CONTROL SYSTEM DATA ALLISON 4TH GENERATION CONTROLS

Transcription

1 CONTROL SYSTEM DATA ALLISON 4TH GENERATION CONTROLS Contents: APPLICABLE MODELS: 1000 Product Family 2000 Product Family 3000 Product Family 4000 Product Family H 40/50 EP 1.0 Maximum Power and Ground Wire Lengths /2000, 3000, 4000 Product Families 1.2 H 40/50 EP 2.0 Control Module Data Voltages Current Temperature Limits Component Weight 3.0 Allison Shift Selector Data Voltage Requirements Current Requirements Temperature Limits Component Weight Digital Display 4.0 Other Controls Components Wiring Harness and Connectors Throttle Position Sensor (TPS) Vehicle Interface Module (VIM) 5.0 Speedometer Output 6.0 Input and Output Requirements 6.1 Switch-To-Ground Inputs 6.2 Switch-To-Battery Inputs 6.3 Switch-To-Ground Outputs 6.4 Switch-To-Battery Output 6.5 Neutral Start Output List of Referenced Documents Revision History G4DATA 2015 Allison Transmission, Inc. All Rights Reserved. March 5, 2015

2 ALLISON 4TH GENERATION CONTROLS SYSTEM DATA 1.0 MAXIMUM POWER AND GROUND WIRE LENGTHS BASED ON TOTAL CIRCUIT RESISTANCE REQUIREMENTS 1.1 MAXIMUM POWER AND GROUND WIRE LENGTHS 1000/2000, 3000, 4000 PRODUCT FAMILIES Input and output voltages for this control system are defined at the TCM pins. Voltage potentials develop along all cables and circuit traces depending on material, length, and thickness. The input and output voltages listed do not account for parasitic voltage drops in the vehicle wiring system. Vehicle design must accommodate parasitic voltages associated with vehicle wiring. Proper choices in wire lengths and thicknesses can reduce the effects of parasitic voltages. The following table provides a guide to the selection of conductors for the TCM power and ground circuits. Maximum A + B Wire Length for: G4-108A Resistance for length A must be less than 1.0 mω. Total resistance for Lengths (A + B) must be 100 mω or less. mω per Single Wire Double Wire meter (ft) System* System* GA at 20 C meter (ft.) meter (ft.) (0.3952) (253) (506) (0.6281) (159) (318) (0.9988) (100) (200) (1.59) (62) (124) (2.52) (39) (78) (4.02) (24) (48) N/A 9.1 (6.39) (30) Maximum C Wire Length: 12.2 meters (40 feet) * Lengths based on standard annealed copper wire. NOTE: All data is applicable to both 12-volt and 24-volt installations. Conversions between Metric and U.S. units are not necessarily equivalent. Allison 4th Generation Controls: System Data March 5, 2015 Page 2

3 1.0 MAXIMUM POWER AND GROUND WIRE LENGTHS (CONTINUED) BASED ON TOTAL CIRCUIT RESISTANCE REQUIREMENTS 1.2 MAXIMUM POWER AND GROUND WIRE LENGTHS H 40/50 EP Input and output voltages for this control system are defined at the component pins. Voltage potentials develop along all cables and circuit traces depending on material, length, and thickness. The input and output voltages listed do not account for parasitic voltage drops in the vehicle wiring system. Vehicle design must accommodate parasitic voltages associated with vehicle wiring. Proper choices in wire lengths and thicknesses can reduce the effects of parasitic voltages. The following table provides a guide to the selection of conductors for the power and ground circuits for the various Allison H 40/50 EP controls components. Maximum A + B Wire Length for: mω per Single Wire Double Wire meter (ft) System* System* GA at 20 C meter (ft.) meter (ft.) (0.3952) (253) (506) (0.6281) (159) (318) (0.9988) (100) (200) (1.59) (62) (124) (2.52) (39) (78) (4.02) (24) (48) N/A 9.1 (6.39) (30) Total resistance for Lengths A + B must be 100 mω or less. Resistance for length A must be less than 1.0 mω. Allison recommends that the wire from the battery to the bus bars (Length A) be at least 1/0 gauge. Maximum C Wire Length: 12.2 meters (40 feet) * Lengths based on standard annealed copper wire. Conversions between Metric and U.S. units are not necessarily equivalent. Allison 4th Generation Controls: System Data March 5, 2015 Page 3

