User Manual
Contents
1. Inputs amp 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 amp 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 shutdown2. 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 amp 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 amp Measured Value 2 Tracking This error condition only applies to drive by wire PID Controllers This error condition occurs when TP amp 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
3. 4 Power and Ground Wiring Bat Bat 28 29 30 37 38 39 13 14 15 19 20 21 22 Additional Power and Ground pins are provided to simplify and to meet the current requirements of any devices connected to the PWM outputs As a general principle if no outputs are being used then wiring one power and one ground pin is sufficient If the DBW 4 outputs are used then all power and ground pins should be wired up Wire to suit connector 22 Tefzel Mil Spec M22759 16 22 MoTeC DBW 4 19 Introduction Appendix F DBW 4 Pin List by Pin Number The DBW 4 uses a 66 pin autosport connector with the following pin out Pin Function DBW 4 DBW Use Pin Function DBW 4 DBW Use 1 34 PID4 PWM 2 DBW 4 PMW2 2 PID4 PWM 1 DBW 4 PMW 1 35 CJC1 3 PID3 PWM 2 DBW 3 PMW 2 36 DV A 37 BATTERY 5 38 BATTERY 6 39 BATTERY 7 PID3 PWM 1 DBW 3 PMW 1 40 RS232 TRANSMIT 8 41 DIGITAL IN 5 9 42 DIGITAL IN 6 10 43 11 44 12 RS232 GND 45 DV 13 BATTERY 46 5V DBW 3 4 TP TP2 5V 14 BATTERY 47 CANO LO 15 BATTERY 48 CAN1 LO 16 PID2 PWM 2 DBW 2 PMW 2 49 PID2 PWM 1 DBW 2 PMW1 17_ CJC2 50 18 OV DBW 3 4 TP TP2 0V 51 19 BATTERY 52 20 BATTERY 53 5V DBW 1 2 TP TP2 5V 21 BATTERY 54 CANO HI 22 BATTERY 55 CAN1 HI 23 DIGITAL IN 1 56 PID1 PWM 2 DBW 1 PMW2 24 DIGITAL IN 2 57 25 58 PID1 MV 1
4. 6 When all calibrations have been performed send the configuration to the DBW 4 by pressing the F5 key MoTeC DBW 4 13 Introduction Diagnostic Fault Condition Monitoring To view the Diagnostic Fault Information select the Monitor Faults option under the File menu All red indicators indicate an error condition green indicators indicate OK Note that if any error conditions are present the particular PID Controller will be shutdown If any drive by wire type PID Controllers are shutdown then all other drive by wire type PID Controllers will also be shutdown Monitor Faults PID 1 Faults PID 2 Faults PID 3 Faults PID 4 Faults Commanded Shutdown No Contig Error Meas Meas2 Tracking Set P Meas Tracking Status PWM Error Meas End of Scale Meas2 End of Scale Commanded Shutdown No Config Error Meas Meas2 Tracking Set P Meas1 Tracking Status PWM Error Meas End of Scale Meas2 End of Scale Firmware Upgrades Commanded Shutdown No Config Error Meas1 Meas2 Tracking Set P Meas Tracking Status PWM Error Meas1 End of Scale Meas2 End of Scale Commanded Shutdown No Config Error Meas Meas2 Tracking Set P Meas Tracking Status PWM Error Meas1 End of Scale Meas2 End of Scale The Send Firmware option in the File menu can be used to upgrade the firmware of the DBW 4 unit The DBW 4 unit must be powered and connected to the CAN cable to perform the upgrade MoTeC DBW 4 14 Introduction Appendices A
5. is disconnected before applying power Step 3 Click on the Tab PID1 to PID4 for the controller to be calibrated Ensure that the Group type for the controller is set to Other Press the Calibrate button to begin the calibration After reading the displayed safety warning and checking the actuator wiring click Next to continue Step 4 Set the low limit for the measured position by following the instructions displayed see below For indication purposes the raw position value will be displayed as the actuator position is changed Note that the Set button can be pressed again if the measured position was set incorrectly When the low limit position has been set click Next to continue MoTeC DBW 4 12 Introduction Calibrate Step 2 Set Measured Value 1 to its minimum value Set the low limit by clicking the Set button Measured Value 1 raw 835 lt Back Cancel Step 5 Set the high limit for the measured position by following the instructions displayed see below For indication purposes the raw position value will be displayed as the actuator position is changed Note that the Set button can be pressed again if the measured position was set incorrectly When the high limit position has been set click Finished to continue Calibrate Step 3 Set Measured Value 1 to its maximum value Set the high limit by clicking the Set button Measured Value 1 raw 835 lt Back Finished Cancel Step
