Danfoss Integrated Automotive Controls User guide
Technical Information
Integrated Automotive Control (AC)
for MP1 and H1P Single Pumps
www.danfoss.com
Technical Information
Integrated Automotive Controls for H1 and MP1 Single Pumps
Revision history Table of revisions
Date Changed Rev
April 2020 Changed document number from 'BC00000213' and 'L1223856' to 'BC152986482596' and
added new model code options
August 2019 Added MP1 pump 0601
May 2017 Major update 0501
May 2014 Size 165 added DA
February 2014 Layout in DITA CMS CA
October 2013 Converted to Danfoss layout BA
January 2013 All frame sizes into one document AA
0703
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Technical Information
Integrated Automotive Controls for H1 and MP1 Single Pumps
Contents
General information
Automotive controls description................................................................................................................................................5
Targeted applications.....................................................................................................................................................................5
Hydrostatic propel methods........................................................................................................................................................ 5
Automotive transport mode...................................................................................................................................................5
Automotive ECO mode.............................................................................................................................................................5
Non-automotive work mode..................................................................................................................................................5
Creep-automotive work mode...............................................................................................................................................6
Static mode................................................................................................................................................................................... 6
Functional safety standards..........................................................................................................................................................6
Type A standards.........................................................................................................................................................................6
Type B1 standards.......................................................................................................................................................................6
Type B2 standards.......................................................................................................................................................................7
Type C standards.........................................................................................................................................................................7
Required hardware components................................................................................................................................................7
Functions
Function overview........................................................................................................................................................................... 8
Basic functions...................................................................................................................................................................................9
System mode selection.............................................................................................................................................................9
Mode transition control............................................................................................................................................................9
Drive pedal.................................................................................................................................................................................... 9
Engine speed potentiometer/hand throttle..................................................................................................................... 9
Inching............................................................................................................................................................................................ 9
Pump/engine rpm....................................................................................................................................................................10
Hydromotor rpm.......................................................................................................................................................................10
Temperature sensors...............................................................................................................................................................10
Pump profiling and ramping................................................................................................................................................10
Hydromotor profiling and ramping...................................................................................................................................10
Hydromotor brake pressure defeat (BPD) control........................................................................................................10
Maximum hydromotor torque at low vehicle speed...................................................................................................11
State and direction change...................................................................................................................................................11
Status LED....................................................................................................................................................................................11
Protection and safety functions................................................................................................................................................11
Start protection......................................................................................................................................................................... 11
Quick stop in automotive mode......................................................................................................................................... 11
Operator presence detection...............................................................................................................................................11
Hydromotor overspeed protection....................................................................................................................................11
Hydraulic system overheat protection............................................................................................................................. 12
Performance functions.................................................................................................................................................................12
ECO fuel saving mode.............................................................................................................................................................12
Cruise control.............................................................................................................................................................................12
Vehicle constant speed drive (CSD)...................................................................................................................................12
Vehicle speed limitation.........................................................................................................................................................12
Filter for drive pedal.................................................................................................................................................................12
Dynamic brake light.................................................................................................................................................................13
Automated park brake control............................................................................................................................................ 13
Reverse buzzer...........................................................................................................................................................................13
Vehicle speed dependent output.......................................................................................................................................13
