PDM User Manual A5 - Precision AutoResearch
Contents
1. The wiper unit can be wired using an OEM wiper controller with the PDM supplying the power only The OEM controller normally performs the intermittent and motor braking functions 2 Two Switch Method On Output sa QA PDM Off o e Fast F Home au Q i 7 Park Switch The wiper unit can be wired in a simple two switch arrangement one switch for power and the other to select fast or slow The PDM supplies power only Motor braking is performed by the combination of the park switch and the on off switch Note this arrangement cannot perform intermittent operation since the wiper will not park if the PDM simply removes power Note The switches must handle the wiper motor current typically 4 amps MoTeC Installation 21 3 Relay Method S Relay ontrol Output Switches PDM Ll Slow S X Output pon EE Off F Home e E Park Switch The two switch method can be modified for intermittent operation by replacing the on off switch with a relay The PDM controls the relay to perform the intermittent function This requires two PDM outputs one to supply power and the other to control the relay Motor braking is performed by the combination of the park switch and the relay switch The PDM must be configured with the appropriate logic to p2. Oe A 42 Copyright 2007 MoTeC Pty Ltd 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 20 June 2008 MoTeC Introduction 3 Introduction The PDM16 and PDM32 replace conventional relays fuses and circuit breakers by providing electronically switched power to the various electrical systems in the vehicle including motors lamps ECUs and data systems This simplifies wiring and switch requirements while increasing reliability The PDM16 has 16 outputs and the PDM32 has 32 outputs Each output is over current protected and can be controlled via a combination of switch inputs CAN messages and logic functions In addition to performing simple functions such as flashing indicator lamps the logic functions can be used to selectively turn off systems during low battery voltage or engine starting The PDMs also provide full diagnostic information including output currents and error status that can be monitored on a PC or transmitted via CAN to a display or logging device Throughout this manual the PDM16 PDM32 will be referred to as the PDM except where details specific to a particular product are discussed Bat
3. 0 to 54 une 2 amp steps 6 0 7 Output 20 Current Output 23 Current A sito e550 oi Ais Output 25 Current 0 2 amp steps Output 26 Current 6 0 7 Output 27 Current 7 0 7 Output 28 Current rar r Base ld 4 1 0 0 7 Compound Id 3 Output 22 Current Base Id Output 30 Current 0 to 255 0 to 51 amps Output 31 Current 0 2 amp steps Output 32 Current 30 Appendices CAN ID Byte Bit Channel Scalig __________ 0 0 7 Compundld 0 Baselde 3 0 7 re eo 6 0 7 Output6 Load 0 0 7 Compundld 1 AP O Baselde 8 0 7 M ng m 6 0 7 Output 13 Load 0 0 7 Compundld 2 gg Baseld 3 10 7 z CEN roe eoe bd 6 0 7 Output20Load Output 23 Load Output 24 Load R Output 25 Load Ms 255 0 to 255 1 steps Output 26 Load e 10 7 Output 27 Load Output 28 Load 0 0 7 Compoundid 4 0 0 7 Compound Id 3 Output 22 Load Base ld 2 Output 30 Load 0 to 255 0 to 255 Output 31 Load 196 steps Output 32 Load MoTeC Appendices 31 CAN ID Byte Bit Channel Scalng 0 0 7 Compoundld 0 Base Id 0 to 255 0 to 51 V 3 0 2 V steps 6 0 7 Output 6 Voltage 0 0 7 Compoundld 1 Base Id 0 to 255 0 to 51 V 3 0 2 V steps 6 0 7 Output 13 Voltage 0 0 7 Compoundld 2 J Base Id 3 6 0 7 Output 20 Voltage 0 to 25
4. Bit Channel Scaling 0 4 7 Compoundid O 0 0 O Input State 1 O Input 2 State O Input 4 State 0 Inactive 0 Input 5 State 1 Active 0 Imput6State 0 Input State 1 7 0 Input8 State O Input 11 State oo EE Input 12 State O Inactive 0 Input 13 State 1 Active 0 Input 14 State O Input 15 State 7 O Input 16 State Compound Id 2 Base Id 0 Input 17 State Base Id 0 Base Id 0 0 0 Input 18 State JO Input 19 State 0 Input 20 State Bor Kn Inactive dd e PDM Internal Oto 125 2 0 C to 125 C Temperature 1 C steps 0 to 255 0 V to 31 V PDM Battery Voltage 0 1216 V steps O a 0 OK Global Error Flag 1 one or more outputs is in either Fault or Over Current error 0 to 255 0 to 255 amps 0 to 255 0 V to 15 68 V 9 5V internal rail 0 0615 V steps voltage Should read close to 9 5 V when the Battery voltage is gt 10 5V 4 2 3 4 5 0 7 MoTeC Appendices 29 6 07 Reset Source CANID Bye Bit Channel Scaling o 0 0 7 Compoundid 0 0 0 0 00 00 Base ld 3 0 7 ee nm 10 7 Output 6 Current Compound Id 1 0 to 255 0 to 127 5 amps Output 8 Current 0 5 amp steps Base Id 0 to 255 0 to 51 amps 0 2 amp steps 6 0 7 Output 13 Current 0 0 7 Compoundld 2 Base Id 3 10 7 Output 17 Current o 255
5. unless the voltage drop dictates that it should be larger This method may also ensure that the starter motor does not overheat during excess cranking Alternatively two 20 amp outputs may be paralleled allowing cranking for any period of time subject to overheating of the starter motor Electronic Devices The PDM can supply power to electronic devices such as engine management systems data acquisition systems radios etc Many electronic devices will have a short inrush current The PDM will largely ignore this due to the Output Load filtering see the Over Current Shutdown section for details The PDM provides reverse battery protection to protect itself and the connected devices The PDM provides load dump clamping to protect itself and to help protect the connected devices Ignition Systems Inductive Ignition Systems Most inductive ignition systems draw a peak current of about 8amps some draw as much as 20 Amps however the average current is much less In most cases inductive ignition systems can be connected to an 8amp output however the Output Load current must be checked to ensure it stays well clear of 100 Note that the average current will increase with increasing RPM so the Output Load should be checked at maximum RPM CDI Ignition Systems CDI Ignition systems can draw peak currents of as much as 50 Amps It is recommended that all CDI ignition systems are connected to a 20Amp output Note that the averag
