S1X Generic Speed Control System

MAKING MODERN LIVING POSSIBLE System Description S1X Generic Speed Control System powersolutions.danfoss.com

Revision history Table of revisions Date Changed Rev August 2015 Danfoss Layout 0600 September 2004 October 2001 E D 2 BLN-96-0401-E Rev 0600 August 2015

Contents Overview S1X Microcomputer System Block Diagram Theory of Operation Description...4 Features...4 System Components... 4 LED Overview...5 System Block Diagram... 6 General... 7 Modes for Travel Speed Setpoint... 7 Non Automotive Mode...7 FNR Set...7 Automotive Mode... 7 RPM Set...7 FNR RPM... 8 Drive Direction...8 Gear and Ramp Selection... 8 All Range Antistall Control... 9 Speed Calculation Modes...9 SIMPLE_NORMI_MODE : 0...9 SIMPLE_CALC_MODE : 1...9 DIESEL_MODE : 2...9 DRUM_1_MODE : 3...9 DRUM_2_MODE : 4...9 DRUM_1_DIESEL_MODE : 5... 10 DRUM_2_DIESEL_MODE : 6... 10 Constant Speed Drive...10 CSD Open Loop... 10 CSD Closed Loop...10 CSD Open Loop and Closed Loop... 10 Special Roller Features... 10 Vibration ON/OFF Control... 10 Waterflow Control... 10 System Connection Diagram System Connection Diagram...11 BLN-96-0401-E Rev 0600 August 2015 3

Overview Description The Danfoss Speed Control System combines the capabilities of modern digital electronics with the worldwide proven Danfoss axial piston pump series and bent axis motor series to enhance machine performance. The microprocessor-based S1X provides flexibility and is designed for the future. The control concept contains several individual selectable functions such as: ramp drive control, antistall, CSD, brake and speed calculation. Additional to these standard drive s special roller features like water control and vibration ON/OFF are implemented. With easy-to change parameters (in software) it is possible to make an individual setup for different kind of machine types. Features Environmentally hardened for mobile applications Supply voltage 12 V DC or 24 V DC Proportional Valve or EDC Analog direction or digital direction Software changes without hardware operations Wide range of system configuration options Easy to service Flexible ramp 4 Software gears with different ramps Constant speed drive Antistall function 7 different kind of speed calculations Vibration ON/OFF control Waterflow control CAN J1939 connection Different Brake functions System Components S1X-46-G2 Amp K164 S1X Electronic CAN Manual Graphic Interface, english 4 BLN-96-0401-E Rev 0600 August 2015

S1X Microcomputer LED Overview 174 155 7 6 POWER SYSTEM 5 4 55,75 MODE STATUS 60,25 8,5 8,5 10 9 10 123,5 10,5 2 3 1 1 14 15 28 29 42 55 1 S1X 2 Mounting slots 3 AMP connector 4 Diagnostic LED red Error check (STATUS) Lights up if an error is detected. 5 Diagnostic LED yellow Software check (MODE) Flashes with approx. 0.5Hz (slow) if the program is running fine. Flashes with approx. 5Hz (fast) if no program is loaded. No flashing if in setup mode. 6 Diagnostic LED green 5V DC internal (SYSTEM) Lights up if 5V DC internal is O.K. 7 Diagnostic LED green Battery after ignition switch (POWER) Lights up if the battery voltage is connected after ignition. S01697b BLN-96-0401-E Rev 0600 August 2015 5

System Block Diagram System Block Diagram PPU Diesel RPM Engine EIF Speed limitation setpoint potentiometer A D Setpoint calculation logic Ramp & State machine Antistall CSD Control handle Drive setpoint Analog FNR A D Ramp control ON/OFF Antistall switch DI DI Ramp control logic Status output ramp control Hydrostatic gear switch 1st/2nd gear (Option) Drive mode switch FNR Set/RPM Set DI DI RS232 interface for SUSMIC- DIA 1 to 4 Automatic/Standby brake switch or digital FNR Reverse switch (Option) DI Engine Rpm Timer Diesel RPM setup CAN Bus Wheel Rpm (Option) Timer Speed calculation Speed dependent (Vibration) Speed dependent release (Vibration) Wheel Rpm (Option) Timer Auxiliary setpoint potentiometer A D Cycle control (Water) Cycle relay (Water) Emergency stop F 10A Voltage regulator V t + Batt. - 12V DC S01718b 6 BLN-96-0401-E Rev 0600 August 2015

