI systemsand end users achieve personal success. Ourtraining curriculum is available in a variety offormats—including virtual classrooms andprivate on-site events—and is designed by roleand by task so users can quickly obtain theknowledge and skills they need.System CompletionInterested in a turnkey solution? Contact yourNI sales manager to learn about various optionsfor second-level integration provided by ourIntegration Engineering Services or an NI Partner.Options include test program development,custom operator interface development, testfixture development, production line integration,tester migration, and ainingYour Solu

ECU Test System 04 The Solution The ECU Test System (ECUTS) is a functional tester for end-of-line (EOL) test of automotive ECUs built on NI's adaptive, open technology. Our systems R&D engineers have integrated the following core components into this system, so you can focus your energy on implementing your test plan.