6. will normally reject switch bounce 8 Operation CAN Inputs The PDM can receive CAN messages allowing the outputs to be controlled by other devices The PDM receives CAN messages on any of four sequential CAN IDs The IDs must be within the standard address range To enter the base CAN address select the Global Setup item in the configuration tree Channels are extracted from the CAN messages by specifying a CAN address and an offset The offset determines which byte in the message is used Each CAN generated channel will be set to zero on start up until a matching CAN message is received If any of the CAN messages are not received for 1 second then the corresponding timeout channel will be set to TRUE This channel can be used in a condition if required During the CAN timeout period the channel value remains at the last received value 8 Bit Values The PDM can receive 8 bit values which can be used directly or masked with a bit mask 16 Bit Values The PDM may receive 16 bit signed values A divide factor must be specified to reduce the value to fit into the 8 bit result channel which has a range of 0 to 255 unsigned For example a 16 bit RPM value with resolution of 1 RPM could be divided by 100 to give a value with a resolution of 100 RPM The maximum channel value of 255 will be equivalent to 25500 RPM If the value after division is greater than 255 then the result value will be clamped to 255 The PDM treats the
7. 0 x 60 x 28 mm 7 09 x 2 36 x 1 10 in PDM16 130 x 60 x 28 mm 5 12 x 2 36 x 1 10 in Case Machined aluminium Environmental protection Rubber seal on lid and connectors conformal coating on PCB 26 Appendices 20 Amp Outputs Number of 20 A outputs PDM32 8 PDM16 8 Maximum output current 20 A continuous 115 A transient typical Cr Over current shutdown Programmable in steps of 1 A Protection Short circuit and thermal overload protection Inductive load clamp voltage 17 V relative to Batt Maximum inductive load 1 5 J junction temperature 150 C load energy current 20 A Number of 8 A outputs PDM32 24 PDM16 8 Maximum output current 8 A continuous 60 A transient typical Outputs 9 32 Over current shutdown Programmable in steps of 1 A Protection Short circuit and thermal overload LE meten meen Inductive load clamp voltage Output 9 0 7 V relative to Batt Other Outputs 42 V relative to Batt 0 3 J junction temperature 150 C load energy current 20 A Inputs Number of inputs PDM32 23 PDM16 12 Pull up resistor 10 k to Batt Measurement Range of 0 to 51 V resolution 0 2 V 8 bits Calibration High and low trigger voltage high and low trigger times MoTeC Appendices 27 CAN Input Number of messages 4 messages 8 bytes per message CAN Output 28 Appendices Appendix 2 CAN Output Messages The PDM transmits the following messages at 20 Hz CANID__ Byte
8. 16 or ASHD614 1S C25 or ASHD614 1S C35 Pin _ Function PDM32 Connector D 8 Pin Mating Plug Deutsch AS616 08SN gt Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 Output 8 Pin Function A Output B Output2 Outputs D Output4 E Outputs Fo Oupt X G jOupu 7 H Ouput8 MoTeC Appendices 41 Appendix 9 Dimensions PDM16 5 2 Hole 2x To suit M5 or 3 16 U Max Washer or Head 810 6 C Connector L O O o c C O O N a NY A Connector Appendices 42 PDM32 2x To suit M5 or 3 16 5 2 Hole Max Washer or Head 210 6 0081 N amp MoTeC Notes 43 44 Notes MoTeC Notes 45 46 Notes
9. 5 0 to 51 V 0 2 V steps 6 0 7 Output 27 Voltage 0 0 7 Compoundid 4 0 Base Id i 0 0 7 Compound Id 3 Output 22 Voltage Base ld 3 0 0 7 Output 30 Voltage Bu to 51 V 0 7 Output 31 Voltage p 0 7 Output 32 Voltage 32 Appendices _CANID Byte Bit Channel Scaling amp 0 6 7 Compoundld 0 gt O 0 0 5 Output 1 Status 1 0 7 Output2Status Base Id h 2 1 0 7 Output 3 Status Sr off Output 4 Status Output on 2 Output Over Current Error 4 Output Fault Error N ojo NININ Es Output 5 Status Output 6 Status Output 7 Status Output 8 Status Compound ld 1 Output 9 Status Output 10 Status Output 11 Status 0 Output off 1 Output on Output 12 Status 2 E 7 Output 13 Status Output Over Current Error 4 Output Fault Error Output 14 Status Output 15 Status Output 16 Status Compound ld 2 5 Output 17 Status Output 18 Status Output 19 Status 0 Output off 1 Output on Output 20 Status 2 i E Output 21 Status Output Over Current Error 4 Output Fault Error Output 22 Status Output 23 Status Output 24 Status z Compound ld 3 Output 25 Status Output 26 Status Output 27 Status 0 Output off 1 Output on Output 28 Status 2 E Output 29 Status Output Over Current Error 4 Output Fault Error Output 30 Status Output 31 Status Output 32 Status NIN O N OJO ololol