6. 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 tyoes 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 cyc
7. DBW 1 TP 26 59 PID1 MV 2 DBW 1 TP2 27 OV DBW 1 2 TP TP2 0V 60 PID2 MV 1 DBW 2 TP 28 BATTERY 61 PID1 PWM 1 DBW 1 PMW1 29 BATTERY 62 PID2 MV 2 DBW 2 TP2 30 BATTERY 63 PID3 MV 1 DBW 3 TP 31 RS232 RECEIVE 64 PID3 MV 2 DBW 3 TP2 32 DIGITAL IN 3 65 PID4 MV 1 DBW 4 TP 33 DIGITAL IN 4 66 PID4 MV 2 DBW 4 TP2 MoTeC DBW 4 20 Introduction Appendix G DBW 4 Connector Mating Connector Deutsch AS6 18 35SN Wire Wire to suit connector 22 Tefzel Mil Spec M22759 16 22 Crimp Tool Crimp Tool M22520 2 01 Positioner for Crimp Tool M22520 2 07 e Note that the Crimp Contacts are type 22D this is needed to set the crimp tool correctly Wire Stripping Tool The following tool is recommended Ideal Industries 45 2133 stripping tool with LB1195 wire stop Heatshrink Boots Straight Racychem 202K153 Hellermann 156 42 G Right Angle Racychem 222K153 Hellermann 1156 4 G MoTeC DBW 4 21 Introduction Notes
8. NING 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 To calibrate a DBW throttle body the high and low limit positions must be measured and included in the calibration The procedure calibration procedure described here should be repeated for each DBW throttle body connected to the DBW 4 Step 1 Run the DBW 4 software and load the appropriate configuration file for the DBW motor or enter the appropriate PID parameters If one of the supplied configuration files is loaded it is recommended that the configuration be saved under a new name before continuing with the calibration Step 2 Connect the CAN cable from the PC to the DBW 4 and apply power to the DBW 4 Ensure that only the sensor wiring TP TP2 5V and OV is connected to the DBW throttle body and that the wiring to the motor is disconnected before applying power Step 3 Click on the Tab PID1 to PID4 for the DBW throttle to be calibrated Ensure that the Group type for the controller is set to Drive By Wire Press the Calibrate button to begin the calibration After reading the displayed safety warning and checking the motor wiring click Next to continue Step 4 Set the low limits for the measured position by following the instructions displayed see below For indication purposes the raw position v
9. alues for the two measured values will be displayed as the butterfly valve position is changed Note that the Set button can be pressed again if the butterfly position was set incorrectly When the low limit position has been set click Next to continue Calibrate Step 2 Using a feeler gauge of approximately 0 5 mm press on the butterfly until it clamps the feeler gauge Set the low limit position for Measured Value 1 TP and Measured Value 2 TP2 by clicking the Set button Measured Value 1 raw 836 Measured Value 2 raw 221 MoTeC DBW 4 10 Introduction Step 5 This step is only applicable for DBW throttle bodies with a linear characteristic for the Meas2 TP2 sensor ie Meas2 Max Target 100 where the high limits for both measured values are set at the same time Set the high limits for the measured values by following the instructions displayed see below For indication purposes the raw position values for the two measured values will be displayed as the butterfly valve position is changed Note that the Set button can be pressed again if the butterfly position was set incorrectly When the high limit positions have been set click Finished to continue Calibrate Step 3 Move the butterfly to the full throttle position ensuring that the butterfly is NOT opened past the full throttle position The full throttle position must be set at least 2 degrees of rotation from the open throttle mechanical stop po
10. asured separately for measure value 1 TP and measured value 2 TP2 Set the high limit for the measured value 2 TP2 by following the instructions displayed see below It is important to position the butterfly as close to the target eg 62 5 as possible when setting measured value 2 Note that the Set button can be pressed again if the butterfly position was set incorrectly When the measured value 2 high limit position has been set click Finished to continue Calibrate Step 4 Move the butterfly until the Measured Value 1 TP reads 62 5 Then set Measured Value 2 TP2 high limit with Measured Value 1 TP reading 62 5 by clicking the Set button Measured Value 1 scaled 169 0 Cancel Step 8 When all calibrations have been performed send the configuration to the DBW 4 by pressing the F5 key Generic PID Controller Calibration To calibrate a generic PID controller the high and low limit positions must be measured and included in the calibration The procedure calibration procedure described here should be repeated for each PID controller connected to the DBW 4 Step 1 Run the DBW 4 software and load the appropriate configuration file for the connected device or enter the appropriate PID parameters Step 2 Connect the CAN cable from the PC to the DBW 4 and apply power to the DBW 4 Ensure that only the sensor wiring TP 5V and OV is connected to the device and that the wiring to the actuator
