Coils & Electronic Controls

Transcription

1 HYDRAFORCE Coils & Electronic Controls COILS FOR SOLENOID OPERATED VALVES Standard Coils and Proportional Valve Coils Series E Water/Weather Resistant Coils ELECTRONIC CONTROLS FOR PROPORTIONAL VALVES Electronic Controls Introduction Electro-Hydraulic Control Technology DIN Coil-Mount Controllers 0 5 VDC, 10K Pot or 0 20 ma Input VDC Input ma Input K Pot or 0 5 VDC Input Economy Version Soft Shift 12 or 24 VDC Input Remote-Mount PCB (Board Only) Controllers 0 5 VDC, 10K Pot or 0 20 ma Input VDC Input Remote-Mount Metal Box Controllers 0 10 VDC Input ma Input PWM (Pulse Train) Input DIN Rail-Mount Controllers 0 5 VDC, 10K Pot or 0 20 ma Input VDC Input ma Input PWM (Pulse Train) Input Dual Solenoid Driver, Multifunction Potted in Metal Box, 0 5 VDC, ±5 VDC, 0 10 VDC, 0 20 ma, ±20 ma Input Appendix Setup Instructions, Glossary of Terms Electronics in Mobile Equipment EVDR Programmable Electronic Valve Driver ELECTRONIC VEHICLE CONTROLS Electronic Control Units ECU-ML Machine Controller with 72 inputs ECU-MM Machine Controller with 44 inputs ECU-MS Machine Controller with 25 inputs Pin Electrical Connectors for ECU-Mx ECU Technical Reference Information Operator Input Devices Joystick, Single-Axis, EJS1Ax Joystick, Dual-Axis, EJS2Ax Shifter, Column-Mount, ESHFNR Hand Control Unit, , Proportional Roller, ERLxx Foot Pedal, ETHFC Switches Pressure Switches, EWP Proximity Switch, EWA Rocker Switches, ESWRK-xxx Sensors Analog Pressure Sensor, ERPxxx PWM Pressure Sensor, ERPxxx-P Thermistor Temperature Sensor, ERT Ground Speed Radar Sensor, ERRD Directional Speed Sensor, ERS Variable Reluctance Speed Sensor, ERS5K Rotary Position Sensor, Med.-Duty, ERRxxxM-P Rotary Position Sensor, Heavy-Duty, ERRxxxH Displays, Video LCD Display, 240 x 64, Model ELD LCD Display, 320 x 240, Model ELD LCD Display, 320 x 240, Model ELD Gauges, Digital In, Analog-Readout, Model EGAxD Closed-Circuit Video System, Model CCV Lights Heavy Duty Wide-Flood Work Lights

2 Table of Contents CONTENTS INTRODUCTION Electro-Hydraulic Control Technology DIN COIL-MOUNT CONTROLLERS 0 5 VDC, 10K Pot or 0 20 ma Input VDC Input ma Input K Pot or 0 5 VDC Input Economy Version Soft Shift 12 or 24 VDC Input REMOTE-MOUNT PCB CONTROLLERS 0 5 VDC, 10K Pot or 0 20 ma Input VDC Input REMOTE-MOUNT METAL BOX CONTROLLERS 0 10 VDC Input ma Input PWM (Pulse Train) Input DIN RAIL-MOUNT CONTROLLERS 0 5 VDC, 10K Pot or 0 20 ma Input VDC Input ma Input PWM (Pulse Train) Input DUAL SOLENOID DRIVER Multifunction, Potted in Metal Box APPENDIX Setup Instructions Glossary of Terms Electronics in the Mobile Equipment Industries *NEW* EVDR SERIES UNIVERSAL-INPUT DRIVERS Valve Coil Plug-In Type, or Box Type for Separate Mounting. Multiple I/O Capability. See EVDR Selection Guide Introduction ELECTRO-HYDRAULIC CONTROL Electronic Control Electronic control in mobile equipment can consist of the following: Operator Inputs: These inputs can be defi ned as the user interface, and can consist of joysticks, potentiometers, operator panels, or other input devices. Feedback Inputs: These inputs can be defi ned as the machine interface, and can consist of pressure transducers, temperature sensors, fl ow sensors, velocity sensors or RPM sensors. When feedback inputs are used the system is described as closed loop. Controller or ECU: This is the brains of the electronic control. It processes the inputs and converts them into a defi ned output to the hydraulic system. The controller also can have the ability to receive feedback inputs from machine sensors and attenuate its outputs accordingly. The controller can be factory-programmed or have the ability to be user-programmable to meet the specifi c needs of the application. Outputs: Outputs can be on/off voltage signals or proportional PWM signals to control the hydraulic valving. Communications: The controller can have the ability to engage in two-way communications with a bus system (for example: communication between the ECU and a display, or output signal to an input device). ECU Electronic Control Unit ECU s were developed to replace the older sequential relay circuits, that were used for machine control. The ECU works by measuring its inputs and depending on their state, switching its outputs On or Off. The user enters setup instructions, usually via software, that will produce the desired results. Because many of the controller s functions are user-programmable, an ECU has the versatility to be fi eld-modifi ed for changing applications or conditions. Some ECU s have the capability to convert analog inputs, process them digitally, and produce analog outputs. ECUs that do not have built-in converters require separate analog-todigital converters to convert the input. Analog An analog signal is an AC or DC voltage or current, or resistive signal that varies smoothly and continuously. In an analog system, a physical variable is represented by a proportional voltage that varies in correspondence with the physical variable. Electronic circuits that process analog signals are called linear circuits. An example of an analog device is a traditional-style clock that has hour and minute sweep hands that rotate around the dial. As an input, an analog signal can provide infi nite resolution due to its wide frequency range

