Keysight TS-5020 Wiring Manual And Hardware Reference

Keysight TS-5020 Automotive Electronics Functional Test System

Wiring Guide And
Hardware Reference

Notices

© Keysight Technologies 2006 - 2015

No part of this manual may be reproduced
in any form or by any means (including
electronic storage and retrieval or transla­tion into a foreign language) without prior
agreement and written consent from Key­sight Technologies as governed by United
States and international copyright laws.

Manual Part Number

E2240-90001

Edition

Edition 4, March 2015

Printed in Malaysia
Keysight Technologies Microwave Products
(Malaysia) Sdn. Bhd.
Bayan Lepas Free Industrial Zone
11900 Penang, Malaysia

Technical Assistance

You can find information about technical
and professional services, product support,
and equipment repair and service on the
Web:

http://www.keysight.com/con­tacts/English/noscript.html

Double-click the link to Tes t & Me a s u r e -
ment. Select your country from the
drop-down menus. The Web page that
appears next has contact information spe­cific for your country.

If you do not have access to the Internet,
call one of the numbers in Ta b l e 1.

Tab l e 1 Keysight Call Centers

United States
and Canada:

Europe: (41 22) 780 8111

Japan: Measurement

Latin America: 305 269 7548

Asia-Pacific: (85 22) 599 7777

United States
and Canada:

Te s t a n d
Measurement Call
Center
[phone]
(toll-free in US)

Assistance Center
(81) 0426 56 7832

Te s t a n d
Measurement Call
Center
[phone]
(toll-free in US)

Contents

1 Legal Information

Legal Information 1-2

Warranty 1-2
Technology Licenses 1-2
Restricted Rights Legend 1-2
Service And Support 1-3
Keysight On The Web 1-3
Keysight By Phone 1-3

2 Safety and Regulatory Information

Safety Information 2-2

Safety Summary 2-2
Safety Notice 2-2
General 2-2
Environmental Conditions 2-3
Before Applying Power 2-3
Ground The System 2-4
Fuses 2-4
Operator Safety Information 2-4
Safety Symbols and Regulatory Markings 2-5

Electrostatic Discharge (ESD) Precautions 2-7

End of Life: Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/EC 2-8

3 System Overview

System Intended Use 3-2

Instructions For Use 3-2

Test System Specifications and Capabilities 3-3

Test Capabilities – Measurement Sample Methods 3-4

System Capability DC Accuracy Sample 3-4

Test System Interface Description 3-6

Test System Interface Connectors 3-6
Rack Layout with Express Connect Test System Interface 3-28
Rack Layout with L2000 (TITAN) Test System Interface 3-29
System Block Diagrams with Express Connect Test System Interface 3-30
System Block Diagrams with L2000 (TITAN) Test System Interface 3-31

The Keysight 34980A Multifunction Switch/Measure Unit 3-32

Slot Allocation of the 34980A 3-32

TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference iii

PC Cards 3-36

Keysight 53131 Universal Counter 3-36

Keysight 53220 Universal Counter 3-36

Keysight 33220 Function/Arbitrary Waveform Generator 3-37

Power Supplies 3-37

Keysight N6700 MPS 3-37
Channel Names 3-38

4 System Interconnects

System Interconnects for Express Connect Interface 4-2

Connector Keying 4-2
Connectors and Tools 4-3
Connecting Wiring to Test Connectors TC1- TC8 4-3
Crimping Wires to Contacts 4-4
Inserting Contacts and Assembling the Connectors 4-5
Connecting To The Test System Interface 4-6
ESD Protection Measures 4-7
Test Connector Signal Definitions 4-9
General TC Pins Assignment 4-13
Express Connect PCA Connector Definition and Pin Access 4-15
High-Power Connector 4-21

System Interconnect for Mac Panel Interface 4-23

L2000 (TITAN) Connectors and Tools 4-23

5 Test System Interface Cables

U8970-61702 Dual Banana Metric Cable for GPIB/LXI DMM 5-3
U8970-61701 Cable BNC Coax to 3x1 (Non-Isolated) 5-3
U8970-61700 Cable Isolated Instrument BNC 5-3