10. 90 A max C25 contact suits 4 wire 120 A max C35 contact suits 2 wire 150 A max Approximate rating for Tefzel insulated wire in free air 80 C ambient Tefzel wire must not exceed 150 C 16 Installation Battery Isolator Switch Battery positive must generally be connected through an isolator switch or relay The isolator must isolate the battery from all devices in the vehicle including the PDM starter motor and alternator The isolator must be rated to handle the starter motor current When the battery is isolated the engine may run on due to power supplied by the alternator To avoid this the isolator switch should have a secondary switch that is connected to a shutdown input on the ECU Ifthe ECU does not have a shutdown input then the switch can be connected to a PDM input which can then turn off power to the ignition system or the ECU which will cause the engine to stop Battery Negative Both of the Batt pins should be wired to battery negative via 20 wire These pins normally only carry the very low operating current however during a load dump they carry the load dump current which may be 50 amps or higher CAN Wiring PC Communications In order for a PC to communicate with the PDM a mating connector for the MoTeC UTC USB to CAN adapter must be wired to the PDM CAN port If there are no other CAN devices see Appendix 5 PC Connection Wiring otherwise see Appendix 6 CAN amp PC Connection W
11. Molec PDM16 amp PDM32 User Manual Contents INITOQUCUON ae ent 3 OPDEFATION aan DE 4 A essen 4 PDM Manager Software nnaaaaaaaaaaaaaaaaaaaaanaaaaaaaauaaaaaaaaaaaaaaaaa 4 meis Nai 4 Configuration Concepts 4 SONCIONSia a 7 SWichInpuiS rss dd 7 SU MIN remm 8 CAN OUMU Eee ee 8 Standby Mode rs 9 EQUINA CA mo Dmm 9 A otisao e e t 9 Paralleled Outputs 10 Output Protection aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaauanuaaaaaanananaaanaanauaaaa 10 Output Settings iii 11 Output Testing ss 12 Output Channels nennen 12 INSlalla lon assi ritos 14 Metu e 14 Mounino POS MON e jj e 14 Operating Temperature ss 14 A a NUN de MH REN 15 Battery POSVE An A M tienne teen 15 Baten N E einen 16 GANNI O uo ee en 16 IN 17 Output WI MO svara situada Hl ne E 17 UA a sila pt 18 LATINOS en Met Ma TERN ME 18 IVO A 19 Windscroon Allez 19 SOENG S 2 A es N 22 Electronic DEVICES iak aa a an 23 ADPPENGICES aminas 25 Appendix 1 Speeilicati ns zusenden 25 Appendix 2 CAN Output Messages 28 Appendix 3 Fuse Characteristics aaa 34 Appendix 4 Wire Ratings 35 Appendix 5 PC Connection Wiring esee 36 Appendix 6 CAN amp PC Connection Wiring ssssssssss 37 Appendix 7 PDM 16 Connections ka 38 Appendix 8 PDM 32 Connections ka 39 Appendix 9 Dimensions 41 Di AE ROA O re en oe 41
12. N Output OutputName Output Control Status No 0 Off MoTeC Operation 13 1 On Note the output may be off due to Over current Shutdown or Fault Shutdown OutputName Voltage Voltage on the output Yes Resolution 0 2 V OutputName Current Output Current in amps Resolution 0 5 A on Outputs 1 8 Resolution 0 2 A on Outputs 9 32 OutputName Load Output Load Filtered current as a percentage of the maximum current setting Resolution 1 OutputName Status 0 Off 1 On Active 2 Over Current Shutdown 4 Fault Shutdown OutputName Status Active O Output is off No 1 Output is on use status OutputName Status OverCurrent 0 OK 1 Over Current use status Shutdown OutputName Status Fault 0 OK 1 Fault Shutdown use status Z O Z O use Status a non zero Status value means that the output should be on 14 Installation Installation Mounting Mounting Position Mount in a well ventilated area Do not mount the PDM against a hot surface Operating Temperature CAUTION The PDM may get very hot do not touch the PDM during operation The internal temperature of the PDM should not exceed the value in the specifications The temperature can be checked on the Monitor Channels or Monitor PDM screen in PDM Manager it is also transmitted via CAN allowing it to be logged Note that the temperature may take 30 minutes or more to stabilise The temperature will depend on th
13. The PDM will largely ignore this due to the Output Load filtering see the Over Current Shutdown section for details Halogen Lamps Halogen lamps are commonly used in headlights and are more efficient than Tungsten lamps Halogen lamps have similar characteristics to Tungsten lamps Xenon HID Lamps Xenon lamps are also used in headlights and are more efficient than Tungsten and Halogen lamps Xenon lamps have a long duration inrush current that peaks at about 4 times the steady state current The inrush current decays over a period of about 10 seconds This puts a high load on the PDM output during start up To avoid Over Current Shutdown during start up it may be necessary to set a higher Maximum Current than normal For example a Xenon lamp with a MoTeC Installation 19 steady state current of 3 amps may need a Maximum Current setting of 6 to 8 amps to avoid Over Current Shutdown during start up particularly if the battery voltage is low Note that the wire should also be rated at this current Unlike other lamps Xenon lamps draw more current as the battery voltage decreases At 10 volts the lamp will draw 40 more current than at 14 volts For example a lamp that draws 3 amps at 14 volts will draw 4 2 amps at 10 volts This must be allowed for when setting the Maximum Current To ensure that the Maximum Current is set appropriately check that the Output Load value stays safely below 100 during turn on when the battery is
