Technical Information
PLUS+1® Controller
XL104-xxxx
www.danfoss.com
Technical Information
PLUS+1® Controller XL104-xxxx
Revision history Table of revisions
Date Changed Rev
August 2020 First edition 0101
2 | © Danfoss | August 2020 BC320261740866en-000101
Technical Information
PLUS+1® Controller XL104-xxxx
Contents
XL 104-xxxx Controller Family literature references
Technical Information (TI)............................................................................................................................................................. 4
Module product Data Sheet (DS)................................................................................................................................................4
API specifications (API)................................................................................................................................................................... 4
PLUS+1 GUIDE User Manual.........................................................................................................................................................4
User liability safety statements
OEM responsibility........................................................................................................................................................................... 5
Overview
XL104-xxxx Controllers family..................................................................................................................................................... 6
Inputs/outputs types and specificatons
Input types..........................................................................................................................................................................................7
A/D refresh rate............................................................................................................................................................................7
Digital Inputs (DIN).....................................................................................................................................................................7
Digital/Analog Inputs (DIN/AIN)............................................................................................................................................8
Digital/Analog/Frequency (DIN/AIN/FreqIN)....................................................................................................................9
Digital/Analog/Frequency/Resistance/Current (DIN/AIN/FreqIN/ResIN/CrntIN)..............................................10
Output types....................................................................................................................................................................................11
DOUT.............................................................................................................................................................................................12
Single pulse maximum demagnetization energy at 150° C......................................................................................13
PWMOUT/DOUT/PVGOUT.....................................................................................................................................................13
Controller Area Network (CAN)
CAN system design........................................................................................................................................................................15
Specifications for terminating resistor...................................................................................................................................15
Notes on CAN Bus installation...................................................................................................................................................15
Expansion module CAN Bus loading...................................................................................................................................... 15
Product ratings
Power..................................................................................................................................................................................................16
Module supply voltage/maximum current ratings......................................................................................................16
Sensor power supply ratings................................................................................................................................................16
PVG valve power supply ratings..........................................................................................................................................17
Non-volatile memory read/write ratings...............................................................................................................................17
EEPROM write/erase ratings................................................................................................................................................. 17
Vault memory.............................................................................................................................................................................17
General ratings................................................................................................................................................................................17
Wake-up functions........................................................................................................................................................................ 18
Environmental testing criteria...................................................................................................................................................18
Modules housing............................................................................................................................................................................19
Product installation and start-up
Connectors....................................................................................................................................................................................... 20
Mounting.......................................................................................................................................................................................... 20
Machine diagnostic connector................................................................................................................................................. 21
Grounding........................................................................................................................................................................................ 21
Hot plugging................................................................................................................................................................................... 21
Machine wiring guidelines......................................................................................................................................................... 21
Machine welding guidelines......................................................................................................................................................22
PLUS+1® USB/CAN Gateway.......................................................................................................................................................22
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Technical Information
PLUS+1® Controller XL104-xxxx
XL 104-xxxx Controller Family literature references
Literature title Document type Literature ID
PLUS+1® XL104-XXXX Controller Family Technical Information Technical Information BC320261740866
PLUS+1® XL104-XXXX Data Sheet Data Sheet AI318200103711
PLUS+1® Controller XL104-XXXX Functional Safety Implementation Safety Manual BH346381901208
PLUS+1® GUIDE Software User Manual Operation Guide AQ152886483724
Technical Information (TI)
A TI references comprehensive information for engineering and service personnel.
Module product Data Sheet (DS)
A module product DS contains summarized information and parameters that are unique to an individual
PLUS+1® module, including:
Numbers and types of inputs and outputs
•
Module connector pin assignments
•
Module maximum current capacity
•
Module sensor power supply (if present) current capacity
•
Module installation drawing
•
Module weights
•
Product ordering information
•
API specifications (API)
PLUS+1 GUIDE User Manual
Module API specifications contain detailed information about the module BIOS. PLUS+1® BIOS
functionality is pin dependent. Pins are defined in module data sheets as C (connector number) p (pin
number).
API specifications include:
Variable name
•
Variable data type
•
Variable direction (read/write)
•
Variable function and scaling
•
Module API specifications are the definitive source of information regarding PLUS+1® module pin
characteristics.
The Operation Manual (OM) details information regarding the PLUS+1® GUIDE tool used in building PLUS
+1® applications. This OM covers the following broad topics:
How to use the PLUS+1® GUIDE graphical application development tool to create machine
•
applications
How to configure module input and output parameters
•
How to download PLUS+1® GUIDE applications to target PLUS+1® hardwaremodules
•
How to upload and download tuning parameters
•
How to use the PLUS+1® ServiceTool
•
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Technical Information
PLUS+1® Controller XL104-xxxx
User liability safety statements
OEM responsibility
The OEM of a machine or vehicle in which Danfoss products are installed has the full responsibility for all
consequences that might occur. Danfoss has no responsibility for any consequences, direct or indirect,
caused by failures or malfunctions.