Cables For Express Connect Interface 5-4

E6170-61623 Twinax DMM To Inst Matrix Cable 5-4
E6170-61626 DIO And Utility Power Supply To ICA Cable 5-4
E6170-61627 DMM Trig 34980 To ICA 5-6
E6170-61628 DAC 34951 To ICA Cable 5-6
E6170-61629 GP Relay 34938A And Power Supply To ICA Cable 5-8
E6170-61620 General Purpose 96-96 DINC Cable 5-10
E6170-61621 48 Channel Load Card Express Connect Cable 5-10
E6170-61630 CAN PCI To ICA Cable 5-11
E6170-61605 Cable for 8-CH/16-CH/24-CH Load Card to Express Connect 5-12
E6230-61603 Cable for 8-CH Heavy Duty Load Card to Express Connect 5-13

Cables For L2000 (TITAN) Interface 5-14

iv TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference

E6218-61601 Cable, One Matrix (34933A) to L2000 (TITAN) 5-14
E6218-61614 CABLE, E6175A TO L2000 (TITAN) 5-15
E6218-61615 CABLE, E6176A TO L2000 (TITAN) 5-15
E6218-61620 CABLE, N9379A TO L2000 (TITAN) 5-16
E6218-61621 CABLE, 34951-DAC TO L2000 (TITAN) 5-17
E6218-61622 CABLE, 34980-DMM (TRIG) TO L2000 (TITAN) 5-17
E6218-61624 CABLE, E6178B TO L2000 (TITAN) 5-18
E6218-61625 CABLE, ONE U7177A TO L2000 (TITAN) 5-19
E6218-61627 CABLE, DIO TO L2000 (TITAN) 5-20
E6218-61628 CABLE, PS TO L2000 (TITAN) (MED CURRENT) 5-20
E6218-61629 CABLE, 34938 TO L2000 (TITAN) 5-21
E6218-61630 CABLE, CAN TO L2000 (TITAN) 5-21
E2240-61621 Cable, 34934A to ICA (TITAN) 5-22
E2240-61622 Cable, 34939A to ICA (TITAN) 5-23
E2240-61623 Cable, Electronic Load to ICA (TITAN) 5-24
E2240-61626 Cable, System Resources E6198B and PCI DIO 1750 5-25
E6218-61619 Cable, System Resources To L2000 (TITAN) 5-26

E6218-61626 CABLE, Dual 24-CH Load Card To L2000 (TITAN) 5-27

6 Replaceable And Spare Parts

Keysight E2230A Replaceable Parts 6-2

Keysight E2240A Recommended Spare Parts for Express Connect 6-4

Keysight E2240A Recommended Spare Parts for L2000 (TITAN) 6-5

TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference v

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vi TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference

List of Figures

1 Legal Information

2 Safety and Regulatory Information

3 System Overview

Figure 3-1. Express Connect Test System Interface TC1 Through TC4 3-7
Figure 3-2. Express Connect Test system Interface TC1 Through TC8 3-8
Figure 3-3. Macpanel L2000 (TITAN) Test System Interface 3-10
Figure 3-4. Typical TS-5020 System Rack with Express Connect Layout 3-28
Figure 3-5. Typical TS-5020 System with L2000 (TITAN) test interface 3-29
Figure 3-6. TS-5020 Simplified System with Express Connect Block Diagram 3-30
Figure 3-7. TS-5020 Simplified System with L2000 (TITAN) Block Diagram 3-31
Figure 3-8. Rear View Of 34980A Multifunction Switch / Measure Unit 3-32
Figure 3-9. Cut-out View of Slot 4 with Terminal Card To Create Instument/Pin

Figure 3-10. Multiple 34933A configured as Instrumentation and Pin Matrix 3-34
Figure 3-11. Multiple 34934A configured as Instrumentation and Pin Matrix 3-35

Matrix 3-33

4 System Interconnects

Figure 4-1. TC1-TC4 Connector Keying 4-2
Figure 4-2. TC1-TC8 Connector Key Configuration 4-2
Figure 4-3. Crimping Wires to Contacts 4-4
Figure 4-4. Assembling TC1 to TC4 4-5
Figure 4-5. Connecting To The Test System Interface 4-6
Figure 4-6. Adding A Grounding Strap To Reduce ESD 4-7
Figure 4-7. Wrist Strap ESD Connector 4-8
Figure 4-8. Removing A Test Connector Contact 4-8
Figure 4-9. TC1 Pinouts 4-11
Figure 4-10. TC2 Pinouts 4-12
Figure 4-11. TCn Pin Assignments 4-13
Figure 4-12. TCn+1 Pin Assignments 4-14
Figure 4-13. PCA Layout For Full Profile Express Connect (For TC1-TC8 Use) 4-15
Figure 4-14. View of Full Profile Express Connect PC Assembly (2 of 4 possible PC

