Danfoss MCE102A Installation guide

MCE102A

Phased Out Products

Automotive Controller

BLN-95-8993-3 Issued: May 1998

DESCRIPTION

The MCE102A automotive controller enables hydrostatically powered vehicles to operate in a manner similar to a car’s automatic transmission. The automotive control maintains a definite relationship between the engine r.p.m. and the swashplate angle (i.e, displacement) of the variable displacement pump used in the hydrostatic transmission. The transmission ratio (displacement of the pump/displacement of the motor) increases with increasing engine r.p.m. Vehicle speed is obtained by depressing the throttle pedal which controls the vehicle engine r.p.m.

ORDERING INFORMATION

DEVICE

NUMBER

MCE102A1007 12 Vdc .14 amp 200 to 900 Hz Packard External Inch Pot MCE102A1014 12 Vdc .14 amp 200 to 900 Hz Packard External Foot Break MCE102A1022 12 Vdc .14 amp 50 to 225 Hz Terminal Strip External F/V Turn Down MCE102A1030 24 Vdc .7 amp 4 to 20 mA Packard Reverse Acting MCE102A1049 12 Vdc 1.0 amp 10 to 50 Hz Terminal Strip Lead/Lag Filter MCE102A1055 12 Vdc .7 amp 90 to 500 Hz Packard Pressure Transducer Turn Down MCE102A1063 12 Vdc 1.0 amp 200 to 650 Hz Terminal Strip Lead/Lag Filter, 2 Speed MCE102A1071 24 Vdc .7 amp 4 to 20 mA Terminal Strip Reverse Acting MCE102A1097 12 Vdc 1.0 amp 200 to 650 Hz Terminal Strip Lead/Lag Filter, 2 Speed MCE102A1105 12 Vdc .14 amp 1000 to 3000 Hz Terminal Strip Lead/Lag Filter MCE102A1113 12 Vdc .14 amp 200 to 650 Hz Terminal Strip Lead/Lag Filter MCE102A1121 12 Vdc 1.0 amp 600 to 1950 Hz Terminal Strip Lead/Lag Filter, 2 Speed MCE102A1139 24 Vdc .14 amp 1000 to 3000 Hz Terminal Strip Lead/Lag Filter MCE102A1147 12 Vdc .14 amp 200 to 650 Hz Packard Lead/Lag Filter

SUPPLY

VOLTAGE

OUTPUT

CURRENT

INTERNAL

SETPOINT RANGE

CONNECTOR

TYPE

MISCELLANNEOUS

TECHNICAL DATA

ELECTRICAL

SUPPLY VOLTAGE

12 Vdc nominal (11 to 15 Vdc range) 24 Vdc nominal (22 to 30 Vdc range)

OUTPUT CURRENT

1.0 amps maximum in auto mode (12 Vdc models)

0.7 amps maximum in auto mode (24 Vdc models)

OUTPUT VOLTAGE

System supply voltage less 3 volts, maximum (limited by a series resistor on some models).

REVERSE VOLTAGE PROTECTION

A series diode protects against reverse voltage up to 50 Vdc

SHORT CIRCUIT PROTECTION

1.4 to 2.0 amps (12 Vdc models)

0.8 to 1.2 amps (24 Vdc models) Shorted load of more than 2 minutes may degrade device at elevated temperature. Output limited by a series resistor on some models.

TECHNICAL DATA

Phased Out Products

(continued)

ENVIRONMENTAL

VIBRATION

Withstands a vibration test designed for mobile equipment controls consisting of two parts:

1. Cycling from 5 to 2000 Hz in each of the three axes

2. Resonance dwell for one million cycles in each of the three axes

Run from 1 to 10 Gs. Acceleration level varies with frequency.

HUMIDITY

After being placed in a controlled atmosphere of 95% humidity at 38° C (100° F) for 10 days, the controller will perform within specification limits.

RAIN

After being showered from all directions by a high pressure hose down, the controller will perform within specification limits.

SHOCK

50 Gs for 11 milliseconds. Three shocks in both directions of the three mutually perpendicular axes for a total of 18 shocks.