Theory of Operation General PPU Diesel RPM Engine (Option, if one motor system) Drive mode switch FNR Set/RPM Set FNR Setpoint calculation logic Control handle Drive setpoint MCH43BMS100 FNR to engine setoint Setpoint generation Ramp & State machine Antistall CSD Engine Rpm Wheel Rpm (Option) Timer Timer Motor curve (Option) S01823 Modes for Travel Speed Setpoint The system can work with three different setpoint modes. With a drive mode switch it is possible to select between a non automotive mode and an automotive mode. Non Automotive Mode FNR Set This is the basic mode for the application. The drive setpoint depends on the setting of the control handle and the speed limitation potentiometer. The speed limitation potentiometer sets the max. output current to the drive pump in order to give the operator of the machine the best possible range and resolution over the hand lever. The bidirectional mobile control handle generates the drive direction signal. Typical application is vehicle with a diesel engine running full power to fulfil auxiliary functions like cutting, planning or harvesting. In that case the speed of the vehicle is set by the speed setpoint lever (FNR). Automotive Mode There are two different automotive modes available: RPM Set This mode is the classic automotive mode, where the drive setpoint is generated by the engine rpm. The maximum speed can be limited through the speed limitation potentiometer. Typical example for this is the transport drive in higher speed, where no external functions are active. A droop of the engine reduces by principle the setpoint of the pump. BLN-96-0401-E Rev 0600 August 2015 7

Theory of Operation FNR RPM The setpoint of the control handle generates a virtual setpoint of the engine. The engine uses a mechanical link between the handle or pedal. In case of droop, an antistall can compare the engine speed setpoint through the control handle and the actual speed of the engine. The maximum speed can be limited through the speed limitation potentiometer. Drive Direction The drive direction signal is given by the bidirectional mobile control handle (FNR). If a direction switch is required, the switch must work like a control handle. A simple digital direction switch may be used instead of the above. No neutral position is required. An analog signal of 2.5V at the control handle input is defined as neutral, 3.5V at the control handle input are defined as forward and 1.5V at the control handle input are defined as reverse. Gear and Ramp Selection For each hydrostatic gear, the ramp times for acceleration and deceleration can be set individually. Ramp Parameters Acceleration Deceleration Ramp PT1 TAU Up Ramp T1 Down Ramp Up Ramp Down Ramp T1 Up Ramp PT1 TAU Down S01748_11e As shown above the ramps have an adjustable exponent, linear and PT1 delay part. These parts can be set different for acceleration and deceleration. 8 BLN-96-0401-E Rev 0600 August 2015

Theory of Operation All Range Antistall Control The antistall is to be activated if necessary. If active, it starts working below a predefined diesel RPM limit, or above a predefined engine load value EEC2 (CAN). It controls the output current to pump without overloading diesel engine. Depending on the droop and the control parameters the swashplate angle is descreased. Transient Response of the Antistall Controller RPM 0 t Ι 100% 0 t S01748_08e Speed Calculation Modes SIMPLE_NORMI_MODE : 0 In this mode, a simple speed calculation is done. In the setup, there are maximum values for speed in each gear. The vehicle speed is dependent on setpoint to max. speed in each gear. No PPU is necessary, no motor data or gear ratio data are necessary. No constant speed possible, speed setpoint is the same as actual speed. SIMPLE_CALC_MODE : 1 In this mode, the calculation of speed works with motor data and ratios. The pump volume and the wheel diameter gives the speed setpoint. No constant speed possible, speed setpoint is the same as actual speed. DIESEL_MODE : 2 In this mode, the Diesel RPM is in the calculation. All other data works as the same, as in 1.Constant speed is without effect, antistall is possible. DRUM_1_MODE : 3 The real vehicle speed in this mode is calculated with the wheel motor RPM. The gear ratio and the wheel diameter belong to the calculation of the real vehicle speed. The speed setpoint is calculated from engine rpm and lever position. CSD (Constant Speed Drive) compares the speed of the setpoint with the actual value by the wheel PPU. The antistall controller output is the setpoint for CSD. DRUM_2_MODE : 4 Same logic than in DRUM_1_MODE. In this mode, there are 2 PPUs for the speed to calculate the correct speed in curves. The vehicle speed is the average of both speeds. BLN-96-0401-E Rev 0600 August 2015 9

Theory of Operation DRUM_1_DIESEL_MODE : 5 For constant speed drive, it is necessary, to use a setpoint for speed, and an actual speed to compare in a closed loop system. The setpoint works with mode 2, the actual speed works with mode 3. The CSD speed setpoint is dependent on the diesel engine. The antistall controller output is the setpoint for CSD. DRUM_2_DIESEL_MODE : 6 For constant speed drive, it is necessary, to use a setpoint for speed, and an actual speed to compare in a closed loop system. The setpoint works with mode 2, the actual speed works with mode 4. The CSD speed setpoint is dependent on the diesel engine. The antistall controller output is the setpoint for CSD. Constant Speed Drive The CSD function can be activated independent or additional to the antistall function. The CSD function can work in three different modes. CSD Open Loop This constant speed mode is possible if an engine PPU is installed. A reduction of an engine rpm could be used as an increased displacement for the pump. Possible speed mode: DIESEL_MODE CSD Closed Loop The closed loop mode needs a speed detection. This is done by one or two wheel PPU s. The speed is calculated with the number of pulses per revolution, the gear ratios and the wheel diameters. This measured vehicle speed can be compared with a speed setpoint and controlled by a closed loop CSD function. Possible speed mode: DRUM_1_MODE DRUM_2_MODE DRUM_1_DIESEL_MODE DRUM_2_DIESEL_MODE CSD Open Loop and Closed Loop This mode needs a measured speed detection and a engine speed detection. The closed loop function must compensate less difference. Possible speed mode: DRUM_1_DIESEL_MODE, DRUM_2_DIESEL_MODE. Special Roller Features Vibration ON/OFF Control The ON/OFF control depends on the actual vehicle speed. Parameters for start at low speed and stop at high speed can be set individually for each gear. Waterflow Control The ON/OFF time is calculated depending on potentiometer setpoint and actual vehicle speed. 10 BLN-96-0401-E Rev 0600 August 2015