11. imum length of the bus is 16m 50ft including the MoTeC CAN Cable PC to CAN Bus Communications Cable CAN Devices such as MoTeC ADL BR2 etc may be connected to the trunk with up to 500mm 20in of twisted wire The connector for the CAN Communications Cable may also be connected to the trunk with up to 500mm 20in of twisted wire and should be within 500mm of one end of the trunk If desired two CAN Cable connectors may be used so that the MoTeC CAN Cable may be connected to either side of the vehicle Both connectors must be within 500mm of each end of the trunk CAN Cable Connector 100R Terminatin z e Resistors at Gen These wires must be Twisted end of the CAN Bus Minimum one twist per 50mm 2in 500mm d d lt lt CAN Bus gt gt Max CAN H a PES a S F S 500mm z 9 SE 4 Pa Zz Max SE SE 500mm Max CAN Device eg BR2 Short CAN Bus If the CAN Bus is less than 2m 7ft long then a single termination resistor may be used The resistor should be placed at the opposite end of the CAN Bus to the CAN Cable connector MoTeC DBW 4 18 Introduction Appendix E DBW 4 to M800 Wiring DBW 4 Boe ECU peer Bat CAN Cable See pin list Connector See pin list 71 S ov SE B24 147 CAN LO 72 a B23 48 CAN HI Su A Sp S CAN LO X004 See the CAN Bus Any Other Wiring Specification CAN Device for more Detail Any Other CAN Device DBW
12. le 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 e Measured Values 1 amp 2 for each PID AV1 AV8 e Measured Value 1 with PID diagnostic information The following data is transmitted by the DBW 4 at 50Hz e 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 e 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 MoTeC DBW 4 8 Introduction Configuration The DBW 4 unit is configured using the MoTec DBW 4 Manager Software This software can load save configurations and display diagnostic information DBW 4 Manager communicates with the DBW 4 using the MoTeC CAN cable The software is used to configure all PID Parameters as well as calibrate the maximum minimum and measured value ranges Before starting configuration and setup ensure that all wiring to the actuator
13. og input values are transmitted over the CAN bus as well as PID fault conditions The DBW 4 has the following inputs and outputs e 8Analog voltage inputs AV 1 8 for PID Controller feedback and generic use e 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 DBW 4 Unit Measured Value Measured Value Tracking Measured Value 1 PID Controller Measured Value 2 Throttle Body Figure 1 DBW 4 Unit in a drive by wire application MoTeC DBW 4 4 Introduction Abbreviations amp 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 amp Measured Value 2 For drive by wire PID applications Measured Value 1 refers to TP amp 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
14. olet 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 DIVER O CU d siii hse secant dei res iescaevewistcwacdeteneumeaeanes 3 Abbreviations amp Definitions ccceeeeseeeeeeeeeeeeeeeeeees 4 Inputs amp OULD URS sisecstacadctsohsapricasscaisdiastiasarstiaece nearer 5 PID Fault COMGITONS oii scccssedsvassecscecend cade eege NEE eegen 6 COMMUNI CAUOIS tg cdteeceeesctexcaoesccteamrectiasinsaatecieestieaeans 7 GAIN ege eessen 7 Firmware Upgrades xii csccssosecivachcacevevvecseeepevcanctavenstvveeseseuvudqeasccvaesctetvleaveeesveseeey 7 Configuration See 8 Drive By Wire Calibration cccccccccccssccccessseeeeceeneeeeeecsnseeecesseeeeeessnaeeeesssaeees 9 Generic PID Controller Calibration 0 ccccceseeeeeeeeeeeeeeeeneeseeeeseneeeeeneeessaeees 11 Diagnostic Fault Condition Monitoring 13 Firmware Upgrade EE 13 Appendices ee keete oni sctianecssenewssnmanvebeweweeicts 14 Appendix A General Specifications ccccccsscccceesssseeeesssneeeeecsaeeeeeessaeeeeens 14 Appendix B Input Characteristics cccccccessscceecssseeeeesssseeeeecsaeeeeeessaeeeens 15 Appendi