3 HYDRAFORCE Electro-Hydraulic Control Technology ELECTRO-HYDRAULIC CONTROL (cont d) Inputs Outputs Power Control Signal (User Interface) Joystick Potentiometer Operator Panel Other ECU Personality Features Needed User Programmable Factory Set Packaging Cost Other Hydraulic System On/Off Proportional Diagnostic Feedback Inputs Sensors Communications Fieldbus, Wireless Digital Digital signals vary in discrete (discontinuous) values to represent information for input. A digital signal is normally in the form of a series of pulses that rapidly change from one distinct, fi xed voltage level to another. An example of a digital device is a clock that displays the time in actual numerals that change in one-numeral increments. As an input, the resolution is dependent on the number of bits of information processed or available to the controller. In digital systems, physical variables are represented by numerical values using the binary (base 2) number system. Electronic Control Platforms Some of the different forms that mobile electronics can take are described in the chart shown on this page. There is an increasing complexity and cost as the controllers move from single-function analog controls to complete complex digital control systems. Digital vehicle controllers offer a high level of sophistication by executing a programmed sequence of functions that constantly control all motion parameters. Increasing Complexity and Value Electronic Control Technology Platforms for the Mobile Equipment Market On/Off Functions Vehicle Control Systems Vehicle Control Subsystems Transmission Controller Digital Control Products Microprocessor Digital Signal Processor PID Controller Motor Controller Pump Controller Closed Loop Flow Controller Fan Drive (with Sensor Input) Analog Control Products Proportional Valve Controllers Soft Shift Soft Shift/Hold Low Cost Fan Drive Converter Controller with Position Feedback (Servo Mechanism)

4 Proportional Valve Controller DIN Coil Mount DESCRIPTION 0 5 VDC, 10K Pot or 0 20 ma Input A convenient, plug-mounted control amplifier for controlling HydraForce proportional valves that have solenoids with DIN 43650A/ISO 4400 electrical connectors. OPERATION This control module uses closed-loop current control with superimposed dither to supply a proportional valve solenoid with a proportional control signal. The input signal to this controller can be from a 10K potentiometer, 0 5 VDC, 0 20 ma, or from other pre-set levels. GENERAL SPECIFICATIONS Plug Housing: Polyamide Plug Lid: Polycarbonate Weight: 30 g (1.06 oz.) without cable Connections: Mounted cable with unterminated wires provided; Length: approximately 2 meters (79") SCHEMATIC FEATURES Mounts directly to solenoid coils with DIN 43650A connectors. IP65 weather resistant when used with base gasket (supplied). Adjustments accessible with a removable cover. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. Connector can be disconnected from coil when powered. Maximum current adjustment does not affect minimum current setting. Independent ramp adjustments and internal supply for potentiometer. Dither frequency and amplitude are adjustable for maximum valve performance. RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal Options: 10K external potentiometer (accepts 5K to 50K pots), or 0 5 VDC signal, or 0 20 ma current signal (see connection diagrams) Input Resistance: Voltage Control: 125K Ohms; Current Control: 50 Ohms Output Current: up to 2000 ma (see ordering info.) Minimum Current Range: ma (adjustable; see ordering info.) Maximum Current Range: ma (adjustable; see ordering info) Ramp Up and/or Down: seconds (independently adjustable) Dither Frequency: Hz (adjustable) Dither Amplitude: 0 10% of maximum current (adjustable) Operating Conditions: 40 to 85 C; 0 to 85% relative humidity Environmental Protection: IP65 with cover and base gasket installed V PS (9-32 VDC) + POWER GND ACTIVE REVERSE POLARITY PROTECTION STEP-DOWN CONVERTER V PS TO 5.5 V STEP-UP DC/DC CONVERTER +12 V 12 V POTENTIOMETER INPUT +5 V REFERENCE VOLTAGE IN (0-5 VDC) CURRENT IN (0-20 ma) SIGNAL GND VOLTAGE REFERENCE GENERATOR RAMP UP DITHER GENERATOR RAMP DOWN INDEPENDENT RAMP CONTROL FUNCTION DITHER FREQUENCY R D R DITHER I-MAX. R MAX. DITHER AMPLITUDE I-MIN. +5 V +5 V R M R MIN. R DA ERROR AMPLIFIER + VOLTAGE TO HIGH FREQUENCY PWM CONVERTER CURRENT SENSING AND SHORT CIRCUIT PROTECTION S 1 SOLENOID OUTPUT S

5 HYDRAFORCE 0 5 VDC, 10K Pot or 0 20 ma Input DIMENSIONS (+) Power Supply Red ( ) Power Supply Black 0 20 ma Input Blue Potentiometer Power White 0 5 VDC Input Green Input Ground Brown ADJUSTMENTS DETAIL APPROX M Adjustments Under Cover. See Detail Falling Ramp Dither Amplitude Rising Ramp Dither Frequency Minimum Current Maximum Current INCH MILLIMETRE M CONNECTIONS For Complete Set-Up Instructions, see page For Either 0 20 ma or 0 5 VDC Control: Turn ramp screws fully counterclockwise to eliminate ramping. Use I-Min. screw to set minimum speed with minimum control input. Use I-Max. screw to set maximum speed with 100% of control input. 10K Potentiometer (Pot.) Control 0 to 20 ma Control 0 to 5 VDC Control Supplied by User Wire Color Supplied by User Wire Color Supplied by User Wire Color (+) Power Red (+) Power Red (+) Power Red ( ) Power Black ( ) Power Black ( ) Power Black Not Used Blue (+) 0 20mA Blue Not Used Blue (+) Pot. White Not Used White Not Used White 10K Pot. Green Not Used Green (+) 0 5V Green ( ) Pot. Brown ( ) 0 20mA Brown ( ) 0 5V Brown TO ORDER Part Number Output I-Min. Setting I-Max. Setting Cable Length ma Max. 0 to 500 ma 600 to 2000 ma 2 meters ma Max. 0 to 150 ma 400 to 1200 ma 2 meters

