POWER SYSTEM MODE STATUS

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1 SX NFPE Control System System Description 4, 60,2 8, 8, , 0, AMP Stecker AMP Connector

2 Overview DESCRIPTION The Sauer-Danfoss NFPE (Non-Feedback Proportional Electric) System for Automotive Applications using NFPE Pump only, Two Position or Proportional Controlled Motor combines the future-oriented technology of the Off Highway Digital Electronic Control with Sauer-Danfoss's proven axial piston pump technology. The SX mobile computer combines enhaed control performae with a flexible control scheme. The controller converts engine speed to an automotive drive signal to control the non-feedback proportional axial piston pump. Also, the controller supplies a speed dependent control for a two position controlled motor or electric proportional control for a bent axis motor. With easily changeable control parameters, it is possible to tailor the vehicle's driving behavior to the individual requirements of the machine. Two important features of the Sauer-Danfoss control system are the integral park brake control, which is an essential part of the success of the HST in the forklift truck market and the integral motor control which provides an automatic shift of two position or proportional motors. With this control the HST motor always starts at maximum displacement. FEATURES Selectable driving behavior (setting different parameters) with service tool software. Engine overspeed protection (ih mode). High propel speed at low engine speed. Less noise emission. Two automotive control curves (selectable via mode switch). Electronic ramps instead of orifices. Less oil viscosity sensitivity. Easy start-up procedure during production if needed. Integral park brake control (no downhill rolling). Integral two position motor control (motor starts at max. displacement). Integral motor control (electric proportional control J ). COMPONENTS Series 42 or Series 90 NFPE axial piston pump Series or - bent axis motor Series bent axis motor with J or J4 control SX NFPE Mobile Computer Ih Pedal KEPA46 (968) - Optional Ih Sensor MCX0B04 (24666) - Optional note rotation and polarity High speed axial piston motor plus axle or CAM motors 200, Sauer-Danfoss Sauer-Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Sauer -Danfoss reserves the right to alter its products without prior notice. This also applies to products already ordered provided that such alterations can be made without subsequent changes being necessary in specifications already agreed. All trademarks in this material are properties of the respective companies. Sauer-Danfoss and the Sauer-Danfoss logotype are trademarks of the Sauer-Danfoss Group. All rights reserved. 2 BLN E Rev. C 08/200

3 SX Mobile Microcomputer LED OVERVIEW 4 6 4, 60,2 8, 8, , 0, SX 2 Mounting slots AMP connector 4 Diagnostic LED red Error check () Lights up if an error is detected. Diagnostic LED yellow Software check () Flashes with approx. 0.Hz (slow) if the program is running fine. Flashes with approx. Hz (fast) if no program is loaded. No flashing if in setup mode. 6 Diagnostic LED green V DC internal () Lights up if V DC internal is O.K. Diagnostic LED green Battery after ignition switch () Lights up if the battery voltage is connected after ignition. BLN E Rev. C 08/200 S069b

4 Control Characteristics NEW NFPE CONTROL BLOCK SERIES 90 M6 M M M4 M A M2 B L S L2 valves S0 CONTROL CHARACTERIS- TICS OF PILOT CURRENT TO THE NFPE Figure : Example of pump automotive control curves Ι Ι NOM. Figure 2: Example of proportional motor automotive control curve Ι Ι Ι DROOP Ι Ι START Ι START 0 RPM 0 RPM START RPM RPM DROOP RPM NOM. RPM 0 RPM MAX. DISPLACEMENT RPM MIN. DISPLACEMENT RPM HI RPM S048_2e S048_0e Figure : Example of two position motor control setting Ι threshold max. displacement min. displacement 0 RPM S048_09e 4 BLN E Rev. C 08/200

5 System Diagram DIAGRAM EXAMPLE: PUMP AND FIXED MOTOR CONTROL SX + Batt. 2/24V DC - FNR switch Ih pedal or sensor Hand brake switch NFPE Valve valve forward valve reverse Axial piston or CAM motor(s) Engine PPU Series 90/42 Brake solenoid Brake S00c BLN E Rev. C 08/200