14. at 12 volts not charging Motors Electric motors draw additional current during start up Typically the start up current is 3 to 5 times the steady state current and it dies out in less than a second This start up current is largely ignored by the PDM due to the Output Load filtering see the Over Current Shutdown section for details The current in a motor increases with increasing load on the motor A motor draws maximum current when it is stalled The Maximum Current setting should take this into account Note that a motor may draw more current as it or the device that it is connected to ages This should be allowed for when setting the Maximum Current Note that motor speed control is currently not supported Windscreen Wipers The PDM can drive windscreen wiper motors however the PDM cannot be connected to both the fast and slow motor windings at the same time This is due to the voltage generated by the slow winding during fast operation which will cause braking of the motor and possibly damage the PDM Note that the following schematics are shown for common ground wiper unit Some wiper units have common positive in which case the schematics must be adjusted accordingly A wiper unit can be wired in one of the following ways 20 Installation 1 OEM Controller Method Output gt PDM e OEM ji gt 1 controller F Home Control gt T Park Switches o Switch
15. e current will increase with increasing RPM so the Output Load should be checked at maximum RPM 24 Installation Engine Management Systems The current drawn by an engine management system will depend on the type of loads it is connected to and the operating conditions Fuel injectors draw current in pulses The maximum average current drawn by the fuel injectors is when they are at maximum duty cycle For servo devices such as Drive by Wire motors maximum current is drawn when making large transitions Check that the Output Load is clear of 100 under worst case operating conditions i e when the injectors are operating at maximum duty cycle servo devices such as drive by wire motors are making large transitions and any auxiliary loads are drawing maximum current MoTeC Appendices 25 Appendices Appendix 1 Specifications General Current consumption 35 mA typical operating 5 mA typical standby Total output current PDM32 120 A continuous PDM16 100 A continuous devices Protection for PDM Also assists in protecting connected devices Operating temperature 110 C max internal 100 C recommended Typical 85 C max ambient for 120 A total load for 110 C internal depending on mounting air circulation load distribution These specifications apply for a 12V battery for a 24 V battery reduce specified temperatures by 20 C Weight PDM32 405 g 0 89 lbs PDM16 330 g 0 72 lbs Dimensions PDM32 18
16. e total load current a higher current will cause a higher temperature It is also highly dependent on ambient temperature and how the PDM is mounted If the internal temperature exceeds the specifications cooling may be achieved by one or more of the following e Relocating the PDM to a cooler mounting position e Increasing air circulation around the PDM case e Ducting cool air over the PDM case e Fitting a heatsink to the back surface of the PDM case MoTeC Installation 15 Wiring Starter HE Isolator Motor Alternator Battery A y Battery Input AM Switches H gt Inputs PDM CAN e OV S CAN Bus vvv ECU Data Logger Jl Other Motors Lights Devices LL JE PDM wiring overview Battery Positive Battery positive is supplied to the PDM via the single pin connector which is avallable in three different variants to suit different cable sizes Deutsch ASHD614 1S C16 C25 or C35 The wire gauge should be chosen according to the wire temperature limit and acceptable voltage drop Note that the temperature of the wire is affected by the ambient temperature alr circulation current wire gauge the temperature of any surrounding wires and the covering sheath C16 contact suits 6 wire
17. ed to any PDM output The output should be configured to turn on when the Global Error channel is TRUE Outputs All outputs are high side type outputs they switch Batt to the output pin All outputs have hardware thermal overload protection fault logic and over current logic 10 Operation Paralleled Outputs Two or more output pins can be connected in parallel to increase current capacity Outputs that are connected in parallel must all be of the same type either all8 amp or all 20 amp Paralleled outputs must be configured to use acommon channel or an identical condition to activate them Output Protection Over Current Shutdown An Over Current Shutdown occurs when the Output Load value exceeds 100 which corresponds to the maximum current setting The Output Load value is filtered so that it normally increases and decreases slowly modelling how the temperature of a wire responds to the current flowing through it The resultant characteristic is very similar to a thermal circuit breaker which is often used in motor sport applications It is also similar to a slow blow fuse See Appendix 3 Fuse Characteristics for details The filtering of the load value ensures that the start up current inrush current of motors and lamps does not cause the output to shutdown during this period It also allows for short term overloads to occur without the output shutting down A large over current such as a short circuit wil