6 Proportional Valve Controller DIN Coil Mount DESCRIPTION 0 10 VDC Input A convenient, plug-mounted control amplifier for controlling HydraForce proportional valves that have solenoids with DIN 43650A/ISO 4400 electrical connectors. OPERATION This control module uses closed-loop current control with superimposed dither to supply a proportional valve solenoid with a proportional control signal. The input signal to this controller can be from a 0 10 VDC source. FEATURES Mounts directly to solenoid coils with DIN 43650A connectors. IP65 weather resistant when used with base gasket (supplied). Adjustments accessible with a removable cover. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. Can be disconnected from coil when powered. Maximum current adjustment does not affect minimum current setting. Independent ramp adjustments and internal supply for potentiometer. Dither frequency and amplitude are adjustable for maximum valve performance. GENERAL SPECIFICATIONS Plug Housing: Polyamide Plug Lid: Polycarbonate Weight: 30 g (1.06 oz.) without cable Connections: Mounted cable with unterminated wires provided; Length: approximately 2 meters (79") RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal: 0 10 VDC Input Resistance: 225K Ohms Output Current: up to 2000 ma (see ordering info.) Minimum Current Range: ma (adjustable; see ordering info.) Maximum Current Range: ma (adjustable; see ordering info.) Ramp Up and/or Down: seconds (independently adjustable) Dither Frequency: Hz (adjustable) Dither Amplitude: 0 10% of maximum current (adjustable) Operating Conditions: 40 to 85 C; 0 to 85% relative humidity Environmental Protection: IP65 with cover and base gasket installed SCHEMATIC V PS + (9-32 VDC) POWER GND ACTIVE REVERSE POLARITY PROTECTION STEP-DOWN CONVERTER V PS TO 5.5 V STEP-UP DC/DC CONVERTER +12 V 12 V NOT USED +5 V RAMP UP RAMP DOWN +5 V VOLTAGE IN (0-10 VDC) NOT USED SIGNAL GND INDEPENDENT RAMP CONTROL FUNCTION DITHER FREQUENCY R D R DITHER DITHER GENERATOR I-MAX. R MAX. DITHER AMPLITUDE I-MIN. R M R MIN. R DA ERROR AMPLIFIER + VOLTAGE TO HIGH FREQUENCY PWM CONVERTER CURRENT SENSING AND SHORT CIRCUIT PROTECTION S 1 SOLENOID OUTPUT S

7 HYDRAFORCE 0 10 VDC Input DIMENSIONS (+) Power Supply Red ( ) Power Supply Black Not Used Blue Not Used White 0 10 VDC Input Green Input Ground Brown ADJUSTMENTS DETAIL APPROX M Adjustments Under Cover. See Detail Falling Ramp Dither Amplitude Rising Ramp Dither Frequency Minimum Current Maximum Current INCH MILLIMETRE M CONNECTIONS For Complete Set-Up Instructions, see page Basic Setup: Turn ramp screws fully counterclockwise to eliminate ramping. Use I-Min. screw to set minimum speed with minimum control input. Use I-Max. screw to set maximum speed with 100% of control input. 0 to 10 VDC Control Supplied by User (+) Power ( ) Power Not Used Not Used (+) 0 10V ( ) 0 10V Wire Color Red Black Blue White Green Brown TO ORDER Part Number Output I-Min. Setting I-Max. Setting Cable Length ma Max. 0 to 500 ma 600 to 2000 ma 2 meters ma Max. 0 to 150 ma 400 to 1200 ma 2 meters

8 Proportional Valve Controller DIN Coil Mount DESCRIPTION 4 20 ma Input A convenient, plug-mounted control amplifi er for controlling HydraForce proportional valves that have solenoids with DIN 43650A/ISO 4400 electrical connectors. OPERATION This control module uses closed-loop current control with superimposed dither to supply a proportional valve solenoid with a proportional control signal. This controller will accept a 4 20 ma input signal from a programmable logic controller (PLC) or other control systems. GENERAL SPECIFICATIONS Plug Housing: Polyamide Plug Lid: Polycarbonate Weight: 30 g (1.06 oz.) without cable Connections: Mounted cable with unterminated wires provided; Length: approximately 2 meters (79") FEATURES Mounts directly to solenoid coils with DIN 43650A connectors. IP65 weather resistant when used with base gasket (supplied). Adjustments accessible with a removable cover. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. Connector can be disconnected from coil when powered. Maximum current adjustment does not affect minimum current setting. Independent ramp adjustments. Dither frequency and amplitude are adjustable for maximum valve performance. RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal Options: 4 20 ma current signal Input Resistance: 50 Ohms Output Current: 1200 ma Minimum Current Range: ma, adjustable Maximum Current Range: ma, adjustable Ramp Up and/or Down: seconds, independently adjustable Dither Frequency: Hz, adjustable Dither Amplitude: 0 10% of maximum current, adjustable Operating Conditions: 40 to 85 C; 0 to 85% relative humidity Environmental Protection: IP65 with cover and base gasket installed SCHEMATIC V PS + (9-32 VDC) POWER GND ACTIVE REVERSE POLARITY PROTECTION STEP-DOWN CONVERTER V PS TO 5.5 V STEP-UP DC/DC CONVERTER +12 V 12 V +5 V RAMP UP RAMP DOWN +5 V CURRENT LOOP TRANSMITTER CURRENT IN (4-20 ma) SIGNAL GND INDEPENDENT RAMP CONTROL FUNCTION DITHER FREQUENCY R D R DITHER DITHER GENERATOR I-MAX. R MAX. DITHER AMPLITUDE I-MIN. R M R MIN. R DA ERROR AMPLIFIER + VOLTAGE TO HIGH FREQUENCY PWM CONVERTER CURRENT SENSING AND SHORT CIRCUIT PROTECTION S 1 SOLENOID OUTPUT S