Danfoss has no responsibility for any accidents caused by incorrectly mounted or maintained
•
equipment.
Danfoss does not assume any responsibility for Danfoss products being incorrectly applied or the
•
system being programmed in a manner that jeopardizes safety.
All safety critical systems shall include an emergency stop to switch off the main supply voltage for
•
the outputs of the electronic control system. All safety critical components shall be installed in such a
way that the main supply voltage can be switched off at any time. The emergency stop must be easily
accessible to the operator.
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Technical Information
PLUS+1® Controller XL104-xxxx
Overview
XL104-xxxx Controllers family
PLUS+1® Mobile Machine Modules are designed to provide flexible, expandable, powerful and cost
effective total machine management systems for a wide variety of vehicle applications.
These modules communicate with one another and other intelligent systems over a machine Controller
Area Network (CAN) data bus.
PLUS+1® controller products utilize modular designs wherever possible. This modularity extends to
product housings, connectors and control circuitry.
PLUS+1® hardware products are designed to be equally effective in a distributed CAN system, with
intelligence in every node, or as stand-alone control for smaller machine systems.
While targeted to single-machine controller applications unlike the PLUS+1® MC/SC controllers with an
expanded moduce architecture, the PLUS+1® Compliant systems are incrementally expandable;
Additional modules can be easily added to the machine CAN bus to increase system capabilities or
computational power.
The XL104-xxxx comes in a standard 104 pin housing but is available in various depopulated variants.
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Technical Information
PLUS+1® Controller XL104-xxxx
Inputs/outputs types and specificatons
PLUS+1® modules have input or output pins that support multiple functions. Pins that support multiple
input or output types are user-configurable using PLUS+1® GUIDE software. Refer to product data sheets
for the input/output (I/O) content of individual modules.
Input types
Digital (DIN)
•
Digital or Analog (DIN/AIN)
•
Multifunction: Digital or Analog or Frequency (DIN/AIN/FreqIN)
•
Multifunction: Digital or Analog or Frequency or Resistance or 4-20 mA Current (DIN/AIN/FreqIN/
•
ResIN/CrntIN)
Digital or Analog or CAN shield (DIN/AIN/CAN Shield)
•
Each PLUS+1® module input pin supports one of the above functional types. For pins with multiple
functions, input configurations are user programmable using PLUS+1® GUIDE templates.
Each input type has been designed for different Functional Safety performance level. Refer to the PLUS
+1® XL104-XXXX Safety Manual for more information.
General response time to input time
Description Comment
Response to input below minimum
voltage
Response to input above maximum
voltage
Response to input open
Voltage working ranges
Non-damaging, non-latching; reading saturates to the low limit.
Non-damaging, non-latching; reading saturates to the high limit.
Pin configuration dependent: No pull up/ no pull down = floating Pull up to 5
Vdc = 5 Vdc
Pull down = 0 Vdc
Pull up / pull down = 2.5 Vdc
DIN: 0V to 5V
DIN/AIN: Programmable (see specific data sheets for ranges).
DIN/AIN/FreqIN: Programmable
DIN/AIN/FreqIN/ResIN/CrntIN: Programmable
A/D refresh rate
Analog to digital (A/D) refresh rates for PLUS+1® family
PLUS+1®module A/D refresh rate
XL104-XXXX All: 1.00 ms
Digital Inputs (DIN)
Digital inputs (DIN) connected to PLUS+1® dedicated digital input pins are debounced in software. Digital
input debounce is defined as an input being in a given state for three samples before a state change is
reported. The sample time is a function of application loop time.
DIN inputs can be pulled to +5Vdc, pulled to ground or operated with no pull up/pull down.
Digital (DIN) Specifications
Description Units Minimum Typical Maximum Comment
Input voltage range V 0 — 36
Rising threshold voltage V — — 4.12 Guaranteed high voltage.
Falling threshold voltage V 0.85 — — Guaranteed low voltage.
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PLUS+1® Controller XL104-xxxx
Inputs/outputs types and specificatons
Digital (DIN) Specifications (continued)
Description Units Minimum Typical Maximum Comment
Input impedance kΩ 230 233 236 No pull up or pull down with 0V to 5.7V input
Input impedance (5 V/GND) kΩ 13.9 14.1 14.3 Pull up to +5 V or pull down to ground with 0V
Digital/Analog Inputs (DIN/AIN)
Digital/Analog mode (DIN/AIN) general information
Multifunction pins that are configured to be Digital input (DIN) are subject to the same update rates as
the Analog input (AIN) function for that pin. Debounce is not used, as hysteresis is built into the function.
The time to recognize a transition is dependent on the timing of the switch activation and the sample
rate.
These inputs can be pulled to +5Vdc, pulled to ground, pulled to +2.5Vdc, or operated with no pull up/
pull down.