18. ent multiplier 25 A 5A 25 From Graph Trip Time approx 1 second From Table Multiplier approx 80 Trip Time 1 x 80 0 8 seconds MoTeC Appendices 35 Appendix 4 Wire Ratings Current Rating Current Rating Resistance Resistance at 80 C at 100 C ohms m ohms 1000 ambient ambient amps The current ratings above are for Tefzel insulated wire and are an indication only and will not apply in all circumstances The actual maximum current rating is determined by the maximum allowed temperature for the wire which in the case of Tefzel insulated wire is 150 C The temperature of the wire is affected by many factors including the temperature of adjacent wires how the wires are bundled and how the wires are covered as well as the ambient temperature and the current Suitable Wire Gauges Suitable wire gauges for the 8 amp outputs are 24 to 20 Suitable wire gauges for the 20 amp outputs are 20 to 16 36 Appendices Appendix 5 PC Connection Wiring If the PDM does not connect to any other CAN devices then the following wiring scheme may be used to provide a connection point for the MoleC UTC USB to CAN adapter which allows connection to aPC via USB If other devices are connected to the CAN bus a different wiring scheme is required see Appendix 6 CAN amp PC Connection Wiring If the wiring length is less than 2 m 7 ft then the terminating resistor is recommended but not essential UTC Connec
19. equirements and also ensures that the PDMs have the correct configuration file When performing online activities such as Monitor Channels PDM Manager will connect to the PDM with the serial number of the loaded configuration file If there is no file loaded then the serial numbers for all connected PDMs will be displayed allowing any PDM to be selected To enter the serial number select the Global Setup item in the configuration tree Updating Firmware To control the PDM operation the PDM contains software referred to as firmware The firmware in the PDM is updatable which allows the operation of the PDM to be updated when new versions become available The version of the PDM firmware must match the firmware version distributed with the PDM Manager software When a new version of the PDM Manager software is installed on the PC the PDM firmware needs to be updated as well The firmware can be updated using Online Update Firmware in PDM Manager Channels Channels are used to link the various systems within the PDM configuration For example The input pin system generates a channel for each configured input pin Depending on the state of the input pin the channel value will be zero or one The resulting channel can be selected to control a particular output or used as an input to a complex logic function a condition that combines a number of channels to create a new channel This new channel can then be used to co
20. erform on off and intermittent operation based on the state of the control switches Slow operation can be achieved using the switch or intermittent operation can be used to give a similar effect which avoids the need for a high current switch Note The fast slow switch and on off relay must handle the wiper motor current typically 4 amps The control switches can be low current types since they only connect to PDM inputs 4 Direct Method C Output 9 ontrol w S Switches gt PDM e Input lt F Home L e 73 Park Switch The wiper unit can be wired directly to the PDM as long as it is only connected to one output In this method the park switch is wired directly to a PDM input so the park logic must be configured in the PDM 22 Installation This method requires the use of Output 9 which performs motor braking The PDM performs motor braking by momentarily shorting the output to ground when the output turns off The PDM must be configured with the appropriate logic to perform on off and intermittent operation based on the state of the control switches Slow operation can be achieved using a switch between the fast and slow windings as used in the other methods or intermittent operation can be used to wipe less frequently The control switches can be low current types since they only connect to PDM inputs Solenoids The current drawn by a normal single coil
21. iring Communications to other Devices The PDM transmits messages that may be received by other devices connected to the same CAN bus The CAN communication rate in the other devices must be set to the same speed as in the PDM 1 Mbit sec The CAN bus must be wired according to Appendix 6 CAN amp PC Connection Wiring MoTeC Installation 17 Input Wiring The PDM Switch Inputs are intended for use with a switch that is directly wired between a PDM input pin and the PDM OV pin It is possible to connect to a switch that is wired to another system in the vehicle In this case ensure that the voltage levels are set appropriately as there may be ground voltage variations between devices Each input has an internal 10 kohm pull up resistor to Batt Tip e f standby current is important wire the switches so that they are normally open during standby as this will reduce the standby current Input Switch Connected to Battery If an input is driven from a device that switches to battery then an external pull down resistor is required If possible the switch should be rearranged so that it switches to OV to avoid the need for the resistor In some cases this is not possible for example if the signal comes from an electronic device such an ECU that has an output that can only switch to battery This could be a signal that indicates when to turn the full pump on The resistor should be 15000hms 1 4watt and should be connected bet