Load independent pump displacement control (option AC2)................................................................................ 13
J1939 CAN subsystem data interface................................................................................................................................13
Engine control and protection
J1939 CAN engine interface.......................................................................................................................................................15
Kubota engine protocol.............................................................................................................................................................. 15
Engine anti-stall protection........................................................................................................................................................15
All range engine overspeed.......................................................................................................................................................15
Engine over speed protection with retarder........................................................................................................................15
Cold start protection.....................................................................................................................................................................15
Technical specifications
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Technical Information
Integrated Automotive Controls for H1 and MP1 Single Pumps
Contents
Automotive Control connection diagram.............................................................................................................................16
Battery and sensor voltage supply.......................................................................................................................................... 17
CAN communication.....................................................................................................................................................................18
Digital inputs................................................................................................................................................................................... 18
Forward-Neutral-Reverse (FNR) switch..................................................................................................................................18
Mode switch A and B.................................................................................................................................................................... 19
Analog Inputs..................................................................................................................................................................................20
Drive/Creep pedal..........................................................................................................................................................................20
General requirements and recommended settings of a pedal or potentiometer............................................20
Engine speed potentiometer/hand throttle........................................................................................................................ 20
Inch pedal......................................................................................................................................................................................... 21
Cruise control.................................................................................................................................................................................. 21
Pump rpm.........................................................................................................................................................................................22
Hydromotor rpm............................................................................................................................................................................22
PWM outputs...................................................................................................................................................................................23
Pump control...................................................................................................................................................................................23
Hydromotor control......................................................................................................................................................................23
Digital outputs................................................................................................................................................................................ 23
Hydromotor Brake Pressure Defeat (BPD) control.............................................................................................................24
Digital output A1 and A2.............................................................................................................................................................25
Environmental and protection characteristics....................................................................................................................25
Mating Connectors
Customer connectors (CC1, CC2 and CC3)........................................................................................................................... 27
PPC connector ................................................................................................................................................................................29
CAN connector................................................................................................................................................................................30
CAN bus adapter............................................................................................................................................................................ 30
MP1 pumps size 28-45cc model code
Automotive control parts for MP1...........................................................................................................................................32
H1 pumps size 45-250cc model code
Automotive control parts for H1P............................................................................................................................................34
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Technical Information
Integrated Automotive Controls for H1 and MP1 Single Pumps
General information
Automotive controls description
The Integrated Automotive Control solutions are designed to support single path hydrostatic
transmissions systems consisting of one pump (available sizes: MP1 28-45cc and H1P 45-250cc) and one
or more hydromotor. Danfoss offers several software configurations to cover the application demands.
With the pre-installed application software and easily changeable control parameters, it is possible to
tailor the vehicles driving behavior to the individual requirements of the customer. The Semi-AutoCalibration function for the pedals and a Quick-Start Guide with implemented Hyperlinks in the Service
tool will make changes and tuning more easily and effective.
Targeted applications
Automotive controls for H1 and MP1 pumps are targeted for the following applications.
Wheel loader
•
Telehandler
•
Dumper
•
Sweeper
•
Snow blower
•
Forestry machines
•
Hydrostatic propel methods
The application software offers different hydrostatic propel methods (defined as mode types).
Up to 4 system modes can be defined individually by parameter.
Automotive transport mode
Proportional pump and hydromotor displacement control.
The setpoint of the pump and hydromotor drive curves are given by the engine rpm. The engine rpm is
commanded by a drive pedal.
•
Drive pedal controls engine rpm
•
Engine rpm controls vehicle speed
•
Load dependent mode
•
Brake/inch signal reduces vehicle speed
•
Coast down when the drive pedal is released
Automotive ECO mode
The ECO fuel saving mode is designed for the Automotive Transport mode. It needs a CAN controlled
engine, an electric drive pedal and a larger pump displacement.
The ECO mode function reduces the engine rpm setpoint automatically when a vehicle speed is reached.
This function reduces fuel consumption and noise emission. The pump displacement will increase to
keep the vehicle speed on the same level with a reduced engine rpm. The ECO mode is automatically
switched off if the vehicle slows down or the driver releases the electric drive pedal.
The ECO mode is available in all Automotive Transport modes and can be enabled individually in each of
the four system modes.
Non-automotive work mode
Proportional pump and hydromotor displacement control.
The setpoint of the drive curves are given by the drive pedal command independent of the engine rpm.
The engine rpm is commanded by a handle throttle to fulfill the requirements of the work hydraulic.