Description Comment
Response to input below minimum
voltage
Response to input above maximum
voltage
Pull up/pull down configuration No pull up / pull down is standard with pull up or pull down programmable;
voltage.
to 5.7V input voltage.
Non-damaging, non-latching; reading saturates to the low limit.
Non-damaging, non-latching; reading saturatesto the high limit.
failure modes are detectable.
Digital/Analog mode (DIN/AIN) specifications
Description Units Minimum Typical Maximum Comment
Allowed voltage at pin V 0 – 36
DIN mode
Rising threshold
voltage
Falling threshold
voltage
AIN mode Low range (DAF and DAFRC only)
Minimum discernible
voltage
Maximum discernible
voltage
Precision mV – 1.3 –
Worst case error mV – – 120 Over the full temp
Input imdedance kΩ 230 233 236 No pull up or pull down
Input impedance (5 V/
GND)
Input impedance (2.5V)kΩ 7.1 7.3 7.4 Pull to +2.5 V
V – – Programmable Guaranteed high
voltage may be varied
with the selected
Analog range
V Programmable – – Guaranteed low
voltage may be varied
with the selected
Analog range
mV – – 13.1
V 5.14 – 5.37
range
kΩ 13.9 14.1 14.3 Pull up to +5 V or pull
down to ground
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PLUS+1® Controller XL104-xxxx
Inputs/outputs types and specificatons
Digital/Analog mode (DIN/AIN) specifications (continued)
Description Units Minimum Typical Maximum Comment
AIN mode High range
Minimum discernible
voltage
Maximum discernible
voltage
Precision mV – 9 –
Worst case error V – – 1.1 Over the full temp
Input impedance kΩ 108 109 111 No pull up or pull down
Input impedance (5 V/
GND)
Input impedance (2.5V)kΩ 6.9 7.0 7.1 Pull to +2.5 V
Digital/Analog/Frequency (DIN/AIN/FreqIN)
mV 0 – 150
V 34.1 35.3 36.4
range
kΩ 13.0 13.2 13.4 Pull up to +5 V or pull
down to ground
Frequency mode (FreqIN) general information
Description Comment
Frequency (Hz)
Period (0.1 μsec
Expected measurement
Channel to channel phase shift (paired inputs)(0.1 ms)
PWM duty cycle (0.01%) – Duty cycle measurement only valid up to 5kHz
Edge count
Quadrature count (paired inputs driven from a quadrature encoder)
If the frequency goes to zero, the data will not decay over time. The data will be updated once a new
pulse is seen or the measurement times out. It is possible to monitor the count of pulses to know when
the frequency reading is updated.
Frequency mode (FreqIN) specifications
Description Units Minimum Typical Maximum Comment
Frequency range Hz 0 – 10,000 In steps of 1 Hz, max 0.1%
Frequency range when
input is used as a
quadrature count or phase
shift
PWM duty cycle Hz 0 – 5000 Max 0.01% error
Low range
Rising voltage threshold V 0.11 – 0.30 Voltage required for
Falling voltage threshold
(low range)
Middle range
Rising voltage threshold V 1.78 – 3.92 Voltage required for
Falling voltage threshold V 0.84 – 2.79 Voltage required for
Hz 0 – 5000 In steps of 1 Hz, max 0.1%
V 0.04 – 0.22 Voltage required for
error
error
frequency input to read
high
frequency input to read low
frequency input to read
high
frequency input to read low
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PLUS+1® Controller XL104-xxxx
Inputs/outputs types and specificatons
Frequency mode (FreqIN) specifications (continued)
Description Units Minimum Typical Maximum Comment
High range
Rising voltage threshold V 11.8 – Voltage required for
Falling voltage threshold V 5.6 – Voltage required for
Digital/Analog/Frequency/Resistance/Current (DIN/AIN/FreqIN/ResIN/CrntIN)
Resistance mode (ResIN) general information
When configured as a resistance/rheostat/temp sensor input, the device will provide up to 3.76 mA
current to an external load which can then be measured. The equation for calculating AD counts for a
given load is: AD counts = (30996 x RL / (RL + 1322)). The following chart shows the relationship between
AD counts and load.
High range mode, Low range mode and the pull up / pull down features are not available when the input
is configured in Resistance mode.
frequency input to read
high
frequency input to read low
Load resistance versus ADC counts
The following chart shows the relationship between load resistance versus worst case error over the full
operating temperature -40°C to 85°C (-40°F to 158°F).
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Technical Information
PLUS+1® Controller XL104-xxxx
Inputs/outputs types and specificatons
Load resistance vs worst case error
Resistance mode (ResIN) specifications
Description Units Minimum Typical Maximum Comment
Allowed voltage at pin V 0 — 36
Measured resistance Ω 0 – 10,000
Output types
Current mode (CrntIN) general information
High range mode, Low range mode and the pull up / pull down features are not available when the input
in configured in Current mode.