4 2.0 CONTROL MODULE DATA G4-118A 1000/ /4000 H 40/50 EP TCM TCM VCM V IGN Wire # V BAT + Wire # 110 / / / 170 V BAT Wire # 109 / / / 169 NOTES: All voltages and currents are as measured at the Control Module* pin. Wire lengths, connection points, terminal corrosion, and system current draw should be considered when choosing wire sizes and lengths for Control Module* battery power and battery return connections. Conversions between metric and U.S. units are not necessarily equivalent. Control Module* Configuration 12-volt 24-volt Control Module* Model Designations A50, A51, A52, A53, A54 A53 PARAMETER VALUE VALUE UNITS Voltage Input at Control Module* V BAT Min. Temporary Control Module Operation Volts Minimum Temporary CAN Communication Volts Minimum Continuous Operation Volts Maximum Continuous Operation Volts Minimum While Engine Cranking Volts Jump Start Volts Reverse Voltage Protection from 0.1Ω source 16.0 ** 32.0 ** Volts Ignition Sense (V IGN ) Minimum Volts Current Input at Control Module* 1000/ / Product Families H40/50EP I BAT Maximum During Normal Operation Amperes Maximum After Ignition Shutdown ma I IGN Maximum Ignition Input Current ma VIM Relay Contacts*** Maximum Continuous Amperes Maximum Intermittent Amperes Maximum Continuous All Relays Amperes Minimum Amperes * Control Module = TCM (A50, A51, A52, or A53) for 1000/2000/3000/4000 Product Families = TCM (A54) & VCM (A54) for H 40/50 EP ** Reverse voltage for time required to blow Little fuse # or equivalent *** VIM = Vehicle Interface Module for 1000/2000/3000/4000 only; Values are for inductive loads Allison 4th Generation Controls: System Data March 5, 2015 Page 4

5 2.0 CONTROL MODULE DATA (CONTINUED) Control Module* Configuration 12-volt 24-volt Control Module* Model Designations A50, A51, A52, A53, A54 A53 PARAMETER VALUE VALUE UNITS Temperature Limits 1000/ / Product Families H40/50EP Operating: Maximum Continuous 105 (220) 85 (185) 105 (220) 85 (185) o Operating: Minimum Exposure (Startup) - 40 (- 40) - 40 (- 40) - 40 (- 40) - 40 (- 40) o Non-Operating: Maximum Continuous 140 (284) 140 (284) 140 (284) 140 (284) o Non-Operating: Minimum Continuous - 54 (- 65) - 54 (- 65) - 54 (- 65) - 54 (- 65) o Component Weight Control Module* assembly 0.56 (1.23) 0.56 (1.23) kg (lb) * Control Module = TCM (A50, A51, A52, A53) for 1000/2000/3000/4000 Product Families = TCM (A54) & VCM (A54) for H 40/50 EP Temperature Limits are for still air surrounding the component (measured 20mm from component) Conversions between Metric and U.S. units are not necessarily equivalent. Allison 4th Generation Controls: System Data March 5, 2015 Page 5

6 3.0 ALLISON SHIFT SELECTOR DATA NOTES: Applicable to the 3000 and 4000 Product Families all selector types Applicable to the H 40/50 EP keypad pushbutton selectors only All voltages and currents are as measured at the shift selector pin. Wire lengths, connection points, terminal corrosion, and system current draw should be considered when choosing wire sizes and lengths for power and ground requirements. Conversions between metric and U.S. units are not necessarily equivalent. PARAMETER VALUE UNITS Voltage Input Minimum Temporary Operation 9.0 Volts Minimum Continuous Operation 10.5 Volts Maximum Continuous Operation 32.0 Volts Minimum While Engine Cranking 4.5 Volts Maximum Reverse Battery Continuous (with no damage) 32.0 Volts Current Input Typical at Nominal Input Voltage 160 ma Maximum Current Draw (I DRAW ) at Any Continuous V DC 300 ma Maximum at standby 2.5 ma Maximum Dimmer 100 ma Temperature Limits * Operating: Maximum Continuous 85 (185) o Operating: Minimum Exposure (Startup) 40 ( 40) o Non-Operating: Maximum Continuous 105 (220) o Non-Operating: Minimum Continuous 54 ( 65) o Component Weight Lever Selector 1.50 (3.30) kg (lb) Standard Keypad Pushbutton Selector 0.22 (0.48) kg (lb) Common Keypad Pushbutton Selector 0.23 (0.51) kg (lb) Compact Keypad Pushbutton Selector 0.24 (0.54) kg (lb) Strip Pushbutton Selector (3-Button) 0.25 (0.55) ** kg (lb) Strip Pushbutton Selector (6-Button) 0.37 (0.82) ** kg (lb) Digital Display Minimum brightness at maximum intensity Color 350 Foot-Lamberts at 150 cm Blue-green ( nanometers) * Values are for still air surrounding the component (measured 20mm from component) ** Estimated data Allison 4th Generation Controls: System Data March 5, 2015 Page 6