9 HYDRAFORCE 4 20 ma Input DIMENSIONS (+) Power Supply ( ) Power Supply (+) 4-20 ma Input Signal Ground Red Black White Green Adjustments Under Cover. See Detail ADJUSTMENTS DETAIL APPROX M Ramp Down Dither Amplitude Ramp Up Dither Frequency Minimum Current Maximum Current INCH MILLIMETRE M CONNECTIONS For Complete Set-Up Instructions, see page Basic Setup: Turn ramp screws fully counterclockwise to eliminate ramping. Use I-Min. screw to set minimum speed with minimum control input. Use I-Max. screw to set maximum speed with 100% of control input. 4 to 20 ma Control Supplied by User (+) Power ( ) Power (+) 4 20mA ( ) 4 20mA Wire Color Red Black White Green TO ORDER Part Number Output I-Min. Setting I-Max. Setting Cable Length ma Max. 0 to 150 ma 400 to 1200 ma 2 meters

10 Proportional Valve Controller DIN Coil Mount DESCRIPTION 10K Pot or 0 5 VDC Input Economy Version A convenient, plug-mounted control amplifier for controlling HydraForce proportional valves that have solenoids with DIN 43650A/ISO 4400 electrical connectors. OPERATION This control module supplies a proportional valve solenoid with a proportional control signal. The input signal to this controller can be from a 10K potentiometer or a 0 5 VDC source. This economy version has no ramp adjustments. Dither frequency and amplitude are factory pre-set. FEATURES Mounts directly to solenoid coils with DIN 43650A connectors. IP65 weather resistant when used with base gasket (supplied). Adjustments accessible with a removable cover. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. Connector can be disconnected from coil when powered. Maximum current adjustment does not affect minimum current setting. Internal supply for potentiometer. GENERAL SPECIFICATIONS Plug Housing: Polyamide Plug Lid: Polycarbonate Weight: 30 g (1.06 oz.) without cable Connections: Mounted cable with unterminated wires provided; Length: approximately 2 meters (79") RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal Options: 10K external potentiometer (accepts 5K to 50K pots), or 0 5 VDC current signal (see connection diagrams) Input Resistance: 187K Ohms Output Current: up to 2000 ma (see ordering info.) Minimum Current Range: ma (adjustable) Maximum Current Range: ma (adjustable) Internal Supply for Setpoint Potentiometer: +5VDC Dither Frequency: 90 or 220 Hz (±10% of full scale) Preset at Factory Dither Amplitude: 5% Preset at Factory Operating Conditions: 40 to 85 C; 0 to 85% relative humidity Environmental Protection: IP65 with cover and base gasket installed SCHEMATIC V PS + (9-32 VDC) POWER GND ACTIVE REVERSE POLARITY PROTECTION POTENTIOMETER INPUT +5 V REFERENCE VOLTAGE IN (0-5 VDC) SIGNAL GND VOLTAGE REFERENCE GENERATOR R IN DITHER GENERATOR I-MAX. R D LOW DROP OUT (LDO) VOLTAGE REGULATOR R MIN. R MAX. R M I-MIN. ERROR AMPLIFIER + +5V VOLTAGE TO HIGH FREQUENCY PWM CONVERTER CURRENT SENSING AND SHORT CIRCUIT PROTECTION S 1 SOLENOID OUTPUT S

11 10K Pot or 0 5 VDC Input Economy Version DIMENSIONS HYDRAFORCE (+) Power Supply ( ) Power Supply Potentiometer Power 0 5 VDC Input Input Ground Red Black White Green Brown APPROX M Adjustments Under Cover. See Detail ADJUSTMENTS DETAIL Maximum Current Minimum Current INCH MILLIMETRE M CONNECTIONS For Complete Set-Up Instructions, see page K Potentiometer (Pot.) Control Supplied by User Wire Color (+) Power Red ( ) Power Black (+) Pot. White 10K Pot. Green ( ) Pot. Brown 0 to 5 VDC Control Supplied by User (+) Power ( ) Power Not Used (+) 0 5V ( ) 0 5V Wire Color Red Black White Green Brown TO ORDER Part Number Dither Freq. Output I-Min. Setting I-Max. Setting Cable Length Hz 2000 ma 0 to 500 ma 600 to 2000 ma 2 meters Hz 2000 ma 0 to 500 ma 600 to 2000 ma 2 meters