OPERATING TEMPERATURE

-20 to 65° C (-4 to 149° F)

STORAGE TEMPERATURE

-30 to 65° C (-22 to 149° F)

PERFORMANCE

MAXIMUM OUTPUT VOLTAGE

The maximum output voltage to the load shall be the supply voltage less three volts up to rated load current.

MAXIMUM OUTPUT CURRENT

With the output terminal shorted to ground, the maximum output current shall be from 1.4 to 2.0 amps (12 Vdc models) or 0.8 to 1.2 amps (24 Vdc models), depending on temperature.

OPERATING SUPPLY VOLTAGE

11 to 15 Vdc, or 24 to 30 Vdc optional with added components

SUPPLY CURRENT

1.1 amps maximum (except for shorted loads) (12 Vdc models)

0.8 amps maximum (except for shorted loads) (24 Vdc models)

VOLTAGE RANGE

The controlled voltage decreases from supply minus 3 volts down to zero.

SENSITIVITY

The sensitivity control changes the proportioning band from 4% (turned clockwise) to 75% (turned counter clockwise) of calibrated r.p.m. The proportioning band is defined as the change necessary to reduce output voltage from 100% to 20% of rated output. Sensitivity control may be removed and replaced with a fixed resistance in some models.

THEORY OF OPERATION

The automotive controller monitors engine r.p.m. as a variable frequency through the alternator or pulse pickup. The controller’s calibration (point of maximum displacement) is at or near the r.p.m. at which the engine is capable of maximum horsepower. The output is directed to the pump displacement control through a double-pole double-throw center off switch. For vehicle forward, neutral and reverse, see Automotive Control System Diagram.

Between low idle and low r.p.m., the engine is well below setpoint (see Controller Output Vs. Engine RP M and Reverse Acting Controller), which the controller interprets as a lugged condition; consequently there is no propel. As engine r.p.m. increases, the controller output increases, the rate of increase being determined by the gain setting of the controller. The engine r.p.m. that corresponds to maximum ratio is determined by the engine r.p.m. calibration potentiometer. Vehicle speed will continue to increase with increasing engine r.p.m. even though the transmission ratio remains unchanged above the high r.p.m. calibration point.

The transmission ratio is proportional to engine r.p.m., an d overhauling loads resulting in high engine r.p.m. will keep the pump at full angle, resulting in dynamic braking limited by the engine horsepower absorption. Therefore, to guarantee

adequate braking, the vehicle mechanical brake must be applied.

The automotive controller is adaptable to applications with either medium or heavy duty transmissions. Additional features such as HI/LOW range, reverse acting, pressure transducer turn down, lead/lag and inching may also be incorporated into the system.

The feedback circuit may be modified to accept a dc signal. 4 to 20 mA from a pressure transducer or 0 to 6 Vdc from a tachometer are two types of dc signals acceptable for feedback.

The unit may be modified to provide decreasing output for increasing r.p.m. (reverse acting).

BLN-95-8993-3

AUTOMOTIVE CONTROL SYSTEM DIAGRAM

Phased Out Products

ENGINE

B A D C

+12 V

GRD

EDC

RED

BLACK

WHITE

+12 V

FORWARD

NEUTRAL

REVERSE

GREEN

F/V

+2 VOLT REF

PROPORTIONAL TRANSMISSION CONTROL BOARD

ENGINE CALIBRATION POTENTIOMETER

SLOPE ADJUST POTENTIOMETER

SERIES RESISTOR IN SOME MODELS TO LIMIT CURRENT IF

DIRECT DRIVING AN ELECTRICAL DISPLACEMENT CONTROL (EDC).

STARTER RELAY

CONTROLLER OUTPUT Vs. ENGINE RPM REVERSE ACTING CONTROLLER

AUTOMOTIVE CONTROL BOARD

% OF FULL DRIVE

CONTROLLER OUTPUT VOLTAGE

LOW

RPM

IDLE

HIGH RPM

CALIBRATION

GAIN

ENGINE RPM

HIGH IDLE

100

% OF FULL DRIVE

CONTROLLER OUTPUT

CALIBRATE

POINT

1417

GAIN

PRESSURE 0-6 Vdc or CURRENT (4-20 mA)

14191418

BLN-95-8993-3

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