22. l cause the Output Load value to increase rapidly causing the output to shutdown in a short period of time to protect the wire and the PDM output Note that in some cases a short circuit may cause a Fault Shutdown before the Over Current Shutdown occurs The amount of filtering is not adjustable and is set with a time constant of 20 to 50 seconds based on the maximum current setting These values have been determined to conservatively suit the appropriate wire gauge for the selected current setting Tips e The Output Load and Output Current values are transmitted on CAN so that they can be logged by another device Check the logged Output Load value to ensure it is not too close to 100 during normal operation and during start up e The Output Load and Output Current values can also be monitored using PDM Manager MoTeC Operation 11 Fault Shutdown A Fault Shutdown occurs when the output voltage is lower than expected This can be caused by a short circuit or thermal overload of the output Output Settings Maximum Current This sets the current at which the output will shutdown The output current may exceed ihis value for a period of time which allows for the start up inrush current of devices such as motors and lamps See the Over Current Shutdown section for details The maximum current can be set to 10 amps on the 8 amp outputs and 25 amps on the 20 amp outputs This allows the maximum current setting to be set clear of the
23. larger wire gauge is needed than the current rating would suggest Number of Retries 8 Retry Delay After an Over Current Shutdown or a Fault Shutdown occurs the PDM will attempt to turn the output on again if the Number of Retries is configured The Number of Retries setting determines how many times an output will attempt to turn on again The Retry Delay setting determines how long an output remains shutdown before it is turned on again The retry count for an output is reset whenever the condition driving the output firstly changes to FALSE then changes to TRUE i e when the condition driving the output turns off then on again Master Retry The Master Retry feature turns all outputs that are in error back on If there is still a fault on the output the output will go into error again and will go through the normal retry sequence To be able to initiate the retry by pressing a button the button is wired to a switch input that generates a channel This channel is used as the triggering channel for the Master Retry Master Retry is configured in the PDM Manager Global Setup Output Testing Outputs may be manually turned on and off using Online Test Outputs in PDM Manager Each output to be tested must be configured in the PDM before it can be tested using Test Outputs Output Channels The following channels can be monitored using PDM Manager Some are transmitted via CAN to other devices Channel Name Description CA
24. lt lt CAN Bus gt gt dios CAN HI ZI CAN 8 canto a XXXX XX Te XX _ CAN Device CAN Device CAN Device eg BR2 eg M800 eg PDM Short CAN Bus If the CAN Bus is less than 2 m 7 ft long then a single termination resistor may be used The resistor should be placed at the opposite end of the UTC connector 38 Appendices Appendix 7 PDM 16 Connections PDM16 Connector A 26 Pin Mating plug Deutsch AS616 26SN Function C Batt Pin B D im c EA a b Roc 7 PDM16 Connector B 1 Pin Mating Plug ASHD614 1S C16 or ASHD614 1S C25 or ASHD614 1S C35 Pin Function PDM16 Connector C 8 Pin Mating Plug Deutsch AS616 08SN Pin Funcion B Output2 J C Outputs D o Ouput4 E Ouput5 F Oupt6 3M GQ Output7 CP MoTeC Appendices 39 Appendix 8 PDM 32 Connections Function Input 5 PDM32 Connector B 26 Pin Mating Plug Deutsch AS616 26SN Pin Function B Output10 gt gt D jOutputi2 E j Oupui3 J G Outputi5 H jOuputi J jOutpti7 K jOuputi8 o L jOutpti9 M _ Output20 N jOupu21 P o Ouput22 R Output S Output24 T Output25 U Output 28 V jOutpt27 W Output28 X Output29 Y j Outut30 a Outpt32 b Bate 40 Appendices Mating Plug ASHD614 1S C
25. normal running current even for devices that draw the maximum specified current of 8 or 20 amps Notes e Ensure that the maximum current has been set appropriately by checking that the Output Load value is less than 100 under all operating conditions See Over Current Shutdown section for details e he wire used must be capable of carrying the current specified in the maximum current setting See Appendix 4 Wire Ratings e Set the maximum current well clear of the normal operating current of the device but within the current rating of the wire Use a larger wire to achieve this if necessary For example for a device that draws no more than 5 amps except at start up use a wire that is rated at 8 amps and set the maximum current to 8 amps to give a clear margin e Don t try and protect the connected device by setting the current close to the normal current of the device as this is unlikely to be effective and could result in an inadvertent shutdown The purpose of the maximum current setting is to protect the wire from overheating not to protect the connected device e Some devices draw more current under circumstances such as high or low battery voltage Also a motor will draw increased current when under more load Set a good margin and where possible check the Output Load value under these varying circumstances 12 Operation e Consider the voltage drop of the wire when selecting the wire size Sometimes this dictates that a