Assembly shown) 4-16
Figure 4-15. PCA Layout For Low Profile Express Connect (For TC1-TC4 Use) 4-17
Figure 4-16. TS-5020 System Connector (J6 or J60) TC1 and TC2 Assignments 4-18
Figure 4-17. TS-5020 System Connector (J6 or J60) TCn Assignments 4-19
Figure 4-18. TS-5020 Configuration Connector (J7 or J40) 4-20
Figure 4-20. Recommended System Grounding 4-22

TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference vii

5 Test System Interface Cables

Figure 5-1. U8970-61702 (Dual Banana Metric Cable) 5-3
Figure 5-2. U8970-61701 (Cable BNC Coax to 3x1) 5-3
Figure 5-3. U8970-61700 (Cable Isolated Instrument BNC) 5-3
Figure 5-4. E6170-61623 Twinax DMM To Inst Matrix Cable 5-4
Figure 5-5. E6170-61626 DIO And Utility Power Supply To ICA Cable 5-4
Figure 5-6. E6170-61627 DMM Trig 34980 To ICA 5-6
Figure 5-7. E6170-61628 DAC 34951 To ICA Cable 5-6
Figure 5-8. E6170-61629 Cable 5-8
Figure 5-9. E6170-61620 General Purpose 96-96 DINC Cable 5-10
Figure 5-10. E6170-61621 48 Channel Load Card Express Connect Cable 5-10
Figure 5-11. E6170-61630 CAN PCI To ICA Cable 5-11
Figure 5-12. E6170-61605 Cable for Load card to Express Connect. This cable can be used

for E6175A, N9377A, E6176A, E6177A, U7177A and N9378A. 5-12
Figure 5-13. Cable for E6178B 8-CH Heavy duty Load card to Express Connect 5-13
Figure 5-14. E6218-61601 Cable, One Matrix (34933A) to L2000 (TITAN) 5-14
Figure 5-15. E6218-61614 CABLE, E6175A TO L2000 (TITAN) 5-15
Figure 5-16. E6218-61615 Cable, E6176A to L2000. This cable is used for E6176A and

N9377A 5-15
Figure 5-17. E6218-61620 CABLE, N9379A TO L2000 (TITAN) 5-16
Figure 5-18. E6218-61621 CABLE, 34951-DAC TO L2000 (TITAN) 5-17
Figure 5-19. E6218-61622 CABLE, 34980-DMM (TRIG) TO L2000 (TITAN) 5-17
Figure 5-20. E6218-61624 CABLE, E6178B TO L2000 (TITAN) 5-18
Figure 5-21. E6218-61625 Cable, One U7177A to L2000. This cable is used for E6177A,

U7177A and N9378A. 5-19
Figure 5-22. E6218-61627 CABLE, DIO TO L2000 (TITAN) 5-20
Figure 5-23. E6218-61628 CABLE, PS TO L2000 (TITAN) (MED CURRENT) 5-20
Figure 5-24. E6218-61629 CABLE, 34938 TO L2000 (TITAN) 5-21
Figure 5-25. E6218-61630 CABLE, CAN TO L2000 (TITAN) 5-21
Figure 5-26. E2240-61621 Cable, 34934A to ICA (TITAN). One cable requires two TITAN

receiver block. 5-22
Figure 5-27. E2240-61622 Cable, 34934A to ICA (TITAN) 5-23
Figure 5-28. E2240-61623 Cable, Electronic Load to ICA (TITAN). This cable has an in-line

50A fuse. 5-24
Figure 5-29. E2240-61626 Cable, System Resources E6198B and PCI DIO 1750. This cable

combines the system resources cable for E6198B with the cable for PCI DIO

1750. 5-25

Figure 5-30. E6218-61619 Cable, System Resources to L2000 (TITAN). This cable

combines the system resources cable for E6218A with the cable for PCI DIO

1750. 5-26

Figure 5-31. E6218-61626 Cable, Dual 24-CH Load Card to L2000 (TITAN). This cable

combines 2 24-CH load card cable to a single receiver block. 5-27

6 Replaceable And Spare Parts

viii TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference

List of Tables

1 Legal Information

2 Safety and Regulatory Information

3 System Overview

Table 1-1. Keysight Call Centers and Regional Headquarters 1-3

Table 2-1. Environment Requirements 2-3
Table 2-2. Safety Symbols and Regulatory Markings 2-5
Table 2-3. Suggested Anti-Static Solutions for Site Planning 2-7