7 4.0 OTHER CONTROLS COMPONENTS* PARAMETER VALUE UNITS HARNESS CONNECTORS: Temperatures: Maximum Exposure 120 (250) ** o Intermittent Heat Soak 150 (300) *** o For harness information, refer to: Technical Document 173 (TD-173) for 1000/2000/3000/4000 Product Families Technical Document 169 (TD-169) for H 40/50 EP Low Voltage Harnesses THROTTLE POSITION SENSOR (TPS) Temperatures: Maximum Continuous 120 (250) *** o Intermittent Heat Soak 150 (300) *** o VEHICLE INTERFACE MODULE (VIM): Component Weight: 1.05 (2.32) kg (lb) Operating Temperatures: Maximim Continuous 85 (185) *** o Minimum Exposure (Start-Up) 40 ( 40) *** o Non-Operating Temperatures: Maximim Continuous 105 (220) *** o Minimum Continuous 54 ( 65) *** o * For Control Module data, refer to Table 2. For Shift Selector data, see Table 3. ** Values are for surface of the component *** Values are for still air surrounding the component (measured 20mm from component) Conversions between Metric and U.S. units are not necessarily equivalent. Allison 4th Generation Controls: System Data March 5, 2015 Page 7

8 5.0 SPEEDOMETER OUTPUT 1000/ /4000 H40/50EP TCM TCM Output Wire # Battery Return Wire # WAVEFORM CHARACTERISTICS NOTE: All data is applicable to both 12-volt and 24-volt installations. Parameter Min. Typ Max. Unit Notes Duty Cycle % V Speedo Low Volts V Speedo High V BAT 2.0 V BAT Volts Source Current* 8 V Speedo = V BAT 2.0 Sink Current** 8 V Speedo = 0.5 V Frequency 3700 models 9 or 18 All Others 8, 16, or 40 Pulses per output rev. This signal may not provide an accurate representation of speed below a low-speed threshold. See NOTE below. Load Capacitance 0.1 µf Depends on speedometer (C Load ) system on vehicle. * When V Speedo is High ** When V Speedo is Low NOTE: This signal will not accurately represent speed below a low-end threshold. Before using this signal to represent very low vehicle speed, the validity of the signal must be verified by the vehicle system designer or installer. Such analysis must confirm both the low-speed signal strength and waveform, preferably using an oscilloscope. G Under no load condition, rise and fall time is 90% of steady state voltage obtained in 10% of period. Waveform rise and fall times will vary as a function of the load impedance. Allison 4th Generation Controls: System Data March 5, 2015 Page 8