12 Proportional Valve Controller DIN Coil Mount DESCRIPTION Soft Shift 12 or 24 VDC Input A convenient, plug-mounted controller for HydraForce proportional valves that have solenoids with DIN 43650A/ISO 4400 electrical connectors. OPERATION This controller uses the power supply voltage as the control signal. It has an adjustable increasing ramp and an adjustable I-Max. setting. When power is applied to this controller, its output ramps up to maximum current in a time period that is adjustable within a factory set range. The ramp adjustment allows the user to defi ne the length of time required for the hydraulic valve to reach its maximum output. When electrical power is removed, the output of this controller immediately falls to zero. FEATURES Mounts directly to solenoid coils with DIN 43650A connectors. IP65 weather resistant when used with base gasket (supplied). Adjustments accessible with a removable cover. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof. GENERAL SPECIFICATIONS Plug Housing: Polyamide Plug Lid: Polycarbonate Weight: 30 g (1.06 oz.) without cable Connections: Mounted cable with unterminated wires provided; Length: approximately 2 meters (79") RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Output Current: 2 Amps Max. Ramp Adjustment: 0.01 to 5 seconds I-Max. Adjustment: ma, or ma Dither Frequency: 300 Hz ±10% (fi xed) Dither Amplitude: 10% of rated maximum (fi xed) Operating Conditions: 40 to 85 C; 0 to 85% relative humidity Environmental Protection: IP65 with cover and base gasket installed SCHEMATIC 24 V PS + (9-32 VDC) TRANSIENT PROTECTION D 1 REVERSE POLARITY PROTECTION 7.5 V (LDO) LOW DROP OUT REGULATOR D 2 I-MAX. WAVEFORM GENERATOR ERROR AMPLIFIER + HIGH FREQUENCY PWM MODULATOR S 1 RAMP TIME POWER UP CURRENT SENSING AND SHORT CIRCUIT PROTECTION POWER OUTPUT STAGE SOLENOID OUTPUT S

13 HYDRAFORCE Soft Shift 12 or 24 VDC Input DIMENSIONS (+) 12 or 24 VDC Power Red ( ) 12 or 24 VDC Power Black APPROX M Adjustments Under Cover. See Detail. ADJUSTMENTS DETAIL Rising Ramp Maximum Current INCH MILLIMETRE M Adjustments: Ramp: Single Turn Potentiometer; CCW to increase ramp time. I-Max.: Single Turn Potentiometer; CW to increase I-Max. TO ORDER Part Number I-Max. Setting Adjustable Ramp Time Cable Length to 2000 ma 0.01 to 5 seconds 2 meters to 650 ma 0.01 to 5 seconds 2 meters

14 Proportional Valve Controller PCB Only DESCRIPTION 0 5 VDC, 10K Pot or 0 20 ma Input A printed circuit board-style (PCB) control amplifier for controlling HydraForce proportional valves. Remote mounting in a protected enclosure is required. OPERATION This control module uses closed-loop current control with superimposed dither to supply a proportional valve solenoid with a proportional control signal. The input signal to this controller can be from a 10K potentiometer, 0 5 VDC, 0 20 ma, or from other pre-set levels. FEATURES Adjustments and connections clearly labeled. LED indication of output power level, input level and power on/off. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. Can be disconnected from coil when powered. Maximum current adjustment does not affect minimum current setting. Independent ramp adjustments and internal supply for potentiometer. Filter eliminates electrical noise. Dither frequency and amplitude are adjustable for maximum valve performance. GENERAL SPECIFICATIONS Weight: 25 g (0.88 oz.) Connections: Screw terminals for AWG wire CSA Listing: CSA C22.2 No. 14-M91 RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal Options: 10K external potentiometer (accepts 5K to 50K pots), or 0 5 VDC signal, or 0 20 ma current signal (see connection diagrams) Input Resistance: Voltage: 250K Ohms; Current: 33 Ohms Output Current: up to 2000 ma (see ordering info.) Minimum Current Range: ma (adjustable; see ordering info.) Maximum Current Range: ma (adjustable; see ordering info.) Ramp Up and/or Down: seconds (independently adjustable) Dither Frequency: Hz (adjustable) Dither Amplitude: 0 10% of maximum current (adjustable) Operating Conditions: 40 to 85 C; 0 to 85% relative humidity SCHEMATIC POTENTIOMETER INPUT V PS + (9-32 VDC) +5 V REFERENCE VOLTAGE IN (0-5 VDC) CURRENT IN (0-20 ma) SIGNAL GND POWER GND ACTIVE REVERSE POLARITY PROTECTION VOLTAGE REFERENCE GENERATOR RAMP UP DITHER GENERATOR RAMP DOWN INDEPENDENT RAMP CONTROL FUNCTION DITHER FREQUENCY R D R DITHER I-MAX. DITHER AMPLITUDE STEP-DOWN CONVERTER V PS TO 5.5 V R MAX. I-MIN. +5 V +5 V R M R MIN. R DA STEP-UP DC/DC CONVERTER ERROR AMPLIFIER V 12 V VOLTAGE TO HIGH FREQUENCY PWM CONVERTER CURRENT SENSING AND SHORT CIRCUIT PROTECTION INPUT, OUTPUT AND POWER SUPPLY INDICATORS LOW PASS FILTER C F S 1 SOLENOID OUTPUT S 2 ENABLE