Table 3-1. Typical TS-5020 Instrumentation 3-3
Table 3-2. L2000 (TITAN) Slot 1 (System) 3-11
Table 3-3. L2000 (TITAN) Slot 2 (Instruments) 3-12
Table 3-4. L2000 (TITAN) Slot 3 (DAC) 3-13
Table 3-5. L2000 (TITAN) Slot 4 (RS232) 3-14
Table 3-6. L2000 (TITAN) Slot 6 (Pin Matrix 1st Card 34933A) 3-15
Table 3-7. L2000 (TITAN) Slot 7 to 9 (Matrix Card 34933A) 3-16
Table 3-8. L2000 (TITAN) Slot 6 (Pin Matrix 1st Card (34934A)) 3-17
Table 3-9. L2000 (TITAN) Slot 7 (Pin Matrix 1st Card (34934A)) 3-18
Table 3-10. L2000 (TITAN) Slot 8/21/23 (Pin Matrix Card (34934A)) 3-19
Table 3-11. L2000 (TITAN) Slot 9/22/24 (Pin Matrix Card (34934A)) 3-20
Table 3-12. L2000 (TITAN) Slot 12 to 15 (GP relay Card (34938A)) 3-21
Table 3-13. L2000 (TITAN) Slot 12 to 15 (GP relay Card (34939A)) 3-22
Table 3-14. L2000 (TITAN) Slot 11 to 20 (24-CH Load Card) 3-23
Table 3-15. L2000 (TITAN) Slot 13 to 20 (16-CH Load Card) 3-24
Table 3-16. L2000 (TITAN) Slot 13 to 20 (48-CH Load Card) 3-25
Table 3-17. L2000 (TITAN) Slot 13 to 20 (8-CH Load Card) 3-26
Table 3-18. L2000 (TITAN) Slot 16 & 18(Heavy Duty Load Card & Electronic Load) 3-27
Table 3-19. L2000 (TITAN) Slot 25 (RF) 3-27

4 System Interconnects

Table 4-1. TCx Signal Definitions 4-9

5 Test System Interface Cables

Table 5-1. E6170-61626 Cable Pinout Table 5-5
Table 5-2. E6170-61628 Cable Pinout Table 5-7
Table 5-3. E6170-61629 Cable Pinout Table 5-9

6 Replaceable And Spare Parts

TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference ix

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x TS-5020 Automotive Electronics Functional Test System

1 Legal Information

Warranty .... 1-2

Technology Licenses .... 1-2

Restricted Rights Legend .... 1-2

Service And Support .... 1-3

Keysight On The Web .... 1-3

Keysight By Phone .... 1-3

1 Legal Information

Legal Information

Warranty

The material contained in this document is provided “as is,” and
is subject to being changed, without notice, in future editions.
Further, to the maximum extent permitted by applicable law,
Keysight disclaims all warranties, either express or implied,
with regard to this manual and any information contained
herein, including but not limited to the implied warranties of
merchantability and fitness for a particular purpose. Keysight
shall not be liable for errors or for incidental or consequential
damages in connection with the furnishing, use, or performance
of this document or of any information contained herein.
Should Keysight and the user have a separate written
agreement with warranty terms covering the material in this
document that conflict with these terms, the warranty terms in
the separate agreement shall control.

Technology Licenses

The hardware and/or software described in this document are
furnished under a license and may be used or copied only in
accordance with the terms of such license.

Restricted Rights Legend

If software is for use in the performance of a U.S. Government
prime contract or subcontract, Software is delivered and
licensed as “Commercial computer software” as defined in
DFAR 252.227-7014 (June 1995), or as a “commercial item” as
defined in FAR 2.101(a) or as “Restricted computer software” as
defined in FAR 52.227-19 (June 1987) or any equivalent agency
regulation or contract clause. Use, duplication or disclosure of
Software is subject to Keysight Technologies’ standard
commercial license terms, and non-DOD Departments and
Agencies of the U.S. Government will receive no greater than
Restricted Rights as defined in FAR 52.227-19(c)(1-2)(June

1987). U.S. Government users will receive no greater than
Limited Rights as defined in FAR 52.227-14 (June 1987) or
DFAR 252.227-7015 (b)(2)(November 1995), as applicable in any
technical data.