9 6.0 INPUT AND OUTPUT REQUIREMENTS 6.1 SWITCH-TO-GROUND INPUTS Resistance Based Circuit Voltage / Current Based Circuit 1000/2000/3000/4000 H 40/50 EP H 40/50 EP TCM TCM VCM GPI Wire # 101, 117, 121, 122, 142, 301, 317, 321, 322, 101, 122, 157, 161, 162, , 361, , 161 Signal Return Wire # Parameter Min. Nom. Max. Units Notes Input Activated: R Switch Ohms I Switch 5 ma R Switch less than or equal to 10 ohms V GPI Volts V GPI is defined for an open collector transistor output as referenced to the signal return pin at the control module. Input Deactivated: R Switch 10 kohms I Leakage µa I Leakage is the leakage current of an open collector transistor. V GPI 3.44 Volts V GPI is defined for an open collector transistor output as referenced to the signal return pin at the control module. V PU 5.0 Volts V PU is present whenever the Control Module is on NOTE: All data is applicable to both 12-volt and 24-volt installations. GPI switch-to-ground inputs are designed to be used with two input types: 1. Switches from Allison GPI's to wire 103 or Open collector transistor outputs of other electronic control modules. Voltage differentials between the Allison control module's battery return and the vehicle ground point for another module can cause problems such as ground loops. Switch-to-ground inputs should only be switched to Signal Return wire (wire 103 or 303) of the Allison 4th Generation Controls system. ONLY the Allison 4th Generation Controls Switch-to-Ground Input wires may be switched to Signal Return wires 103 and 303. Do NOT connect wire 103 or 303 to battery return, vehicle chassis, or switch to any wire other than a GPI wire. Allison 4th Generation Controls: System Data March 5, 2015 Page 9

10 6.0 INPUT AND OUTPUT REQUIREMENTS (CONTINUED) 6.2 SWITCH-TO-BATTERY INPUTS 1000/2000/3000/4000 H 40/50 EP H 40/50 EP TCM TCM VCM GPI Wire # 102, 123, , 323, Battery Return Wire # Parameter Min. Max. Units Notes Input Activated: R Switch 2 kohms I Switch 1 15 ma R Switch less than or equal to 10 ohms V GPI 3.44 Volts Input Deactivated: R Switch 200 kohms I Leakage µa I Leakage is the leakage current V GPI 2.0 Volts NOTE: All data is applicable to both 12-volt and 24-volt installations. All voltages are as measured at the Control Module pins. Problems can be averted by minimizing the voltage differentials between the Allison Control Module ground and the ground of voltage source based GPI inputs. Allison 4th Generation Controls: System Data March 5, 2015 Page 10

11 6.0 INPUT AND OUTPUT REQUIREMENTS (CONTINUED) 6.3 SWITCH-TO-GROUND OUTPUTS 1000/2000/3000/4000 H 40/50 EP H 40/50 EP TCM TCM VCM 104, 105, 113, 124, 145, 150, 164, 304, 313, 324, 104, 105, 124, 145, 150, 164 Wire Number 165 (Reverse Warning), 345, (Reverse Warning), 129 (Check Trans Light) 129 (Stop System Indicator) Battery Return Wire # Parameter Min. Max. Units Notes Signal Active: V GPO 1.0 Volts at I GPO = 500 m I GPO 500 ma at V GPO = 1 volt Signal Inactive: TCM On: I GPO 150 µa TCM Off: I GPO 20 µa NOTE: All data is applicable to both 12-volt and 24-volt installations. All voltages are as measured at the Control Module pin. Allison 4th Generation Controls: System Data March 5, 2015 Page 11

12 6.0 INPUT AND OUTPUT REQUIREMENTS (CONTINUED) 6.4 SWITCH-TO-BATTERY OUTPUT GPO1 (General Purpose Output 1) Circuit 3000/4000 Product Families Only Parameter Min. Max. Units Notes Signal Active: V GPO1 (V BAT v) V BAT Volts Min. V GPO1 when I GPO1 = 500 ma I GPO1 500 ma Max. I GPO1 when, (Max. Source V GPO1 = (V BAT - 1.2) volts Current) Signal Inactive: I GPO1 TCM On: 100 µa (Leakage Current when inactive) TCM Off: 20 µa (Leakage Current when inactive) NOTE: All data is applicable to both 12-volt and 24-volt installations. All voltages are as measured at the TCM pin. Allison 4th Generation Controls: System Data March 5, 2015 Page 12

13 6.0 INPUT AND OUTPUT REQUIREMENTS (CONTINUED) 6.5 NEUTRAL START OUTPUT NS (Neutral Start) Circuit 1000/2000/3000/4000 Product Families Only Parameter Min. Max. Units Notes Signal Active: V NS (V Battery Power v) V Battery Power Volts Min. V NS when I NS = 800 ma I NS 800 ma (Max. Source Current) Signal Inactive: I NS TCM On: 100 µa (Leakage Current when inactive) TCM Off: 20 µa (Leakage Current when inactive) NOTE: All data is applicable to both 12-volt and 24-volt installations. All voltages are as measured at the TCM pin. Once activated, the neutral start output will remain On down to V BAT of 4.5 volts. Neutral Start is defined only for passive loads such as a relay. The Neutral Start signal is not intended to be used as a direct input to other controllers. Allison 4th Generation Controls: System Data March 5, 2015 Page 13