Current mode (CrntIN) specifications)
Description Units Minimum Typical Maximum Comment
Allowed voltage at pin V – 5.0 7.0
Minimum discernable
current
Maximum discernible
current
Precision μA – 6
Worst case error μA – – 868
Input impedance Ω 198.6 200 202.6
Digital (DOUT)
•
Pulse width modulated (PWM/DOUT/PVGOUT)
•
mA 0 – 0.1
mA 25.3 – 27
Over the full temperature
range
-40°C to 85°C
(-40°F to 185°F)
Warning
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.
The module will be powered up if battery voltage is applied to the module's output pin. To protect
against unintended movement, secure the machine.
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PLUS+1® Controller XL104-xxxx
Inputs/outputs types and specificatons
Caution
Warranty voids if module is damaged.
Caution
Avoid significant current driven back through an output pin.
DOUT
Digital (DOUT)
Digital outputs can source up to 3 or 4 A
•
XL104-0000: C1p36, C1p46, C2p35, C2p36, C2p45 and C2p46 can source up to 4 A @module
temperature up to 70˚ C [158˚ F]
•
The XL104 controller is capable of sourcing a total of 40 A, and sinking a total of 20A, in ambient
temperatures of -40 to +70°C, with no external cooling measures. At ambient temperatures from +70
to 85°C, the XL controller is capable of 20 A sourcing and 12 A sinking.
Caution
Driving an inductance with higher turn off energy than is safe may cause damage to the device. For safe
levels, please see Single pulse maximum demagnetization energy at 150° C on page 13. Damage can be
avoided by adding an external recirculation diode or driving with a PWM output.
General
Description Comment
Configuration Sourcing only.
Type Linear switching.
Short circuit to ground protection Non-damage, current/thermal limit with status indication; automatic latch
Open circuit detection Fault indication provided. The GUIDE Pin Status requires a load of 500 mA to
Parallel operation Digital outputs from the same module are capable of being connected
Shut off
Overcurrent Protection
Description Units Minimum Maximum Comment
Allowed voltage at pin V 0 36 See Caution statement below
Output voltage, energized state V Vbatt-1.0 Vbatt Overall load conditions.
Output voltage, off state V 0 0.1 At Rload=200 Ω
Output current range for a status bit
to read OK
off /resume.
be connected or an open fault will be declared.
together such that the net current rating is the sum of the individual ratings;
timing is resolved by the operating system; diagnostic capability is
maintained.
Processor control
Additional Safe Bank Shutoff on 4A outputs. Safe Banks are two outputs per
bank. C1p36+C1p46, C2p35+C2p45, C2p36+C2p46
All DOUT include Thermal shutdown.
4A DOUT have Processor controlled Overcurrent limit of 6 A nominal ( 5.0A to
6.7A).
A 0.5 3
Caution
Do not connect a digital output to battery+ (back drive) without a series diode.
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PLUS+1® Controller XL104-xxxx
Inputs/outputs types and specificatons
Single pulse maximum demagnetization energy at 150° C
1. The high side driver (HSD) has a built in voltage clamp for fast demagnetization of inductive loads.
2. The turn off energy is absorbed by the HSD.
3. If the turn off energy is above the HSD maximums shown in following graph, there will be two
options:
•
Use external clamping or a recirculating diode.
•
Use a PWM output that has built in recirculation/clamping.
4. Power trend lines were added to extend the graphs for inductances over 100 mH.
PWMOUT/DOUT/PVGOUT
All PLUS+1® module proportional outputs are Pulse Width Modulated (PWM). PWM frequency is software
adjustable using PLUS+1® GUIDE. There are two modes of PWM operation: open loop and closed loop
(current control).
In open loop mode, current can be sourced or sunk, but the output is a PWM duty cycle. Current feedback
may be monitored in open loop mode, but the output is a constant voltage, not a constant current. The
signal line of PVG valves can be driven with an open loop PWM. The PWM driving the control signal must
be set to 0 at the same time as the digital output driving the PVE power pin is set to 0.
In closed loop mode, current is sourced and a constant current is maintained by the module’s operating
system using internal current feedback. Load impedance must not exceed 65 ohms.
In closed loop mode, the maximum current is limited by measuring the feedback current. There is no
thermal protection. If the maximum current is exceeded, the controller kernel will shut down the output
and latch it. The kernel also limits how quickly the output can be repowered (250 ms). The output cannot
be reset until the command goes to 0 or False (if configured as a digital output).
Proportional outputs that are used as a digital sinking output have a potential for a leakage current of up
to 5 mA when off.
PWM outputs are phase shifted to reduce input current ripple.
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PLUS+1® Controller XL104-xxxx
Inputs/outputs types and specificatons
Refer to individual module data sheets for the maximum allowable output current for each PLUS+1
®
module.
