Danfoss Integrated Automotive Controls User guide

Technical Information

Integrated Automotive Control (AC) for MP1 and H1P Single Pumps

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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	0703
		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

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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-Auto- Calibration 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

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.

Functional safety standards

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.

•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

Hydraulic motors

Orbital hydraulic motors (fixed)

•OMS, OMT and OMV series: size 80-800cc

•TMK, TMT and TMV series: size 160-800cc

Axial piston hydraulic motors with zero degree capability

•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	F2J	F1E	F2E	F3J	F4J	F6L
	(AF1F)	(AF2J)	(AF1E)	(AF2E)	(AF3J)	(AF4J)
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	x	x	x	x	x	x	x
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	x	x	x	x	x	x
Control
Proportional Hydromotor Control							x
Hydromotor Load Limiter							x
Max. Hydromotor torque at low vehicle	x	x	x	x	x	x	x
speed
Status Information by LED blink code	x	x	x	x	x	x	x

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	x	x	x	x	x	x	x
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	x	x	x	x	x	x	x
Stabilizer)

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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,	x	x	x	x	x	x	x
Inputs…)
Load Independent Pump Displacement		x				x
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

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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