14 LIST OF REFERENCED DOCUMENTS Technical Documents (TD's) TD-173, Wiring Harnesses for Transmissions with Allison 4th & 5th Generation Controls TD-169, Low Voltage Harnesses for Allison H 40/50 EP These documents may be found in the Extranet channel of the Allison Transmission website, To locate the referenced document look for Tech Data under the Engineering heading on the Extranet home page. In this document, the reference is identified by italic font. Contact your Allison Transmission representative if you do not have access to the Allison Transmission Extranet. Allison 4th Generation Controls: System Data March 5, 2015 Page 14

15 REVISION HISTORY March 5, 2015 Updated comments regarding component temperature limits to clarify that unless otherwise noted, temperature limits are for still air surrounding the component (measured 20 mm from component) October 29, 2013 Changed E P 40/50 System TM to H 40/50 EP throughout document. In Table 2.0, removed the A54 TCM, used with the H 40/50 EP, from the 24-volt column. December 7, 2009 Added E P 40/50 System TM throughout document, including: - Addition of Table 1.2, Maximum Power and Ground Wire Lengths for the E P 40/50 System TM - Changed Transmission Control Module (TCM) to Control Module to include the E P 40/50 System TM TCM and VCM control modules - Added E P 40/50 System TM wire numbers where appropriate - Added TD-169, Low Voltage Harnesses for Allison Electric Drives TM, to Table 4.0 and to List of Referenced Documents. Added A50 controller to Table 2.0, Control Module Data In Table 6.1, Switch-to-Ground Inputs, added that the V GPI definition is referenced to the signal return pin at the control module. In Table 6.4, Switch-to-Battery Output, V GPO1 = (V BAT - 1.2) volts was V GPO1 = (V BAT - tbd) volts. In Table 6.5, Neutral Start Output, clarified that Neutral Start is not intended as a direct input to other controllers. September 19, 2008 Removed Table 2.2, TCM Data Prior to MY09 Added link to TD173 and List of Referenced Documents May 8, 2008 Renamed document from Controls Specifications to Control System Data Throughout document changed specification to data and specified to defined. March 13, 2008 Table 5 - Speedometer Output: Added notes regarding validity of low-speed signal. June 27, 2007 Added information for Model Year 2009 (Table 2a) June 15, 2006 Table Added information for I Leakage Current October 15, 2005 Table 1 - Added note in lower left corner "Resistance for length A must be less than 1.0 mω". Table 2 - Corrected conversion of 85 o C (from 153 o F to 185 o F) in Temperature Limits - Operating: Maximum Continuous. Allison 4th Generation Controls: System Data March 5, 2015 Page 15

16 Contents Control System Data 1.0 Maximum Power and Ground Wire Lengths Based on Total Circuit Resistance Requirements 1.1 Maximum Power and Ground Wire Lengths 1000/2000, 3000, 4000 Product Families 1.0 Maximum Power and Ground Wire Lengths (continued) Based on Total Circuit Resistance Requirements 1.2 Maximum Power and Ground Wire Lengths H 40/50 EP 2.0 Control Module Data 2.0 Control Module Data (Continued) 3.0 Allison Shift Selector Data 4.0 Other Controls Components* 5.0 Speedometer Output Waveform Characteristics 6.0 Input and Output Requirements 6.1 Switch-to-Ground Inputs 6.0 Input and Output Requirements (continued) 6.2 Switch-to-Battery Inputs 6.0 Input and Output Requirements (continued) 6.3 Switch-to-Ground Outputs 6.0 Input and Output Requirements (continued) 6.4 Switch-to-Battery Output 6.0 Input and Output Requirements (continued) 6.5 Neutral Start Output List of Referenced Documents Revision History Allison 4th Generation Controls: System Data March 5, 2015 Page 16