15. ppendix A General Specifications Physical and Environmental Case Size 99 x 105mm x 40mm Weight 320g Temperature Range 10 to 70 C Power Supply Operating Voltage 9 22V DC Operating Current 150mA excluding sensor currents and outputs Protection Battery transient protection Reverse battery protection via external fuse CAN Communications CAN bus speed 1Mbit s No CAN terminating resistor onboard MoTeC DBW 4 15 Introduction Appendix B Input Characteristics Analog Voltage Inputs Range 0 to 5V Resolution 4 89mV 10bit conversion Input Resistance 100Kohms to 0V Filtering Oversampled for anti aliasing Update rate on CAN 200Hz CAN address OxOFO or Ox0F8 50Hz CAN address Ox0F4 or 0x0FC Internal Temperature Sensor Resolution 1 C Accuracy e DBW 4 case temperature 25 C 2 C e DBW 4 case temperature 10 to 70 C 4 C MoTeC DBW 4 16 Introduction Appendix C Output Characteristics Outputs Current per output when using the given number of outputs e 2 Outputs 1 PID 2 3A e 4Outputs 2PIDs 1 6A e 80Outputs 4 PIDs 1 1A Frequency range for PID PWM outputs 500Hz to approx 10kHz MoTeC DBW 4 17 Introduction Appendix D CAN Wiring Multiple Device The CAN bus should consist of a twisted pair trunk with 100R 0 25Watt 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 max
16. s and sensors are complete as well as all power and communication wiring The main window of DBW 4 Manager is shown below with the settings for each of the four PID controllers on a separate tab Each PID controller can disabled or configured as either a Drive By Wire or generic Other PID controller Values for PID parameters are specified in the documentation supplied by MoTec for each throttle body and are the same parameters that the MoTeC ECU Manager software uses for single drive by wire applications ie non DBW 4 applications Configuration files for several drive by wire motors are supplied with the DBW 4 Manager software These files have all the PID Parameters for the motor type but the motor must still be calibrated before it can be used A configurations with a completed calibration must be sent to the DBW 4 before it will take effect The configuration is sent to the DBW 4 by selecting the Send Config menu option or by pressing F5 DS Motet DBW 4 Manager New Config File Help PID1 piD2 PID3 PID4 Group Drive By Wire v Proportional Gain Meas2 Max Target Integral Gain Meast Low Limit Derivative Gain Meast High Limit PID Period Meas2 Low Limit Dead Band Meas2 High Limit Feed Fwd Gain Meas2 Max Integral P Clamp Nm WITTE Integral N Clamp Meas Filter Const Reg Filter Const Max Duty Max Volts Pi Freq MoTeC DBW 4 9 Introduction Drive By Wire Calibration WAR
17. sition Set the high limit position for Measured Value 1 TP and Measured Value 2 TP2 by clicking the Set button Measured Value 1 raw 835 Measured Value 2 raw 221 lt Back Finished Cancel Step 6 This step is only applicable for DBW throttle bodies with a knee characteristic for the Meas2 TP2 sensor eg Meas2 Max Target 62 5 where the high limit is measured separately for measure value 1 TP and measured value 2 TP2 Set the high limit for the measured value 1 TP by following the instructions displayed see below For indication purposes the raw position values for measured value 1 will be displayed as the butterfly valve position is changed Note that the Set button can be pressed again if the butterfly position was set incorrectly When the measured value 1 high limit position has been set click Next to continue Calibrate Step 3 Move the butterfly to the full throttle position ensuring that the butterfly is NOT opened past the full throttle position The full throttle position must be set at least 2 degrees of rotation from the open throttle mechanical stop position Set the high limit position for Measured Value 1 TP by clicking the Set button Measured Value 1 raw 835 Step 7 MoTeC DBW 4 11 Introduction This step is only applicable for DBW throttle bodies with a knee characteristic for the Meas2 TP2 sensor eg Meas2 Max Target 62 5 where the high limit is me
18. x C Output Characteristics c ccccccsccccesssseeeeessneeeeeesaeeeeeesseeeeens 16 Appendix D CAN Wiring Multiple Device 17 Appendix E DBW 4 to M800 Wiimg 18 Appendix F DBW 4 Pin List by Pin Number 19 Appendix G DBW 4 Connector sssssessssiisseriitanettttttttntttntantttta narenn annee ennn 20 MoTeC DBW 4 3 Introduction Introduction This manual describes the functions and specifications of the MoTeC DBW4 and configuration for use with the MoTeC hundred series ECUs M400 M600 amp 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 anal
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