15 HYDRAFORCE 0 5 VDC, 10K Pot or 0 20 ma Input DIMENSIONS INCH MILLIMETRE Setscrew Adjustments Span I-Max. Zero I-Min. Dither Frequency TP9 R50 R32 TP1 TP8 TP7 Input Level LED Brightness increases as input signal increases. TP10 L3 R46 TP6 Ramp Up (Rising Edge) R49 R48 Ramp Down (Falling Edge) Dither Level (Amplitude) R31 TP5 L2 L1 Power Okay LED TP3 TP2 POW+ POW TP4 +5V REF V IN AGND I IN ENABLE FGND SOL SOL+ Output Level LED Brightness increases as output amperage increases. Screw Terminal Connections for AWG wire (+) Power ( ) Power +5V Reference Voltage In Analog Ground Current In Enable Frame Ground ( ) Solenoid (+) Solenoid Mounting Holes (4) (3.90) Dia. for #6 size screws (not supplied) Note: When Enable is connected to (+) Power or left open, the unit is enabled. When Enable is connected to ( ) Power, the unit will be disabled. CONNECTIONS 10K Potentiometer (Pot.) Control Supplied by User (+) Power ( ) Power 10K Pot. (+) Pot. ( ) Pot. Not Used Enable Frame Gnd. ( ) Coil (+) Coil Screw Terminal For Complete Set-Up Instructions, see page (+) Power ( ) Power (+) 5V Reference Voltage In Analog Gnd. Current In Enable Frame Gnd. ( ) Solenoid (+) Solenoid For Either 0 20 ma or 0 5 VDC Control: Turn ramp screws fully counterclockwise to eliminate ramping. Use I-Min. screw to set minimum speed with minimum control input. Use I-Max. screw to set maximum speed with 100% of control input. 0 to 20 ma Control Supplied by User (+) Power ( ) Power Not Used Not Used ( ) 0 20mA (+) 0 20mA Enable Frame Gnd. ( ) Coil (+) Coil Screw Terminal (+) Power ( ) Power (+) 5V Reference Voltage In Analog Gnd. Current In Enable Frame Gnd. ( ) Solenoid (+) Solenoid 0 to 5 VDC Control Supplied by User (+) Power ( ) Power Not Used (+) 0 5V ( ) 0 5V Not Used Enable Frame Gnd. ( ) Coil (+) Coil Screw Terminal (+) Power ( ) Power (+) 5V Reference Voltage In Analog Gnd. Current In Enable Frame Gnd. ( ) Solenoid (+) Solenoid TO ORDER Part Number Output I-Min. Setting I-Max. Setting ma Max. 0 to 500 ma 600 to 2000 ma ma Max. 0 to 150 ma 400 to 1200 ma

16 Proportional Valve Controller PCB Only DESCRIPTION 0 10 VDC Input A printed circuit board-style (PCB) control amplifier for controlling HydraForce proportional valves. Remote mounting in a protected enclosure is required. OPERATION This control module uses closed-loop current control with superimposed dither to supply a proportional valve solenoid with a proportional control signal. The input signal to this controller can be from a 0 10 VDC source. FEATURES Adjustments and connections clearly labeled. LED indication of output power level, input level and power on/off. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. Can be disconnected from coil when powered. Maximum current adjustment does not affect minimum current setting. Independent ramp adjustments. Filter eliminates electrical noise. Dither frequency and amplitude are adjustable for maximum valve performance. GENERAL SPECIFICATIONS Weight: 25 g (0.88 oz.) Connections: Screw terminals for AWG wire CSA Listing: CSA C22.2 No. 14-M91 RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal: 0 10 VDC Input Resistance: 250K Ohms Output Current: up to 2000 ma (see ordering info.) Minimum Current Range: ma (adjustable) Maximum Current Range: ma (adjustable) Ramp Up and/or Down: seconds (independently adjustable) Dither Frequency: Hz (±10%) Dither Amplitude: 0 10% of maximum current (adjustable) Operating Conditions: 40 to 85 C; 0 to 85% relative humidity SCHEMATIC V PS + (9-32 VDC) NOT USED POWER GND ACTIVE REVERSE POLARITY PROTECTION STEP-DOWN CONVERTER V PS TO 5.5 V +5 V STEP-UP DC/DC CONVERTER +12 V 12 V INPUT, OUTPUT AND POWER SUPPLY INDICATORS RAMP UP RAMP DOWN +5 V VOLTAGE IN (0-10 VDC) NOT USED ANALOG GND INDEPENDENT RAMP CONTROL FUNCTION DITHER FREQUENCY R D R DITHER DITHER GENERATOR I-MAX. R MAX. DITHER AMPLITUDE I-MIN. R M R MIN. R DA ERROR AMPLIFIER + VOLTAGE TO HIGH FREQUENCY PWM CONVERTER CURRENT SENSING AND SHORT CIRCUIT PROTECTION LOW PASS FILTER C F S 1 SOLENOID OUTPUT S 2 ENABLE

17 HYDRAFORCE 0 10 VDC Input DIMENSIONS INCH MILLIMETRE Setscrew Adjustments Span I-Max. Zero I-Min. Dither Frequency TP9 R50 R32 TP1 TP8 TP7 Input Level LED Brightness increases as input signal increases. TP10 L3 R46 TP6 Ramp Up (Rising Edge) R49 R48 Ramp Down (Falling Edge) Dither Level (Amplitude) R31 TP5 L2 L1 Power Okay LED TP3 TP2 POW+ POW TP4 +5V REF V IN AGND I IN ENABLE FGND SOL SOL+ Output Level LED Brightness increases as output amperage increases. Screw Terminal Connections for AWG wire (+) Power ( ) Power Not Used Voltage In Analog Ground Not Used Enable Frame Ground ( ) Solenoid (+) Solenoid Mounting Holes (4) (3.90) Dia. for #6 size screws (not supplied) Note: When Enable is connected to (+) Power or left open, the unit is enabled. When Enable is connected to ( ) Power, the unit will be disabled. CONNECTIONS Basic Setup: Controller is shipped with ramp trim pots fully counterclockwise to eliminate ramping. Use I-Min. screw to set minimum speed with minimum control input. Use I-Max. screw to set maximum speed with 100% of control input. 0 to 10 VDC Control Supplied by User (+) Power ( ) Power Not Used (+) 0 10V ( ) 0 10V Not Used Enable Frame Gnd. ( ) Coil (+) Coil For Complete Set-Up Instructions, see page Screw Terminal (+) Power ( ) Power (+) 5V Reference Voltage In Analog Gnd. Current In Enable Frame Gnd. ( ) Solenoid (+) Solenoid TO ORDER Part Number Output I-Min. Setting I-Max. Setting ma Max. 0 to 500 ma 600 to 2000 ma