Description Comment
Configuration Sourcing or sinking
Type (Linear vs. PWM) PWM
Operating modes Programmable: closed loop current or open loop voltage (duty cycle)
Dual coil PCPs Compensated for induced currents in a non-driven coil (closed loop mode)
Short circuit to ground Output fully protected against damage and fault detected
Mode selection (current or voltage)
and full scale current ranges
Programmable
Do not connect a digital output to battery+ (back drive) without a series diode.
PLUS+1® PWM output circuits are not designed to be used as inputs. Output current feedback readings
should be used for fault checking only.
Warning
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.
The module will be powered up if battery voltage is applied to the module's output pin. To protect
against unintended movement, secure the machine.
Caution
Warranty voids if module is damaged. Avoid significant current driven back through an output pin.
Description Units Minimum Maximum Comment
Full scale proportional current output mA 10 3,000 The current may accidentally be
Output voltage, 100% duty cycle V 0 Vbatt
Output resolution of 3 A mA 0.25
Repeatability of full range % of full
scale
Absolute accuracy of full range % of full
scale
Output settling time ms 100 Depends on load characteristics.
PWM frequency Hz 33 4,000/20,0
Over-current trip point A 7.3
0.5
3 1% typical. Offsets removed when
00
exceeded in open loop mode. If the
current exceeds the trip point, the
output will be latched off.
command is Ø.
There is over-current protection built
into each output driver. If the
instantaneous current exceeds the
trip point, the driver is latched off.
GUIDE application software can reset
the latch and attempt to drive current
again.
A typical overcurrent protection will
retry for 40 ms to allow higher
outrush currents on capacitive loads
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PLUS+1® Controller XL104-xxxx
Controller Area Network (CAN)
CAN system design
All PLUS+1® modules have CAN ports that conform to CAN 2.0B specifications, including CAN shield.
All CAN ports on XL104-xxx controllers can be used to download PLUS+1® GUIDE application programs.
Specifications for terminating resistor
Each end of the main backbone of the CAN bus must be terminated with an appropriate resistance to
provide correct termination of the CAN_H and CAN_L conductors. This termination resistance should be
connected between the CAN_H and CAN_L conductors.
Description Units MinimumMaximumNominal Comment
Resistance Ω 110 130 120 Minimum power dissipation 400
Inductance µH 1
Notes on CAN Bus installation
Total bus impedance should be 60 Ω.
The CAN transceiver will be damaged by any voltage outside of allowable range, (-27 to +36 Vdc), even
with a very short pulse.
If using shielded cable, the shield must be grounded to the machine ground at one point only; preferably
at the mid-point of the CAN bus. Each PLUS+1® module CAN shield pin must be connected to the cable
shield.
Expansion module CAN Bus loading
System designers incorporating PLUS+1® expansion modules in their applications should be aware of
PLUS+1® CAN bus loading and controller memory usage during system design. Each expansion module is
associated with a PLUS+1® controller and uses part of the controller's memory resources for inter-module
communications. The following table can be used to estimate system CAN bus loading and the memory
impact of I/O modules on their associated controller.
Estimated usage of memory and communication resources
Description IX012-010 IX024-010 OX012-010 OX024-010 IOX012-010 IOX024-20
Estimated module bus load
(using default update and
250K bus speed)
Estimated module bus load
(using 70 ms updates and
250K bus speed)
RAM usage on XL104-xxxx TBD TBD TBD TBD TBD TBD
ROM usage on XL104-xxxx TBD TBD TBD TBD TBD TBD
mW (assumes a short of 16 Vdc to
CAN_H).
4% 10% 11% 27% 11% 27%
2% 5% 3% 8% 4% 8%
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PLUS+1® Controller XL104-xxxx
Product ratings
Power
Module supply voltage/maximum current ratings
PLUS+1® XL modules are designed to operate with a nominal 7 to 36 V dc power supply.
The modules will survive with full functionality if the supply voltage remains below 36 Vdc.
Specifications
Description Units Minimum Maximum Comment
Allowed voltage at pin V 0 36
Fuse rating A 0 50
Caution
PCB damage may occur. To prevent damage to the module all module power supply + pins must be
connected to the vehicle power supply to support advertised module maximum output current capacity.
DO NOT use module power supply + pins to supply power to other modules on a machine.
Sensor power supply ratings
PLUS+1® XL modules that support sensor inputs are provided with dedicated, software adjustable,
regulated sensor power supply and ground pins. XL104-xxxx supports two external sensor power
supplies, one fixed 5V supply and one variable supply 3 to 12V. Both are rated for 500mA at 5V.
General
Description Comment
Short circuit to ground Output is not damaged and fault is detected.
Short circuit to battery + Output is not damaged and fault is detected.