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Technical Information
Integrated Automotive Controls for H1 and MP1 Single Pumps
General information
Drive pedal controls vehicle speed
•
Engine rpm is set separately with the hand throttle according to the requirements of work functions
•
Load independent mode
•
Brake/inch signal reduce vehicle speed
•
Vehicle speed limitation by the drive pedal (no roll down the hill)
•
Antistall protects the engine from overloading
•
Creep-automotive work mode
Mechanical controlled engines cannot command the engine rpm by a hand throttle.
The setpoint of the pump and hydromotor drive curves are given by the engine rpm, reduced by the
creep potentiometer. The engine rpm is commanded by a drive pedal.
Drive pedal controls vehicle speed
•
Load dependent mode
•
Creep potentiometer reduces the vehicle speed
•
Brake/inch signal reduces vehicle speed
•
Functional safety standards
Static mode
The engine rpm is commanded by a hand throttle to fulfill the requirements of the work functions.
The vehicle does not drive in this mode.
The AC controller fulfills the safety requirements according to the machine directive (2006/EC).
The design of this general purpose safety controller includes features required for sophisticated machine
control strategies. It is equally suited for use in safety related or general machine control applications. The
controllers support smart digital inputs. Device outputs can be individually controlled by the watchdog
processor.
The Safety Manual of the propel controller solutions is intended to guide the system integrator
concerning functional safety. The document describes a possible implementation of the needed safety
functions and is available on request. Please contact your local Danfoss representative to request the
Safety Manual.
Type A standards
This standard covers all general safety requirements that apply to all types of machines.
IEC 61508 Functional safety of electrical/electronic/programmable electronic safety-related systems
•
Type B1 standards
This standard covers safety and ergonomic design of machinery.
ISO 15998 Controller for Earth moving machinery
•
EN ISO 13849-1:2015 Safety of machinery; Safety-related parts of control systems Part 1 and 2
•
ISO 25119 Agriculture machinery (formerly EN 16590)
•
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Technical Information
Integrated Automotive Controls for H1 and MP1 Single Pumps
General information
Type B2 standards
This standard covers safety components and protective devices. For example: two-hand controls;
interlocking devices; pressure-sensitive devices; guards).
Type C standards
This standard covers detailed safety requirements for a particular machine or group of machines.
ISO 20474-2017 (formerly DIN/EN 474) Earth moving machinery
•
EN 1459-1:2017 Rough terrain trucks; Safety requirements and verification Part 1: Variable reach
•
trucks
EN 4254:2013 Agriculture machinery; Safety Part 1: General requirements
•
EU 167/2013 Agricultural and Forestry vehicles (tractor directive)
•
EU 1322/2014
‒
EU 68/2015
‒
EU 96/2015
‒
EU 208/2015
‒
EU 1788/2016
‒
Required hardware components
Engine
Mechanical or CAN controlled engines. CAN J1939 and proprietary Kubota protocol are supported.
Hydrostatic pumps
Load dependent pumps (NFPE) with embedded AC controller.
•
•
•
•
Hydraulic motors
Orbital hydraulic motors (fixed)
•
•
Axial piston hydraulic motors with zero degree capability
•
•
•
•
MP1 series: size 28, 32, 38 and 45cc
H1 series: size 45, 53, 60, 69, 78, 89, 100, 115, 130, 147, 165, 210 and 250cc
Speed sensor in the pump only for mechanically controlled engines
No pressure sensors required
OMS, OMT and OMV series: size 80-800cc
TMK, TMT and TMV series: size 160-800cc
Series 40 (fixed): size 25, 35, and 44cc
L/K series (variable, 2-position): size 25, 35, 38 and 45cc
H1B series (variable with pressure control PCOR): size 60, 80, 110, 160, 210 and 250cc
H1B series (variable with proportional control): size 60, 80, 110, 160, 210 and 250cc
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Technical Information
Integrated Automotive Controls for H1 and MP1 Single Pumps
Functions
Function overview
The available functions for the individual software solution can be found in the table below. A more
detailed description of the individual functions can be found on the following pages.