26. ntrol an output or as an input to another condition Each channel can only be generated once but may be used in multiple outputs and conditions 6 Operation The value of any channel can be monitored with the PDM manger software by selecting Online Monitor Channels Channel Names Each channel has a name to identify it Channels are arranged in a tree structure when viewed using the Channels window select View Channels Window the Channel Selection screen or the Monitor Channels screen select Online Monitor Channels The tree structure is formed by including a dot between parts of the channel name For example Indicator Left and Indicator Right would appear as Left and Right under a node called Indicator Note that using a dot in the channel names is optional if not used the channel list will be a simple flat list rather than a tree Select Channel sene o Es E E TI q ll output au switch E E right 2 lights POM Ol spare Ol sparen Renaming Channels To rename a channel globally right click on the channel name in the channels window and select Rename This will rename the channel where it is generated as well as all the placed that it is used MoTeC Operation 7 Conditions Conditions are used to form complex logic expressions that can generate new channels or control when an output is turned off or on A condition takes one or more channels and performs one or more logic o
27. ololololo mn 4 Base Id i 4 y Base Id 4 Base ld 4 7 O O N O O OO oiojoj oj o ojojo NINSISISISTOISISISISISINS 0 0 N 6 O E NN 6 LE KOR EEE EEN KOE 6 ER e MoTeC Appendices 33 _CANID Byte Bit Channel Scaling 7 Base Id 5 Base Id 5 Base Id 5 Base Id 5 0 0 7 Compundld 0 gt O 1 0 7 Input Voltage 3 0 7 Input 3 Voltage 0 to 255 0 to 51 V 4 10 7 Input 4 Voltage 0 2 V steps 5 0 7 Input 5 Voltage 6 0 7 Input 6 Voltage 0 0 7 Compoundld 1 4 A4 O 1 0 7 Input8 Voltage 3 0 7 Input 10 Voltage 0 to 255 0 to 51 V 4 0 7 Input 11 Voltage 0 2 V steps 5 0 7 Input 12 Voltage 6 0 7 Input 13 Voltage 0 0 7 Compoundld 2 0 1 10 7 Inputi5 Voltage 2 0 7 Input 16 Voltage 3 10 7 Input 17 Voltage 0to255 01051 V 4 0 7 Input 18 Voltage 0 2 V steps 5 0 7 Inputi9 Voltage 6 0 7 Input 20 Voltage 0 0 7 Compound Id 3 0 to 255 0 to 51 V 0 2 V steps 34 Appendices Appendix 3 Fuse Characteristics Trip time verses over current multiplier at 10Amps 100 00 10 00 Trip Time s 1 00 0 10 T T T T T l f T Over Current Multiplier 76 oo AS E LAOS 100 120 20 140 Example For Current of 25 amps where Max Current is set to 5 amps Over curr
28. perations on these channels The logic operations include AND OR flash and many more A condition generates a new channel with a value of either TRUE 1 or FALSE 0 This channel can be used to control an output or it can be the used in another condition Number of Operations There are a total of 200 logic operations available in the PDM The number of operations used is shown in the status line Switch Inputs The PDM Switch Inputs are intended for use with a switch that is directly wired between a PDM input pin and the PDM OV pin It is possible to connect to a switch that is wired to another system in the vehicle In this case ensure that the voltage levels are set appropriately as there may be ground voltage variations between devices Each input calibration results in a channel with a value of either 0 or 1 which can be used in a condition or to directly control an output The resulting channel value and the input voltage may be viewed in Online Monitor Channels or Online Monitor PDM The trigger voltages are fully programmable The recommended trigger voltages are approximately 3 5 V for the low threshold and 4 2 V for the high threshold The high threshold should be set below 6 V to ensure detection of a high level signal when the battery voltage is low To avoid switch bounce and or to delay recognition when the switch changes state the inputs also have programmable trigger times A trigger time of 0 1 second
29. received value as a signed 16 bit value i e 32768 to 32767 Negative values are clamped to 0 CAN Output A fixed set of messages are sent to other devices via CAN MoTeC Operation 9 The CAN messages include Output Voltage Output Current Output Load Output Status Input State Internal Temperature Battery Voltage Global Error Total Current See Appendix 2 CAN Output Messages for message details Most MoTeC logging devices can receive these messages CAN communications templates are available for these devices These messages can be received by another device and used as follows e For diagnostic purposes Particularly useful if the values are logged in a logging device e To show an alarm on a display device e ouse the value of a PDM input switch to activate a feature in another device To set the CAN address or to disable CAN output select the Global Setup item in the configuration tree Standby Mode The PDM enters a low current Standby Mode when all outputs are off and there is no CAN activity The PDM exits Standby Mode when the state of any input changes or CAN activity resumes Fault Indicator When an output fault occurs the PDM sets the value of the Global Error channel to TRUE PDM Global Error This can be used in the following ways e Adisplay device may receive the Global Error channel via CAN and show an alarm message and activate an alarm light e Afault indicator light can be connect