Fixed 5V Sensor Supply
Description Units Minimum Nominal Maximum Comment
Output voltage (actual) V 4.90 5 5.1 Fixed 5V output
Output voltage (internally
measured)
Output current mA - - 500
Output Load Capacitance µF - 10
V 4.85 5 5.15 +/- 1% from actual
Variable sensor supply
Description Units Minimum Nominal Maximum Comment
Output voltage (actual) V 3 - 12 The voltage level is
Output voltage (internally
measured)
3V setting voltage V 2.90 3.02 3.12
5V setting voltage V 4.89 4.99 5.10
12V setting voltage V 11.94 12.0 12.06
V 2.90 - 12.10 +/- 1% from actual
software adjustable
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PLUS+1® Controller XL104-xxxx
Product ratings
Variable sensor supply (continued)
Description Units Minimum Nominal Maximum Comment
Output current mA - - 500 @5V, Limit to 2.5 watts for
Output load capacitance µF 10
PVG valve power supply ratings
DOUT pins can provide the battery supply voltage required by Danfoss PVG valve electronics for those
control strategies requiring application software control of the valve power source.
When enabled, the DOUT pin passes battery (reference) voltage to the PVG valve electronics. One DOUT
pin can power up to 3 PVG valves.
Non-volatile memory read/write ratings
EEPROM write/erase ratings
Vout greater than 5V
To prevent unexpected memory writes, care must be taken to ensure memory with a high number of
read/write cycles is either U32 or S32 data types.
Write/erase cycles
Description Minimum Maximum Comment
EEPROM write/erase cycles 1 million Minimum valid over entire operating
temperature range.
EEPROM used in XL104-xxxx controllers is rated for 1 million read/write cycles per sector. Sector size is 32
bits. When a value is written to EEPROM, all 32 bits in a particular sector are always written, regardless of
the size of the size of the saved value. If the value being saved in a sector is less than 32 bits (such as U8,
S16, BOOL) adjacent bits in the same EEPROM sector are rewritten with their previous value.
The implication of this memory property is that if two values are being written to the same memory
sector, the useful life of the sector is determined by the value being written most frequently. If that value
exceeds 1 million read/write cycles, all values in the sector may be compromised if the useful life is
exceeded.
Vault memory
Some XL104-xxxx variants have 64 Mbyte of serial flash vault memory (also referred to as application
logging memory).
Application developers can use this memory to log machine event data and use the PLUS+1® Service Tool
to extract the logged data. As there is no real time clock on PLUS+1® modules, vault memory is not time
stamped.
Accessing non-volatile or application log memory can delay the service tool scan.
General ratings
XL controllers general ratings
Description Units Minimum Maximum Comment
Operating temperature ˚C [˚F] -40 [-40] 70 [158] @ 40 Amps sourcing
Operating temperature ˚C [˚F] -40 [-40] 85 (185) @ 20 Amps or less sourcing
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PLUS+1® Controller XL104-xxxx
Product ratings
XL controllers general ratings (continued)
Description Units Minimum Maximum Comment
Storage temperature ˚C [˚F] -40 [-40] 85 [185]
Allowable supply voltage Vdc 7 36
Sensor supply voltage Vdc 4.9 5.1
Analog input voltage levels Vdc 36
Maximum allowable total sourcing
output current
Maximum allowable total sinking
output current
Ingress Protection (IP) rating
CE rating CE compliant.
*
The PLUS+1® modules IP67 rating is only valid when the module mating connector is in place and unused
connector pin positions have sealing plugs installed.
Sensor voltage drops below the
minimum value if module supply
voltage < 7 Vdc. see Sensor power
supply ratings on page 16.
A 40/20 70/85°C [158/185°F]
A 20/12 70/85°C [158/185°F]
*
IP 67
Wake-up functions
Environmental testing criteria
Conditions to wake up XL104-xxxx
Either of two conditions will wake up the controller:
•
The power supplies can be re-energized by cycling battery power.
•
Generating a positive/rising edge on one of several inputs:
Eight of the DIN pins have K15 key switch wake capability. These are C2p11, C2p14, C2p15 and C2p20p25. K15 key switch wake capability will enable the XL104’s internal power supplies when a rising edge is
detected on one of these inputs. This assumes that power on C1p02 and ground on C1p01 are
continuously connected.
Climate environment
Description Applicable standard Comment
Storage temperature
Operating temperature
Thermal cycle
Humidity
Degree of protection IEC 60529
IEC 60068-2-1, test Ab, IEC
60068-2-2 test Bb
IEC 60068-2-1, test Ab, IEC
60068-2-2 test Bd
IEC 60068-2-2, test Na, IEC
60068-2-38 (partial)
IEC 60068-2-78, IEC
60068-2-30 test Db
Damp heat steady state and cyclic.
Chemical environment
Description Applicable standard Comment
Salt mist IEC 60068-2-58 test Kb
Chemical resistance ISO 16750-5
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Technical Information
PLUS+1® Controller XL104-xxxx
Product ratings
Mechanical environment
Description Applicable standard Comment
Vibration
Bump IEC 60068-2-29 test Eb
Shock IEC 60068-2-27 test Ea
Free fall IEC 60068-2-32 test Ed
Electrical/electromagnetic
Description Applicable standard Comment
EMC emission ISO 13766, SAE J1113-13 Electromagnetic compatibility for earth moving machinery.