Basic functions
Function Option code H1P / MP1
F1F
(AF1F)
Automotive Transport Mode x x x x x x x
Non-Automotive Work Mode x x x x x x x
Creep-Automotive Work Mode x x x x x x
4 Selectable System Modes x x x x x x x
Independent Profiling & Ramping for Pump
and Hydromotor
Mode Transition Control x x x x x x x
Drive Pedal with Filter Function x x x x x x x
Brake/Inch Pedal x x x x x x x
Engine Speed Potentiometer/Hand Throttle x x x x x x x
Engine & Hydromotor rpm sensor x x x x x x x
Creep Mode Potentiometer x x x x x x
Pressure Controlled (PCOR) Hydromotor
Control
Proportional Hydromotor Control x
Hydromotor Load Limiter x
Max. Hydromotor torque at low vehicle
speed
Status Information by LED blink code x x x x x x x
x x x x x x x
x x x x x x
x x x x x x x
F2J
(AF2J)
F1E
(AF1E)
F2E
(AF2E)
F3J
(AF3J)
F4J
(AF4J)
F6L
Protection and safety functions
Start Protection x x x x x x x
Quick Stop in Automotive Mode x x x x x x x
Operator Presence Detection x x x x x x x
Hydraulic motor Over Speed Protection x x x x x x x
Hydraulic Overheat protection x x x x x x x
Performance functions
Automotive ECO Mode x x x x x x
Cruise Control x x x
Constant Speed Drive (CSD) x x x x x x x
Vehicle speed Limitation x x x x x x x
Dynamic Brake Light Control by
Deceleration
Automatic Park Brake Control x x x x x x x
Reverse buzzer x x x x x x x
Vehicle speed dependent Output (load
Stabilizer)
x x x x x x x
x x x x x x x
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Technical Information
Integrated Automotive Controls for H1 and MP1 Single Pumps
Functions
Performance functions (continued)
CAN User Interface (e.g. Error messages,
Inputs…)
Load Independent Pump Displacement
Control (Option AC2)
Engine control and protection
Mechanical controlled Engines x x x x x x
CAN J1939 Engine rpm control x x x x x x x
Kubota CAN Engine rpm control x x
Engine Antistall protection x x x x x x x
Engine control and protection (continued)Pi
All range engine over speed protection x x x x x x x
Engine Over Speed Protection with Retarder x x x x x x x
Engine cold start protection x x x x x x x
x x x x x x x
x x
Basic functions
System mode selection
The mode switch defines which of the 4 system modes should be applied.
The mode switch has three digital inputs supplied with battery voltage or received via CAN message. For
diagnostic purpose one mode switch is redundant.
The mode change conditions can be defined by parameter.
Mode transition control
This function allows configuration of an application specific System Mode transition.
The System Mode change condition can be dependent on multiple factors including actual FNR
Direction, Drive Pedal Input, and Vehicle Speed.
Drive pedal
The drive pedal is used as the vehicle speed request.
Depending on the propel mode it can be the engine setpoint (automotive mode) or the pump and
hydromotor command (work mode).
The drive pedal has two redundant analogue signals, supplied with 5V sensor voltage or can received via
CAN (EEC2) standard message.
Engine speed potentiometer/hand throttle
The engine speed potentiometer is used as the engine setpoint in work mode.
The engine speed potentiometer has two redundant analogue signals, supplied with 5V sensor voltage
or can received via CAN (EEC2) standard message.
Inching
The inch function allows the operator to reduce the vehicle speed, stop the machine or keep the vehicle
speed low while rising the engine rpm to meet the flow demand of the work functions.
An increasing inch pedal signal will reduce the pump displacement, thus reducing vehicle speed.
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Technical Information
Integrated Automotive Controls for H1 and MP1 Single Pumps
Functions
There can be a combination brake/inch of the service brake with an additional sensor for an inch signal or
a separate inch pedal.
The inch pedal has two redundant analogue signals, supplied with 5V sensor voltage or can received via
CAN (EBC1) standard message.