18 Proportional Valve Controller Metal Housing DESCRIPTION 0 10 VDC Input A metal box-style control amplifi er for controlling HydraForce proportional valves. The metal housing is IP67 rated. Remote mounting is required. OPERATION This control module uses closed-loop current control with superimposed dither to supply a proportional valve solenoid with a proportional control signal. The input signal to this controller can be from a 0 10 VDC source. FEATURES Adjustments accessible under removable cover. LED indication of output power level, input level and power on/off. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. Can be disconnected from coil when powered. Maximum current adjustment does not affect minimum current setting. Filter eliminates electrical noise. Independent ramp adjustments. Dither frequency and amplitude are adjustable for maximum valve performance. GENERAL SPECIFICATIONS Metal Housing: Conformal coated; IP67 rated Weight: Metal Box without cable: 400 g (14.1 oz.) Connections: Mounted cable with unterminated wires provided; Length: Approx. 1.5 meters (59") CSA and CE Listings: CSA C22.2 No. 14-M91 CE: EN , EN RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal: 0 10 VDC Input Resistance: 250K Ohms Output Current: up to 1200 ma Minimum Current Range: ma, adjustable Maximum Current Range: ma, adjustable Ramp Up and/or Down: seconds, independently adjustable Dither Frequency: Hz, adjustable Dither Amplitude: 0 10% of maximum current, adjustable Operating Conditions: 40 to 85 C; 0 to 85% relative humidity SCHEMATIC V PS + (9-32 VDC) NOT USED POWER GND ACTIVE REVERSE POLARITY PROTECTION STEP-DOWN CONVERTER V PS TO 5.5 V +5 V STEP-UP DC/DC CONVERTER +12 V 12 V INPUT, OUTPUT AND POWER SUPPLY INDICATORS RAMP UP RAMP DOWN +5 V VOLTAGE IN (0-10 VDC) NOT USED ANALOG GND INDEPENDENT RAMP CONTROL FUNCTION DITHER FREQUENCY R D R DITHER DITHER GENERATOR I-MAX. R MAX. DITHER AMPLITUDE I-MIN. R M R MIN. R DA ERROR AMPLIFIER + VOLTAGE TO HIGH FREQUENCY PWM CONVERTER CURRENT SENSING AND SHORT CIRCUIT PROTECTION LOW PASS FILTER C F S 1 SOLENOID OUTPUT S 2 ENABLE

19 HYDRAFORCE 0 10 VDC Input DIMENSIONS For PCB (circuit board) only, refer to page (+) Power Supply Red ( ) Power Supply Not Used (+) 0 10V ( ) 0 10V Not Used Black Yellow/Red Stripe Yellow Yellow/Black Stripe Yellow/Blue Stripe Mounting Holes (4) (6.35) Dia Enable Frame Ground ( ) Coil (+) Coil Purple Shield Orange/Black Stripe Orange/Red Stripe Note: When Enable is connected to (+) Power or left open, the unit is enabled. When Enable is connected to ( ) Power, the unit will be disabled. Approx M INCH MILLIMETRE CONNECTIONS For Complete Set-Up Instructions, see page Basic Setup: Controller is shipped with ramp trim pots fully counterclockwise to eliminate ramping. Use I-Min. screw to set minimum speed with minimum control input. Use I-Max. screw to set maximum speed with 100% of control input. 0 to 10 VDC Control Supplied by User (+) Power ( ) Power Not Used (+) 0 10V ( ) 0 10V Not Used Enable Frame Gnd. ( ) Coil (+) Coil Wire Color Red Black Yellow/Red Stripe Yellow Yellow/Black Stripe Yellow/Blue Stripe Purple Shield Orange/Black Stripe Orange/Red Stripe TO ORDER Part Number Output I-Min. Setting I-Max. Setting ma Max. 0 to 150 ma 400 to 1200 ma