EMC immunity ISO 13766 Electromagnetic compatibility for earth moving machinery.
Electrostatic discharge EN 60-1 000-4-2
Auto electrical transients
Short circuit protection Danfoss test Inputs and outputs survive continuous short circuit. Normal
Reversed polarity protection Danfoss test Survives reverse polarity at supply voltage for at least five
IEC 60068-2-6 test Fc, IEC
6008-2-64 test Fh
ISO 7637-2, ISO
7637-3
function resumes when short is removed.
minutes.
Modules housing
PLUS+1® modules housing features a assembly that is tamper-proof. Once assembled at the factory, the
housing cannot be opened for service.
Caution
Opening the device voids the warranty. Device is not field serviceable. Do not open the device.
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Technical Information
PLUS+1® Controller XL104-xxxx
Product installation and start-up
Connectors
PLUS+1® modules use DEUTSCH connectors. Danfoss assembles mating connector kits, referred to as 50p
C1 and 50p C2 kits, and 4p Cp kit.
Mating connector bag assembly ordering information is found in module product data sheets.
DEUTSCH mating connector part information
Description 4 pin Connector CP 50 pin connector C1 50 pin connector C2
Crimp tool HDT48-00 (solid contacts) (20
Contacts
Connector plug Grey No-Key DTP06-4S DRC26-50S01
Wedge WP-4S Not required Not required
Strip length 3.96 to 5.54 mm [0.156 to 0.218
Real seal maximum
insulation OD
Sealing plugs 114017 0413-204-2005 0413-204-2005
Mating connector
bag assembly
Mating connector
bag assembly
to 24 AWG)
DTT20-00 (stamped contacts)
(16 to 20 AWG)
Solid: 0462-203-12141
10, 12, 14 AWG
Stamped: 1062-12-0166
10, 12, 14 AWG
in]
3.4 mm to 4.95 mm [0.134 to
0.195 in]
11188220 (10 to 14 AWG) 10100946
HDT48-00 (solid contacts) (20
to 24 AWG)
DTT20-00 (stamped contacts)
(16 to 20 AWG)
Solid: 0462-201-2031
(20 to 24 AWG)
Stamped: 1062-20-0144
(16 to 20 AWG)
3.96 to 5.54 mm [0.156 to
0.218 in]
2.41 mm [0.095 in] 2.41 mm [0.095 in]
(20 to 24 AWG)
10102024
(16 to 20 AWG)
HDT48-00(solid contacts) (20
to 24 AWG)
DTT20-00 (stamped
contacts)
(16 to 20 AWG)
Solid: 0462-201-2031
(20 to 24 AWG)
Stamped: 1062-20-0144
(16 to 20 AWG)
DRC26-50S02
3.96 to 5.54 mm [0.156 to
0.218 in]
11249153
(16 to 20 AWG)
Danfoss crimp extraction tool part information
Description Part number
Crimp tool for 20 to 24 AWG 10100745
Crimp tool for 16 to 20 AWG 10102028
Extraction tool DEUTSCH 114010; 12 AWG 11068808
Extraction tool DEUTSCH 0411-240-2005; 16 to 20, 20 to 24 AWG 10100744
Mounting
Take care to position the module connector so that moisture drains away from the unit.
If the module is side mounted, provide a drip loop in the harness. If the module is mounted vertically, the
connector should be on the bottom of the module.
Provide strain relief for mating connector wires.
Caution
Module damage may occur. Use caution when installing modules. Due to the size of the mating connector
wire bundle, it is possible to damage the module if excessive pressure is applied during the installation of
harness strain relief.
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Technical Information
PLUS+1® Controller XL104-xxxx
Product installation and start-up
Fasteners
Recommended outer diameter (OD) Recommended torque
6.0 mm (0.25 in) 2.26 N•m (20 in•lbs)
Mating connectors
Recommended torque
2.26 N•m (20 in•lbs)
Machine diagnostic connector
Grounding
Hot plugging
Machine wiring guidelines
It is recommended that a diagnostic connector be installed on machines that are controlled by PLUS+1
modules. The connector should be located in the operator's cabin or in the area where machine
operations are controlled and should be easily accessible.
Communication (software uploads and downloads and service and diagnostic tool interaction) between
PLUS+1® modules and personal computers is accomplished over the vehicle CAN network. The diagnostic
connector should tee into the vehicle CAN bus and have the following elements:
•
CAN +
•
CAN -
•
CAN shield
Proper operation of any electronic control system requires that all control modules including displays,
microcontrollers and expansion modules be connected to a common ground. A dedicated ground wire
of appropriate size connected to the machine battery is recommended.
Machine power should be off when connecting PLUS+1® modules to mating connectors.
Warning
®
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.