1-2 TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference

Service And Support

Keysight On The Web

Keysight By Phone

Legal Information 1

Any adjustment, maintenance, or repair of this product must be
performed by qualified personnel. Contact your customer
engineer through your local Keysight Technologies Service
Center.

You can find information about technical and professional
services, product support, and equipment repair and service on
the Web:

Double-click the link to Test & Measurement. Select your country
from the drop-down menus. The Web page that appears next has
contact information specific for your country

http://www.keysight.com/

If you do not have access to the Internet, call one of the
numbers in

Table 1-1 Keysight Call Centers and Regional Headquarters

United States and Canada: Test and Measurement Call Center

Europe: (41 22) 780 8111

Japan: Measurement Assistance Center

Latin America: 305 269 7548

Asia-Pacific: (85 22) 599 7777

Table 1-1.

[phone] (toll-free in US)

(81) 0426 56 7832

Manufacturing Address

Keysight Technologies Microwave Products (Malaysia) Sdn. Bhd.

Bayan Lepas Free Industrial Zone,

11900 Penang,

Malaysia.

TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference 1-3

1 Legal Information

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1-4 TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference

2 Safety and Regulatory Information

Safety Information .... 2-2

Safety Summary .... 2-2

Safety Notice .... 2-2

General .... 2-2

Environmental Conditions .... 2-3

Before Applying Power .... 2-3

Ground The System .... 2-4

Fuses .... 2-4

Operator Safety Information .... 2-4

Safety Symbols and Regulatory Markings .... 2-5

Electrostatic Discharge (ESD) Precautions .... 2-7

End of Life: Waste Electrical and Electronic Equipment (WEEE)

Directive 2002/96/EC .... 2-8

2 Safety and Regulatory Information

CAUTION

WARNING

WARNING

Safety Information

Safety Summary

Safety Notice

The following general safety precautions must be observed
during all phases of operation of this instrument. Failure to
comply with these precautions or with specific warnings
elsewhere in this manual violates safety standards of design,
manufacture, and intended use of the instrument. Keysight
Technologies assumes no liability for the customer's failure to
comply with these requirements.

A CAUTION notice denotes a hazard. It calls attention to an
operating procedure, practice, or the like, that, if not correctly
performed or adhered to, could result in damage to the product or
loss of important data. Do not proceed beyond a CAUTION notice
until the indicated conditions are fully understood and met.

A WARNING notice denotes a hazard. It calls attention to an operating
procedure, practice, or the like that, if not correctly performed or
adhered to, could result in personal injury or death. Do not proceed
beyond a WARNING notice until the indicated conditions are fully
understood and met.

General

This product is provided with a protective earth terminal. The
protective features of this product may be impaired if it is used
in a manner not specified in the operation instructions.

DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE. Do not operate the
product in the presence of flammable gases or flames.

2-2 TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference

WARNING

DO NOT REMOVE RACK PANELS OR INSTRUMENT COVERS. Operating

WARNING

°

°

CAUTION

personnel must not remove any rack panels or instrument covers.
Component replacement and internal adjustments must be made only
by qualified service personnel. Products that appear damaged or
defective should be made inoperative and secured against unintended
operation until they can be repaired by a qualified service personnel.

The protection provided by the TS-5020 system may be impaired if
the system is used in a manner not specified by Keysight.

Environmental Conditions

Safety and Regulatory Information 2

The TS-5020 Automotive Electronics Functional Test System is
designed for indoor use only.
mental requirements.

Table 2-1 Environment Requirements

Environment Conditions Requirements

Maximum Altitude 2000 meters

Temperature (Operation) 5 C to 40 C

Maximum Relative Humidity The test system is designed to operate

This product is designed for use in Installation Category II and
Pollution Degree 2, per IEC 61010-1 and 664 respectively.

Before Applying Power

Table 2-1 shows general environ-

in the range from 5% to 80% relative
humidity (non-condensing).

Verify that the product is set to match the available line voltage
and all safety precautions are taken. Note the external markings
of the instruments described in

Regulatory Markings”.

TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference 2-3

“Safety Symbols and

2 Safety and Regulatory Information

WARNING

WARNING

WARNING

Ground The System

Fuses

To minimize shock hazard, the instrument chassis and cover
must be connected to an electrical protective earth ground. The
instrument must be connected to the ac power mains through a
grounded power cable, with the ground wire firmly connected
to an electrical ground (safety ground) at the power outlet. Any
interruption of the protective (grounding) conductor or
disconnection of the protective earth terminal will cause a
potential shock hazard that could result in personal injury.

Use only fuses with the required rated current, voltage, and
specified type (normal blow, time delay). Do not use repaired
fuses or short-circuited fuse holders. To do so could cause a
shock or fire hazard.

In order to avoid electrical hazards, all system internal fuses must
be replaced by trained and qualified personnel.

Operator Safety Information

Module connectors and Test Signal cables connected to them
cannot be operator accessible.

M

Cables and connectors are considered inaccessible if a tool (e.g.
screwdriver, wrench, socket, etc.) or a key (equipment in a
locked cabinet) is required to gain access to a conductive
surface connected to any cable conductor (High, Low or Guard).

Assure the equipment under test has adequate insulation
between the cable connections and any operator-accessible parts
(doors, covers, panels shields, cases, cabinets, etc.)

Verify there are multiple and sufficient protective means (rated
for the voltages you are applying) to assure the operator will
NOT come into contact with any energized conductor even if
one of the protective means fails to work as intended. For

2-4 TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference

Safety symbols

Safety and Regulatory Information 2

example, the inner side of a case, cabinet, door cover or panel
can be covered with an insulating material as well as routing the
test cables to the front panel connectors of the module through
non-conductive, flexible conduit such as that used in electrical
power distribution.

Safety Symbols and Regulatory Markings

Symbols and markings on the system, in manuals and on
instruments alert you to potential risks, provide information
about conditions, and comply with international regulations.

Table 2-2 defines the symbols and markings you may find in a

manual or on an instrument.

Table 2-2 Safety Symbols and Regulatory Markings

Warning: risk of electric shock.

Warning: hot surface

Caution: refer to accompanying documents.

Laser radiation symbol: marked on products that have a laser output.

Alternating current.

Both direct and alternating current.

Three-phase alternating current.

Earth (ground) terminal

Protective earth (ground) terminal

Frame or chassis terminal

Terminal is at earth potential. Used for measurement and control circuits designed to be operated
with one terminal at earth potential.

Terminal for neutral conductor on permanently installed equipment.

TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference 2-5

2 Safety and Regulatory Information

Safety symbols

Terminal for line conductor on permanently installed equipment.

Standby (supply); units with this symbol are not completely disconnected from ac mains when this
switch is off. To completely disconnect the unit from ac mains, either disconnect the power cord, or
have a qualified electrician install an external switch.

Regulatory markings

This text indicates that the ISM device complies with Canadian ICES-001.

Cet appareil ISM est conforme à la norme NMB-001 du Canada.

The CSA mark is a registered trademark of the Canadian Standards Association. A CSA mark with
the indicators “C” and “US” means that the product is certified for both the U.S. and Canadian
markets, to the applicable American and Canadian standards.

The C-tick mark is a registered trademark of the Spectrum Management Agency of Australia. This
signifies compliance with the Australia EMC Framework regulations under the terms of the Radio
Communication Act of 1992.

This instrument complies with the WEEE Directive (2002/96/EC) marking requirement. This affixed
product label indicates that you must not discard this electrical/electronic product in domestic
householdwaste.

The CE mark is a registered trademark of the European Community. This CE mark shows that the
product complies with all the relevant European Legal Directives.

2-6 TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference

Electrostatic Discharge (ESD) Precautions

CAUTION

Static electricity is destructive to your production process and
the TS-5020. Careless handling and poor site planning can cause
system reliability problems and reduce your product yield. The
system may not be as easily damaged as the modules you will be
testing, but good anti-static planning will help ensure high
reliability.

The ESD symbol below indicates areas where ESD caution must
be exercised. This is to prevent damage to instruments and/or
test disruption.

ESD Symbol

Caution: Static Sensitive.

Electrostatic discharge in this area may cause equipment damage or
test disruption.

Safety and Regulatory Information 2

While not an exhaustive list of anti-static precautions, Table 2-3
shows suggestions to consider as you plan your system area:

Table 2-3 Suggested Anti-Static Solutions for Site Planning

Precaution Suggested Solution

Anti-static flooring Plan to use an anti-static floor

covering or mats.