6 System Diagram DIAGRAM EXAMPLE: PUMP AND TWO POSITION MOTOR CONTROL SX + Batt. 2/24V DC - FNR switch Ih pedal or sensor Mode switch NFPE Valve valve forward valve reverse Engine PPU engine Series 90/42 Motor displacement Vg max S02c 6 BLN E Rev. C 08/200

7 System Diagram DIAGRAM EXAMPLE: PUMP AND PROPORTIONAL MOTOR CONTROL SX + Batt. 2/24V DC - FNR switch Ih pedal or sensor Mode switch NFPE Valve valve forward valve reverse PPU motor Series Engine PPU engine Series 90/42 valve motor control S0c BLN E Rev. C 08/200

8 System Diagram GENERAL DIAGRAM SX FNR switch Ih pedal or sensor Mode switch Creeper drive + - Batt. 2/24V DC Creeper drive switch or Handbrake switch NFPE Valve valve forward valve reverse PPU motor Series Engine PPU engine Series 90/42 Motor displacement Vg max valve motor control Brake solenoid S06a 8 BLN E Rev. C 08/200

9 Theory of Operation THEORY OF OPERATION Automotive Curve FNR Switch Ih Pedal/Sensor The Sauer-Danfoss SX Mobile Computer controls the axial piston pump via (2) proportional pressure reducing valves. The automotive control curve is a fution of the engine speed measured with the integral pulse pick-up on the pump. The automotive curve has to be set according to the available torque characteristic of the combustion engine bearing in mind the need for additional auxiliary power. The curve can be optimized during the prototype phase via a laptop computer using the Sauer-Danfoss WinGPI. The driving direction is selectable with the FNR switch. A ramp is adjustable for reversing, switching to neutral and acceleration/deceleration. The ih pedal/sensor reduces the current to the pressure reducing valves which results in a destroked transmission pump. This fution allows the operator to keep the vehicle propel speed low while raising the engine speed to meet the flow demand from the auxiliary futions. The ih sensor requires calibration during vehicle setup or a preadjusted sensor. Note: If a potentiometer is used, it should have a resistae value of kω and 0 kω. If there is a need for the whole range, then the potentiometer must have series resistors. The series resistors have to be approximately % of the resistae value. The voltage of the analog input must irease if the pedal is pushed. 68Ω kω 68Ω Engine Overspeed Protection Park Brake Control Two Position Motor Control Proportional Motor Control Mode Switch Handbrake Switch Creep Mode Speed Limitation In case of engine overspeed while ihing, the pump current is ireased proportionally up to the max. value (adjustable: RPM overspeed START, RPM overspeed END = 00%). In case of engine overspeed due to downhill driving (exceeding the braking performae of the engine) mechanical brakes are needed to protect the engine. The park brake control operates an electrical ON/OFF solenoid to protect the vehicle from rolling in the neutral swashplate position of the axial piston pump. The control can be a fution of the output current to the pressure reducing valves or of the ih pedal. The control provides an automatic shifting of the two position bent axis motor. The switchpoint of the motor is a fution of engine speed. The switchpoint for the motor has to be optimized during the prototype phase. The control provides an automotive curve to control an electric proportional motor with a J or J4 control. The control curve is a fution of the engine speed and is adjustable totally independent of the pump curve. The curves have to be optimized during the prototype phase.the control pressure of the motor (X) is charge pressure (2 bar). Two different and independent automotive curves for the pump and motor can be selected by the mode switch, allowing for optimization of the driving behavior of the vehicle individually for both modes (work/transport). The handbrake input overrules the FNR signal. If the handbrake is activated, the system will go into the stop mode like switching the FNR to neutral. The creep mode works similar to the ih pedal/sensor, but it will use the adjustable acceleration/deceleration delay times. The creep mode must be activated with a digital input. The system can recognize the activation in all conditions or only in neutral, depending on the configuration. The creep mode does not contain an engine overspeed protection and will only work if the engine is above an adjustable RPM. The speed limitation reduces the current to the hydrostatic motor or pump if the vehicle exceeds a certain speed. This can prevent the motor from overspeeding while driving downhill. On the transmission side, a speed signal is required, which is under diagnostic. If no speed signal is detected in conditions where the vehicle normally should move, an error will be set, and the automotive curve will be used for the motor. This automotive curve should not be critical regarding overspeeding the motor. If the speed signal returns, both curves can be used again and the error will be deleted. BLN E Rev. C 08/200 9