Improperly protected power input lines against over current conditions may cause damage to the
hardware. Properly protect all power input lines against over-current conditions. To protect against
unintended movement, secure the machine.
Caution
Unused pins on mating connectors may cause intermittent product performance or premature failure.
Plug all pins on mating connectors.
The following is recommended when wiring on a machine:
•
Protect wires from mechanical abuse, run wires in flexible metal or plastic conduits.
•
Use 85˚ C (185˚ F) wire with abrasion resistant insulation and 105˚ C (221˚ F) wire should be
considered near hot surfaces.
•
Use a wire size that is appropriate for the module connector.
•
Separate high current wires such as solenoids, lights, alternators or fuel pumps from sensor and other
noise-sensitive input wires.
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Technical Information
PLUS+1® Controller XL104-xxxx
Product installation and start-up
•
Run wires along the inside of, or close to, metal machine surfaces where possible, this simulates a
shield which will minimize the effects of EMI/RFI radiation.
•
Do not run wires near sharp metal corners, consider running wires through a grommet when
rounding a corner.
•
Do not run wires near hot machine members.
•
Provide strain relief for all wires.
•
Avoid running wires near moving or vibrating components.
•
Avoid long, unsupported wire spans.
•
Ground electronic modules to a dedicated conductor of sufficient size that is connected to the
battery (-).
•
Power the sensors and valve drive circuits by their dedicated wired power sources and ground
returns.
•
Twist sensor lines about one turn every 10 cm (4 in).
•
Use wire harness anchors that will allow wires to float with respect to the machine rather than rigid
anchors.
Machine welding guidelines
PLUS+1® USB/CAN Gateway
Warning
High voltage from power and signal cables may cause fire or electrical shock, and cause an explosion if
flammable gasses or chemicals are present. Disconnect all power and signal cables connected to the
electronic component before performing any electrical welding on a machine.
The following is recommended when welding on a machine equipped with electronic components:
•
Turn the engine off.
•
Remove electronic components from the machine before any arc welding.
•
Disconnect the negative battery cable from the battery.
•
Do not use electrical components to ground the welder.
•
Clamp the ground cable for the welder to the component that will be welded as close as possible to
the weld.
Communication (software uploads and downloads and service and diagnostic tool interaction) between
PLUS+1® modules and a personal computer (PC) is accomplished using the vehicle's PLUS+1® CAN
network.
The PLUS+1® CG150-2 USB/CAN gateway provides the communication interface between a PC USB port
and the vehicle CAN bus. When connected to a PC, the gateway acts as a USB slave. In this configuration,
all required electrical power is supplied by the upstream PC host. No other power source is required.
Refer to the PLUS+1® GUIDE Software User Manual, AQ152886483724, for gateway set-up information.
Refer to the CG150-2 USB/CAN Gateway Data Sheet, AI00000190, for electrical specifications and
connector pin details.
22 | © Danfoss | August 2020 BC320261740866en-000101
Danfoss
Power Solutions GmbH & Co. OHG
Krokamp 35
D-24539 Neumünster, Germany
Phone: +49 4321 871 0
Danfoss
Power Solutions ApS
Nordborgvej 81
DK-6430 Nordborg, Denmark
Phone: +45 7488 2222
Danfoss
Power Solutions (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: +1 515 239 6000
Danfoss
Power Solutions Trading
(Shanghai) Co., Ltd.
Building #22, No. 1000 Jin Hai Rd
Jin Qiao, Pudong New District
Shanghai, China 201206
Phone: +86 21 2080 6201
Products we offer:
Hydro-Gear
www.hydro-gear.com
Daikin-Sauer-Danfoss
www.daikin-sauer-danfoss.com
DCV directional control
•
valves
Electric converters
•
Electric machines
•
Electric motors
•
Gear motors
•
Gear pumps
•
Hydrostatic motors
•
Hydrostatic pumps
•
Orbital motors
•
PLUS+1® controllers
•
PLUS+1® displays
•
PLUS+1® joysticks and
•
pedals
PLUS+1® operator
•
interfaces
PLUS+1® sensors
•
PLUS+1® software
•
PLUS+1® software services,
•
support and training
Position controls and
•
sensors
PVG proportional valves
•
Steering components and
•
systems
Telematics
•
Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and
electric components. We specialize in providing state-of-the-art technology and solutions
that excel in the harsh operating conditions of the mobile off-highway market as well as the
marine sector. Building on our extensive applications expertise, we work closely with you to
ensure exceptional performance for a broad range of applications. We help you and other
customers around the world speed up system development, reduce costs and bring vehicles
and vessels to market faster.
Danfoss Power Solutions – your strongest partner in mobile hydraulics and mobile
electrification.
Go to www.danfoss.com for further product information.
We offer you expert worldwide support for ensuring the best possible solutions for
outstanding performance. And with an extensive network of Global Service Partners, we also
provide you with comprehensive global service for all of our components.
Local address:
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products
already on order provided that such alterations can be made without subsequent changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
©
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