Grounding straps Plan for foot straps in conjunction

with anti-static flooring and wrist
straps for system operators.

The system test rack is secured to the pallet of the shipping crate
and wrapped with a plastic wrap. Do not move the crate or the test
rack and pallet to a static sensitive area until you have removed the
plastic wrap from the test rack.

TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference 2-7

2 Safety and Regulatory Information

End of Life: Waste Electrical and Electronic Equipment (WEEE) Directive 2002/96/EC

This product complies with the WEEE Directive (2002/96/EC)
marking requirement. The affixed product label (see below)
indicates that you must not discard this electrical/electronic
product in domestic household waste.

Product Category:

With reference to the equipment types in the WEEE directive
Annex 1, this product is classified as a “Monitoring and Control
Instrumentation” product.

Do not dispose in domestic household waste

To return unwanted products, contact your local Keysight
office, or see:

http://www.keysight.com/environment/product

for more information.

2-8 TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference

3 System Overview

System Intended Use .... 3-2

Instructions For Use .... 3-2

Test System Specifications and Capabilities .... 3-3

Test Capabilities – Measurement Sample Methods .... 3-4

System Capability DC Accuracy Sample .... 3-4

Test System Interface Description .... 3-6

Test System Interface Connectors .... 3-6

Rack Layout with Express Connect Test System Interface .... 3-28

Rack Layout with L2000 (TITAN) Test System Interface .... 3-29

System Block Diagrams with Express Connect Test System Interface ....

3-30

System Block Diagrams with L2000 (TITAN) Test System Interface .... 3-31

The Keysight 34980A Multifunction Switch/Measure Unit .... 3-32

Slot Allocation of the 34980A .... 3-32

PC Cards .... 3-36

Keysight 53131 Universal Counter .... 3-36

Keysight 53220 Universal Counter .... 3-36

Keysight 33220 Function/Arbitrary Waveform Generator .... 3-37

Power Supplies .... 3-37

3 System Overview

WARNING

System Intended Use

Instructions For Use

The Keysight TS-5020 systems are designed to be used in high
volume Electronic Control Modules (ECM) manufacturing sites.
The systems can test ECU’s with 5-80 pins with voltages
0-60Vdc and currents in the 0-30Amp ranges. Typical
applications for TS-5020 system include testing of smart
sensors and ECMs for Antilock-brake, airbag, remote keyless
entry, climate control, sunroof and windows.

The Keysight TS-5020 systems contain all of the
instrumentation needed to test most electronics modules. You
may also add additional instruments and cabling to increase the
test capabilities of the system. The locations of the instruments
and test system interface or mass interconnect are standardized
as much as possible. Because the Keysight TS-5020 Series uses
open system standards, and is configurable by the system
integrator, systems at your site may be different from the
factory configurations.

In the event that additional instrumentation is added that will
shift the center of gravity, a rack stability test must be completed
to verify the stability of the modified rack.

Typical system operation is dependant on the target application. The
system is to be modified by trained personal for the target test module
application. Typically, the test system development process consists of:

• Identify the number of load resources required and assign load

resources

• Identify the number of measurement resources required and assign

measurement resources

• Identify ECM serial interface communications needs and assign

serial resource

• Identify fixture control resources required and assign I/O & power

resources

• Construct test fixture and test system interconnect cabling

required for the specific application

• Develop TXSL based test-plan for specific application

• Develop Software operator user interface for specific application

• Validate and deploy test system to manufacturing site.

3-2 TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference

Test System Specifications and Capabilities

p

g

Ag ilent Technologies Quad 4x8 reed relay switch modu le.

34938A Agilent Technologies 20 Chann el, 5am p form A switch.

34951A Agilent Technologies 4 Channel isolated +/-16V DAC.

Ag ilent Technologies Un iversal Counter

33220A Agilent Technologies 20M hz Function/Arbitrary W aveform Generator

y

N6762A Agilent Technologies Power supply

y

N665xA Agilent Technologies Power supply

Agilent Technologies 21 slot switch/load unit

E6176A Agilent Technologies 16 Ch loadcard

E6178B Agilent Technologies 8 Ch Heavy Duty loadcard

N9377A Agilent Technologies 16 Ch dual load

Ag ilent Technologies 8 Ch low resistance loadca rd

The TS-5020 test system specifications are derived directly from
the specifications of the instrumentation that make up the
system. The overall test system measurement capability is a
combination of the measurement uncertainty as specified by
the individual instrumentation combined with the system
switch paths of the switching sub-systems.