Pump/engine rpm
The pre-installed pump rpm sensor is connected to calculate the pump/engine rpm.
The calculated engine rpm is the setpoint for the automotive drive curve. Optional the engine rpm signal
can received via CAN EEC1 message from the engine controller. In this case, a pump rpm sensor is not
required.
Hydromotor rpm
The hydromotor rpm is measured via a PPU (pulse pickup unit) in the hydromotor. With help of the gear
factor and wheel diameter a vehicle speed is calculated.
The hydromotor rpm is detected by a frequency input with signal level detection. It is supplied with the
5V sensor voltage.
The actual vehicle speed is send out via CAN CCVS message.
Temperature sensors
The temperature sensor integrated in the controller will measure the hydraulic oil temperature.
These functions are:
•
Protection of the complete hydrostatic system by reducing the pump flow (by pump command) at
extreme high temperatures according to user defined temperature curve.
•
Protection of the complete hydrostatic system by reducing the commanded engine rpm at low
temperatures according to a user defined temperature value. When the system has warmed up, the
engine speed limitation is no longer active.
The actual temperature is sent out via CAN TRF1 message.
Pump profiling and ramping
The pump solenoids are supplied by two PWM (pulse width modulation) output signals, independently
configured for the forward and reverse driving direction in each of the four system modes.
For each of the four system modes two independent profile curves for forward & reverse are available.
Hydromotor profiling and ramping
Proportional and 2-Position hydromotors can be controlled directly by a PWM output signal.
The hydromotor command can be defined by a constant value or a profile curve output, individually for
each of the four system modes and driving direction.
Hydromotor brake pressure defeat (BPD) control
The hydromotor BPD control is used in combination with a pressure controlled (PCOR) hydromotor
control.
This function prevents the activation of the internal hydromotor control pressure compensator (PCOR)
during deceleration events. The hydromotor BPD control is activated automatically.
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Technical Information
Integrated Automotive Controls for H1 and MP1 Single Pumps
Functions
Maximum hydromotor torque at low vehicle speed
This function will command the hydromotor to max displacement during low vehicle speed to provide
the maximum available torque.
If the defined vehicle speed is reached, the hydromotor will follow the original drive curve. A hydromotor
or vehicle speed sensor is required to detect the actual vehicle speed.
State and direction change
A driving direction change is always handled in a safe way.
The change request by the FNR switch will initiate the deceleration of the vehicle. The change of the
driving direction is only started, if the actual vehicle speed is below a threshold value.
Status LED
In case of an Error, the red status LED on the controller shows a blink code.
The green LED is continuously on if the controller is supplied with battery power.
Protection and safety functions
Start protection
The safety controlled vehicle start protection prevents commanded, unexpected or otherwise dangerous
vehicle movement after initial power on the engine.
The start protection is monitoring the following signals:
•
Engine rpm
•
Battery voltage
•
Error status
•
Inch calibration
•
FNR in neutral
Quick stop in automotive mode
When operating the vehicle in automotive transport mode, the controller will use the engine rpm as the
setpoint. The electric drive pedal position (out of the deadband) is used as an enable signal.
The driver must press the drive pedal and the engine rpm must rise to move the vehicle. If the driver
releases the drive pedal fully (drive pedal return into the deadband), the pump current will decrease with
an adjustable ramp to a defined value. The vehicle will decelerate much faster compared to the normal
behavior.
Operator presence detection
Driving the vehicle is only allowed if the operator is seated on the driver seat. A programmable time delay
will trigger vehicle shut down if the driver leaves the seat for a longer period of time.
Before a pre-warning signal is shown, there is a possibility to override the seat switch if the driver is
pressing the drive pedal.
Hydromotor overspeed protection
The hydromotor overspeed protection prevents the hydromotor from over speeding by decreasing
pump displacement or increasing hydromotor displacement.
The hydromotor rpm speed limit, is user defined and valid in all four system modes when activated.
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