MoTeC DBW-4 User Manual

DBW-4

Drive By Wire Controller

User Manual

 Copyright – MoTeC Pty Ltd – 2001-2006

The information in this document is subject to change without notice.

While every effort is taken to ensure correctness, no responsibility will be taken for the consequences of any inaccuracies or omissions in this manual.

7 February, 2006

MoTeC DBW-4 2 Introduction

Contents

Introduction .........................................................................3

Abbreviations & Definitions...............................................4

Inputs & Outputs.................................................................5

PID Fault Conditions...........................................................6

Communications.................................................................7

CAN.................................................................................................................... 7

Firmware Upgrades ............................................................................................ 7

Configuration ......................................................................8

Drive By Wire Calibration ................................................................................... 9

Generic PID Controller Calibration ................................................................... 11

Diagnostic/Fault Condition Monitoring.............................................................. 13

Firmware Upgrades .......................................................................................... 13

Appendices........................................................................14

Appendix A: General Specifications ................................................................. 14

Appendix B: Input Characteristics .................................................................... 15

Appendix C: Output Characteristics ................................................................. 16

Appendix D: CAN Wiring – Multiple Device...................................................... 17

Appendix E: DBW-4 to M800 Wiring ................................................................ 18

Appendix F: DBW-4 Pin List by Pin Number .................................................... 19

Appendix G: DBW-4 Connector ....................................................................... 20

Notes ..................................................................................21

MoTeC DBW-4 3 Introduction

PID Controller

Introduction

This manual describes the functions and specifications of the MoTeC DBW4, and configuration for use with the
MoTeC “hundred” series ECUs (M400, M600 & M800). The DBW -4 works with ECU Firmware V3.30T and later.

The DBW4 provides 4 PID Controllers for drive by wire control or generic PID control.

PID Set points are received from the ECU over the CAN bus and are separate for each PID Controller. Each
controller can be individually configured for use as a generic PID Controller or drive by wire PID Controller.

When configured as a drive by wire PID Controller, the throttle position is tracked with 2 analog inputs for each
throttle body. Error checking is done on these inputs to ensure safety. Drive by wire PID Controllers have some
common functionality in that if one controller must be shutdown, for safety or due to an error condition, all other drive
by wire PID Controllers will be shutdown automatically.

When configured as generic PID Controllers, only one analog input is used per PID Controller for feedback, leaving
the remaining analog input for general use.

All scaled analog input values are transmitted over the CAN bus as well as PID fault conditions.

The DBW-4 has the following inputs and outputs:

• 8 Analog voltage inputs (AV 1-8) for PID Controller feedback and generic use.

• 8 PWM outputs (4 pairs) for PID Controller output.

The DBW-4 uses a 66 pin Autosport connector.

WARNING!

Drive by wire throttle body motors are very powerful and can cause serious injury to users or damage to the
throttle body. Never attempt to move the butterfly by hand with the motor connected to the DBW-4 Unit.

Value Tracking

Measured
Value

1

Measured Value

Measured

Measured

Value

2

Figure 1: DBW-4 Unit in a drive by wire application

DBW-4 Unit

Throttle Body

TP2

TP1

Motor

PWM1

PWM2

PWM

Output

Output A

Output B

MoTeC DBW-4 4 Introduction

Abbreviations & Definitions

DBW - Drive By Wire

ECU - Engine Control Unit

O/P - Output

PID - Proportional, Integral, Derivative Controller

PWM - Pulse Width Modulation

TP - Throttle Position One

TP2 - Throttle Position Two

TPD1 - TP One Driver

TPD2 - TP Two Driver

UTC - USB to CAN converter

Measured Value 1 & Measured Value 2

For drive by wire PID applications Measured Value 1 refers to TP & Measured Value 2 refers to TP2.

For generic PID applications Measured Value 1 is the analog input used for PID Controller feedback. The second
analog input is not used by the PID Controller and can be used as a generic analog input.

MoTeC DBW-4 5 Introduction

Inputs & Outputs

Inputs (AV1 – AV8)

The DBW-4 has eight 0-5V analog voltage inputs (AV1 to AV8). These are suitable for Potentiometers, voltage
output sensors and variable resistance (temperature) sensors (these require an external pull-up resistor to 5V).

These inputs are directly connected to the TP & TP2 position potentiometers on drive by wire throttle bodies.