For test system instrumentation specifications &
characteristics, refer directly to the manufacturer
documentation.
may be configured into the system. Refer to the manufacturer
supplied datasheets for detailed specifications.

Table 3-1 Typical TS-5020 Instrumentation

Table 3-1 lists various instrumentations that

System Overview 3

P/N Mfg Descri

34980A A
34933A
34934A Agilent Technologies Quad 4x32 Reed Matrix

34939A Agilent Technologies 64 Channel From A GP Sw itch

53131A
53220A Agilent Technologies 350 MH z Universal Frequency Co un ter /Tim e r

N6752A Agilent Technologie s P o w e r suppl

N664xA Agilent Technologie s P o w e r suppl

E6198B
E6175A Agilent Technologie s 8 C h loa dc ard

E6177A Agilent Technologies 24 Ch loadcard

U7177A Agilent Technologies 24 Ch loadcard with current sense

N9378A
N9379A Agilent Technologie s 4 8 C h high density loadcard

ilent Technologies 8 slot switch /m easu rem ent u nit w / d mm .

tion

TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference 3-3

3 System Overview

Test Capabilities – Measurement Sample Methods

The following test capabilities calculations help you determine
if the Keysight TS-5020 Test System can meet your Electronic
Control Module (ECM) test requirements. The test capabilities
of the Keysight TS-5020 system include the specifications of the
individual instruments used in the test(s) combined with the
offsets in the system environment due to the measurement
paths. The largest contributors to measurement variations are
the instruments and the relays in the paths. The process for
determining system capabilities is:

• Determine the accuracy required to test the ECM. For example, a

particular output driver test measurement requires a measurement
of 12.5 volts ±10 mV.

• Determine the path, including the number of relays, to the DUT

from the based DMM.

• Determine the specification of the instrument from the module

manual specifications section for the particular range which will be
used for the test.

• Calculate the sum of the accuracy uncertainty due to instrument

modules' specifications and system switch paths, and compare it
to accuracy required by the DUT.

System Capability DC Accuracy Sample

relay in the measurement path needs to be included in the algorithm for
calculating the system-level capability. The source voltage of 12.5 volts
is supplied by Power Supply. The 1-year Accuracy vs. Aperture (±(% of
reading + volts)) specification of the Keysight 34980A internal DMM
for dc voltage on the 100-volt range for 16.7/20 milliseconds is

0.0045% + 0.6 millivolt.
The relays for the measurement system route through the 34933 matrix
card, and are all the specified at 50 microvolts offset.

The calculated system capability (accuracy) on the 100-volt range, using

16.7/20 millisecond aperture range, when using the Keysight 34980A
internal DMM within its defined accuracy conditions is:

3-4 TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference

System Overview 3

DMM DC Accuracy + offset

+ relay V offset (DvmHi to abus1)
+ relay V offset (abus1 to Row matrix relay)
+ relay V offset (row matrix relay to abus2)
+ relay V offset (abus2 to DvmLo)

(This equals 4 relay offsets of 50uV each)

Calculated system capability = ±[(0.0045%*12.5 + 0.6 mV) + 4*50uV]

= ±1.36 mV

TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference 3-5

3 System Overview

Test System Interface Description

The Keysight TS-5020 Test System Interface provides a common
connection interface between the test stand and your test
fixture/Unit Under Test (UUT). The Test System Interface
provides flexibility for specific test requirements and is
pre-wired and integrated to test stand equipment,

Test System Interface Connectors

There two types of Test system Interface Connectors;

• Express Connect

• Macpanel L2000 (TITAN)

Express Connect Test System Interface

The Express Connect Test System Interface can contain either
of the following sets of test connectors:

• TC1 through TC4

• TC1 through TC8

Test connectors TC1 to TC4 or TC1 to TC8 provide the majority
of the connections to the UUT.

These connectors are 156-pin, ITT Cannon Zero-Insertion-Force
connectors.

Figure 3-1 and Figure 3-2 show the outline of the connector

sets.

3-6 TS-5020 Automotive Electronics Functional Test System Wiring Guide and Hardware Reference