System Connection Diagram System Connection Diagram 1 2 3 4 5 6 Contact capability min. 6A Malting fuse 10A Max. 3,25A each pin Position shown: Antistall OFF Optional supplied by ASC Position shown: Ramp control ON Used as FNR forward switch position shown: Neutral Optional not installed 7 8 Position shown : 1st/2nd gear 9 Used as brake switch position shown: Standby brake Used as FNR reverse switch position shown: Neutral 10 Position shown : FNR_SET 11 Alternate FB channel configure by software! Important use ONLY ONE = Option * AMP connector, 42pin Ramp control switch or Digital FNR forward switch 6 Sensor (-) * Digital Input 0 Digital Input 1 * Digital Input 2 1 2 3 4 Automatic/Standby switch or Digital FNR reverse switch Antistall switch 4 9 Digital Input 3 * High Current 0 (+) 5 6 Gear switch (Option) 8 High Current 1 (+) 7 High Current 0 FB (-) * High Current 1 FB (-) * Low Current 0 FB (-) Low Current 1 FB (-) * 8 9 10 11 11! A B C D EDC Propel pump VORWÄRTS FORWARD RÜCKWÄRTS REVERSE Proportional valves (Option) nc RS232 Ground Sensor (+) Battery (-) PPU Input 0 PPU Input 1 PPU Input 2 PPU Input 3 * RS232 TxD RS232 RxD High Current 4 (+) * High Current 4 FB (-) * High Current 5 (+) * High Current 5 FB (-) * High Current 2 (+) High Current 3 (+) * 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Terminals Sensor (+) Vibro output (Option) Terminals Sensor (-) 1 2 3 4 5 6 7 8 9 PPU Diesel RPM PPU front left PPU front right 5 7 FNR_SET/RPM_SET (FNR_RPM) Drive mode switch (Option) Water pump (Option) 5 7 SUB-D Diagnostic connector (female), 9pin 10 Terminals Batt. (+) Terminals Batt. (-) Battery (+) Battery (-) 28 29 3 Speed limit setpoint potentiometer nc 30 Analog Input 0 31 Analog Input 1 Low Current 4 FB (-) Low Current 5 FB (-) nc nc CAN High CAN Low CAN Shield Digital Output 0 Digital Output 1 * 32 33 34 35 36 37 38 39 40 41 11! Control handle drive setpoint Inch setpoint potentiometer Auxiliary setpoint potentiometer (Option) CAN Bus Terminals Emergency stop 1 S1 2 F1 + Batt. - 12V DC Battery (+) 42 3 Status ramp control 512791a BLN-96-0401-E Rev 0600 August 2015 11

Products we offer: Bent Axis Motors Closed Circuit Axial Piston Pumps and Motors Displays Electrohydraulic Power Steering Electrohydraulics Hydraulic Power Steering Integrated Systems Joysticks and Control Handles Microcontrollers and Software Open Circuit Axial Piston Pumps Orbital Motors PLUS+1 GUIDE Proportional Valves Sensors Steering Transit Mixer Drives Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and electronic 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. Building on our extensive applications expertise, we work closely with our customers to ensure exceptional performance for a broad range of off-highway vehicles. We help OEMs around the world speed up system development, reduce costs and bring vehicles to market faster. Danfoss Your Strongest Partner in Mobile Hydraulics. Go to www.powersolutions.danfoss.com for further product information. Wherever off-highway vehicles are at work, so is Danfoss. We offer expert worldwide support for our customers, ensuring the best possible solutions for outstanding performance. And with an extensive network of Global Service Partners, we also provide comprehensive global service for all of our components. Please contact the Danfoss Power Solution representative nearest you. Comatrol www.comatrol.com Schwarzmüller-Inverter www.schwarzmuellerinverter.com Turolla www.turollaocg.com Hydro-Gear www.hydro-gear.com Daikin-Sauer-Danfoss www.daikin-sauer-danfoss.com Local address: Danfoss Power Solutions (US) Company 2800 East 13th Street Ames, IA 50010, USA Phone: +1 515 239 6000 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 Trading (Shanghai) Co., Ltd. Building #22, No. 1000 Jin Hai Rd Jin Qiao, Pudong New District Shanghai, China 201206 Phone: +86 21 3418 5200 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 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. BLN-96-0401-E Rev 0600 August 2015 www.danfoss.com Danfoss A/S, 2015