10 MENU CODE COMMAND ESC ENTER SX NFPE Control System Connectors CONNECTORS SX Crimp tool for power timer (09) Die set for power timer (096) Crimp tool for micro timer (09) Measuring Adapter (098)) 2 Recommendation MCX0B04 (24666) only for optimization) 4 We do not supply FNR and mode switches, therefore no connectors can be recommended. AMP Connector (226) NFPE Junior Power Timer (0888) (2x) RS22 Connector (socket) (02) For Field Service and Diagnosis SUSMIC-DIA (0480) RS22 Cable (24) Metri-Pack Connector (44) 2 MCX0B Ih Pedal PPU with Turck Connector (Part of the Pump) straight (0024) or rightangle (002) Junior Power Timer (0888) Motor Displacement Vg max or Junior Power Timer (0888) Pressure Reducing Valve Motor Control S06a 0 BLN E Rev. C 08/200

11 System Connection Diagram CONNECTION DIAGRAM Contact capability min. 6A Malting fuse 0A Position shown: Neutral Used for SUSMIC-DIA Max. current output 2A Displacement: None/2-Position/Proportional Max..2A each pin AMP connector, 42pin F FNR switch Sensor (-) Digital Input 0 2 R Digital Input Digital Input 2 4 Mode switch Digital Input High Current 0 (+) High Current (+) High Current 0 FB (-) High Current FB (-) Creeper drive switch or Hand brake switch 0 2 FORWARD REVERSE NFPE valve RS22 Ground Sensor (+) Battery (-) 4 Terminals (-) Sensor PPU Input 0 PPU Input RS22 TxD RS22 RxD High Current 4 (+) High Current (+) PPU engine PPU motor Diagnostic connector (SUB-D, 9pin, socket) Motor displacement Vg MAX 6 Terminals (-) Battery (+) Battery (-) valve motor control 6 Analog Input 0 Analog Input 0 2 Brake solenoid Battery (+) Terminals (+) Sensor R V R V R V kω R V Ih pedal Creeper drive Terminals (+) S 2 F + - Batt. 2/24V DC a_e BLN E Rev. C 08/200

12 OUR PRODUCTS Hydrostatic transmissions Hydraulic power steering Electric power steering Closed and open circuit axial piston pumps and motors Gear pumps and motors Bent axis motors Radial piston motors Orbital motors Transit mixer drives Planetary compact gears Proportional valves Sauer-Danfoss Hydraulic Power Systems Market Leaders Worldwide Sauer-Danfoss is a comprehensive supplier providing complete systems to the global mobile market. Sauer-Danfoss serves markets such as agriculture, construction, road building, material handling, municipal, forestry, turf care, and many others. We offer our customers optimum solutions for their needs and develop new products and systems in close cooperation and partnership with them. Sauer-Danfoss specializes in integrating a full range of system components to provide vehicle designers with the most advaed total system design. Sauer-Danfoss provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world. Directional spool valves Cartridge valves Hydraulic integrated circuits Hydrostatic transaxles Integrated systems Fan drive systems Electrohydraulic controls Digital electronics and software Battery powered inverter Sensors Sauer-Danfoss (US) Company 2800 East th Street Ames, IA 000, USA Phone: , Fax: Sauer-Danfoss (Neumünster) GmbH & Co. OHG Postfach 2460, D-24 Neumünster Krokamp, D-249 Neumünster, Germany Phone: , Fax: Sauer-Danfoss (Nordborg) A/S DK-640 Nordborg, Denmark Phone: , Fax: Sauer-Danfoss (US) Company 00 Annapolis Lane North Minneapolis, MN 44, USA Phone: , Fax: BLN E Rev. C 08/200