30. solenoid ramps up from zero to its steady state value over a period of time The time taken to do this depends on the inductance and resistance of the solenoid but is normally very short less than 0 1 second This has no affect on the PDM A solenoid will generate a voltage spike when turned off this is clamped and absorbed by the PDM The amount of energy absorbed by the PDM depends on the inductance and current in the solenoid The PDM is capable of absorbing the energy of most normal solenoids in a vehicle Two Stage Solenoids Some solenoids have two windings one that is used to turn the solenoid on the other that is used to hold it on once it has switched This allows optimum turn on characteristics with minimum holding current The current drawn by the turn on winding may be higher than the holding winding Check that the Output Load is well clear of 100 during turn on and during holding Starter Solenoids Starter solenoids typically draw more than 20 amps possibly as much as 40 amps In many cases it is still possible to run them from a single 20 amp output In this case the output will shut down after about 10 to 20 seconds of cranking due to the Over Current Shutdown feature A starter solenoid may also be two stage type Note that the Over Current Shutdown allows excess current for a period of time see the Over Current Shutdown section for details MoTeC Installation 23 In this case the wire can be rated for 20 amps
31. tery Battery Input FO gt CAN bus o Inputs gt inp PDM CAN Switches Outputs i amp vvv ECU des lb Js il Other Motors Lights Devices Overview PDM connections 4 Operation Operation Configuration PDM Manager Software The PDM Manager software is used to e Change the PDM s configuration e Monitor the PDM s operation including the output currents and diagnostics e Test the outputs by manually turning them off and on e Update the firmware PC Connection Use a MoTeC UTC USB to CAN adapter to connect the PC to the PDM Note the MoTeC CAN cable cannot be used with the PDM The PDM requires the mating connector to be wired to it See Appendix 5 PC Connection Wiring for details Configuration Concepts The PDM requires various settings to be configured such as the maximum current settings for the outputs and the circumstances in which to turn the outputs on Configuration Files The configuration settings are stored in a configuration file on the PC The configuration file can be changed without the PC being connected to the PDM The configuration file can be sent to the PDM by using Online Send Configuration in PDM Manager MoTeC Operation 5 Serial Number The PDM serial number must be entered as part of a PDM configuration file A configuration file can only be sent to the PDM with the matching serial number This allows multiple PDMs to be used without special device configuration r
32. tor PDM Green 10 CAN LO 5 White ED CAN HI These wires must be twisted Minimum one twist per 50 mm 2 in 100R Resistor Not essential if the wiring length is less than 2 m 7 ft UTC Connector Type Deltron 716 0 0501 Non latching Neutrik NC5FDL1 Latching MoTeC Appendices 37 Appendix 6 CAN amp PC Connection Wiring CAN wiring requirements where the PDM is to communicate with other devices This scheme includes a connection point for the MoTeC UTC USB to CAN adapter which allows connection to a PC via USB If the PDM does not connect to any other CAN devices then a simplified wiring scheme may be used See Appendix 5 PC Connection Wiring The CAN bus should consist of a twisted pair trunk with 100R 0 25 watt terminating resistors at each end of the trunk The preferred cable for the trunk is 100R data cable but twisted 22 Tefzel is usually OK The maximum length of the bus is 16 m 50 ft CAN devices such as MoTeC PDM M800 etc may be connected to the trunk with up to 500 mm 20 in of twisted wire The UTC connector may also be connected to the trunk with up to 500 mm 20 in of twisted wire If desired two CAN cable connectors may be used so that the UTC may be connected to either side of the vehicle UTC 100R Terminating Connector Resistors at each These wires must be twisted end of the CAN Bus Minimum one twist per 50 mm 2 in io 500 mm
33. ween the input pin and the OV pin The input trigger levels should be set to 4V and 5V to guarantee correct triggering for all possible battery voltages Output Wiring All outputs are high side type outputs they switch Batt to the output pin All outputs have hardware thermal overload protection fault logic and over current logic Paralleled Outputs Two or more output pins can be connected in parallel to increase current capacity Outputs that are connected in parallel must all be of the same type either all 8 amp or all 20 amp Paralleled outputs must be configured to use a common channel or an identical condition to activate them 18 Installation Wire Gauges The wire gauge must be chosen to suit the current consumed by the connected device and to ensure that the voltage drop is acceptable On long runs it may be necessary to use a heavier gauge wire to minimise voltage drop The wire gauge must also be compatible with the connectors pin using a smaller than recommended wire gauge may result in a poor crimp Suitable wire gauges for the 8 amp outputs are 24 to 20 Suitable wire gauges for the 20 amp outputs are 20 to 16 See Appendix 4 Wire Ratings Output Devices Lamps Tungsten Lamps Typically used for tail lights indicator lights and general lighting Tungsten lamps draw additional current during turn on Typically this peaks at about 5 times the steady state current and dies out in about 0 1 second
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