Outputs

All outputs are disabled until the first CAN message is received. Outputs are disabled after no CAN messages have
been received for one second, but will resume once communication is re-established.

When outputs are disabled, all power is removed, relying on a safe return mechanism to return the actuator to a safe
position (eg. The butterfly valve return spring on a throttle bodies).

MoTeC DBW-4 6 Introduction

PID Fault Conditions

This section describes the fault conditions for each type of PID Controller. These fault conditions will be monitored
by the ECU for safe operation. During installation and fault finding, these conditions can be examined with the Motec
DBW-4 Manager software.

Commanded Shutdown

This is not strictly an error condition, but is included with the fault flags and hence handled here. A Commanded
Shutdown occurs when the ECU sets the set point of a PID Controller to a value of 1024. All other drive by wire PID
Controllers will shutdown. For Generic PID Controllers only the controller with a set point of 1024 will be shutdown.
For safety reasons, a power cycle is required to return to normal operation.

No Config Error

This condition occurs when the unit is powered, but not yet configured. In other words the range for both feedback
inputs (analog inputs) of the PID Controller is zero (TP & TP2 for drive by wire PIDs) or when the range of the first
feedback input of the PID Controller is zero (generic PIDs). Un-configured PID Controllers will be shutdown until
configured.

Measured Value 1 & Measured Value 2 Tracking

This error condition only applies to drive by wire PID Controllers. This error condition occurs when TP & TP2 values
are not tracking to within 10% of each other for more than 2 seconds. Since safe operation can not be ensured
under this condition, all drive by wire PID Controllers will be shutdown.

Set Point and Measured Value 1 Tracking

This error applies to all PID Controller types. This error condition occurs when the feedback value for the PID and
the required set point do not correlate to within 10% for more than 1 second. For a drive by wire application, if the
throttle position differs by more than 10% from the required (specified) position for more than 1 second, the PID
Controller (and all other drive by wire PID Controllers) will be shutdown.

Status/PWM Error

This error applies to all PID Controller types. This error condition occurs when an over-current or over-temperature
condition occurs. The limit for over-current is 8A and for over-temperature in the range 160˚C to 190˚C. This
condition shuts down the PID Controller. If the PID Controller is a drive by wire type, all other drive by wire PID
Controllers will be shutdown as well. For safety a power cycle is required to clear this error.

Measured Value 1 End Of Scale

This error applies to all PID Controller types. This error condition occurs when Measured Value 1 (TP for drive by
wire PID Controllers) goes more than a certain amount above or below the calibrated maximum or minimum values
for a more than 1 second. This will cause the PID Controller to be shutdown and all PID Controllers to be shutdown if
this controller is a drive by wire type.

Measured Value 2 End Of Scale

This error only applies to drive by wire PID Controller types. This error condition occurs when Measured Value 2
(TP2 for drive by wire PID Controllers) goes more than a certain amount above or below the calibrated maximum or
minimum values for a more than 1 second. This will cause the PID Controller to be shutdown (and all drive by wire
PID Controllers to be shutdown if this controller is a drive by wire type.)

No CAN Communication

This condition can not be monitored from the MoTec DBW-4 Manager Software, but still causes the PID Controllers
to shutdown, although only temporarily. If no CAN message is received for more than 1 second, all PID Controllers
are shutdown. Once communication is re-established, operation will continue as before. No power cycle is required
to clear this error.

MoTeC DBW-4 7 Introduction

Communications

CAN

The CAN bus is used for PC communications during testing, calibration and firmware upgrades, and for
communicating to the ECU.

The following data is transmitted by the DBW-4 at 200Hz:

• Measured Values 1 & 2 for each PID (AV1-AV8)

• Measured Value 1 with PID diagnostic information.

The following data is transmitted by the DBW-4 at 50Hz:

• Output driver faults

• Internal temperature

• Internal voltages (-5v, 8vAux, 5vAux, Vbat, 4.5v)

• DBW-4 status flags

• DBW-4 firmware version

The following data is received by the DBW-4 from the ECU:

• PID1 to PID 4 set points

Firmware Upgrades

At times MoTeC may release firmware upgrades for the DBW-4 Units. Upgrades are performed over the CAN bus
using a MoTeC CAN cable and the MoTec DBW-4 Manager Software. See the section DBW-4 Configuration for
more information. Currently the MoTec DBW-4 Manager Software does not support the MoTeC UTC.