20 Proportional Valve Controller Metal Housing GENERAL SPECIFICATIONS Metal Housing: Conformal coated; IP67 rated Weight: Metal Box without cable: 400 g (14.1 oz.) Connections: Mounted cable with unterminated wires provided; Length: Approx. 1.5 meters (59") CSA and CE Listings: CSA C22.2 No. 14-M91 CE: EN , EN DESCRIPTION 4 20 ma Input A metal box-style control amplifier for controlling HydraForce proportional valves. The metal housing is IP67 rated. Remote mounting is required. This model is designed for circuits with long wire runs or where electrical interference is a problem. OPERATION This control module uses closed-loop current control with superimposed dither to supply a proportional valve solenoid with a proportional control signal. The input signal to this controller can be from a 4 20 ma source. FEATURES Adjustments accessible under removable cover. LED indication of output power level, input level and power on/off. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. Can be disconnected from coil when powered. Maximum current adjustment does not affect minimum current setting. Current sensing circuit maintains output current regardless of changes in output voltage or coil resistance. Filter eliminates electrical noise; Independent ramp adjustments. Dither frequency and amplitude are adjustable for maximum valve performance. RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal Options: 4 20 ma current signal (see connection diagram) Input Resistance: 33K Ohms Output Current: up to 2000 ma (see ordering info.) Minimum Current Range: ma (adjustable; see ordering info.) Maximum Current Range: ma (adjustable; see ordering info.) Ramp Up and/or Down: seconds (independently adjustable) Dither Frequency: Hz (adjustable) Dither Amplitude: 0 10% of maximum current (adjustable) Operating Conditions: 40 to 85 C; 0 to 85% relative humidity SCHEMATIC V PS + (9-32 VDC) NOT USED POWER GND ACTIVE REVERSE POLARITY PROTECTION STEP-DOWN CONVERTER V PS TO 5.5 V +5 V STEP-UP DC/DC CONVERTER +12 V 12 V INPUT, OUTPUT AND POWER SUPPLY INDICATORS RAMP UP RAMP DOWN +5 V CURRENT LOOP TRANSMITTER NOT USED CURRENT IN (4-20 ma) ANALOG GND INDEPENDENT RAMP CONTROL FUNCTION DITHER FREQUENCY R D R DITHER DITHER GENERATOR I-MAX. R MAX. DITHER AMPLITUDE I-MIN. R M R MIN. R DA ERROR AMPLIFIER + VOLTAGE TO HIGH FREQUENCY PWM CONVERTER CURRENT SENSING AND SHORT CIRCUIT PROTECTION LOW PASS FILTER C F S 1 SOLENOID OUTPUT S 2 ENABLE

21 HYDRAFORCE 4 20 ma Input DIMENSIONS For PCB (circuit board) only, refer to page (+) Power Supply Red ( ) Power Supply Not Used Not Used ( ) 4-20 ma (+) 4 20 ma Black Yellow/Red Stripe Yellow Yellow/Black Stripe Yellow/Blue Stripe Mounting Holes (4) (6.35) Dia Enable Frame Ground ( ) Coil (+) Coil Purple Shield Orange/Black Stripe Orange/Red Stripe Note: When Enable is connected to (+) Power or left open, the unit is enabled. When Enable is connected to ( ) Power, the unit will be disabled. Approx M INCH MILLIMETRE CONNECTIONS For Complete Set-Up Instructions, see page Basic Setup: Turn ramp screws fully counterclockwise to eliminate ramping. Use I-Min. screw to set minimum speed with minimum control input. Use I-Max. screw to set maximum speed with 100% of control input. 4 to 20 ma Control Supplied by User (+) Power ( ) Power Not Used Not Used ( ) 4 20mA (+) 4 20mA Enable Frame Gnd. ( ) Coil (+) Coil Wire Color Red Black Yellow/Red Stripe Yellow Yellow/Black Stripe Yellow/Blue Stripe Purple Shield Orange/Black Stripe Orange/Red Stripe TO ORDER Part Number Output I-Min. Setting I-Max. Setting ma Max. 0 to 500 ma 600 to 2000 ma

22 Proportional Valve Controller Metal Housing GENERAL SPECIFICATIONS Metal Housing: Conformal coated; IP67 rated Weight: Metal Box without cable: 400 g (14.1 oz.) Connections: Mounted cable with unterminated wires provided; Length: Approx. 1.5 meters (59") CE Documented DESCRIPTION PWM (Pulse Train) Input A metal box-style control amplifier for controlling HydraForce proportional valves. The metal housing is IP67 rated. Remote mounting is required. OPERATION This control module uses closed-loop current control with superimposed dither to supply a proportional valve solenoid with a proportional control signal. The input signal to this controller can be from a PWM (pulse train) source. FEATURES Adjustments accessible under removable cover. LED indication of output power level, input level and power on/off. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. Can be disconnected from coil when powered. Maximum current adjustment does not affect minimum current setting. Current sensing circuit maintains output current regardless of changes in input voltage or coil resistance. Independent ramp adjustments. Filter eliminates electrical noise. Dither frequency and amplitude are adjustable for maximum valve performance. RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal: 250 to 5000 Hz PWM (pulse train); 5% to 95% duty cycle; Low < 1.5 volts; High > 3.5 volts; 50 volts maximum Input Resistance: 9.7K Ohms Output Current: up to 2000 ma (see ordering info.) Minimum Current Range: ma (adjustable) Maximum Current Range: ma (adjustable) Ramp Up and/or Down: seconds (independently adjustable) Dither Frequency: Hz (±10%) Dither Amplitude: 0 10% of maximum current (adjustable) Operating Conditions: 40 to 85 C; 0 to 85% relative humidity SCHEMATIC 24 V PS (9-32 VDC) + POWER GND ACTIVE REVERSE POLARITY PROTECTION CONTROL SECTION POWER SUPPLY & REFERENCE +10 V 10 V +5 V REF. DITHER FREQUENCY R 1 R 2 DITHER GENERATOR R8 R9 7.5 V R7 I-MIN. HIGH FREQUENCY PWM OUTPUT STAGE S 1 SOLENOID OUTPUT S AMPS OUT RAMP UP RAMP DOWN R5 ERROR AMPLIFIER + PWM INPUT PWM GND + INPUT SIGNAL NORMALIZATION AND PWM TO VOLTAGE CONVERSION INDEPENDENT RAMP CONTROL FUNCTION I-MAX. R3 R4 R 6 R 10 DITHER LEVEL CURRENT SENSING AND SHORT CIRCUIT PROTECTION ENABLE

23 HYDRAFORCE PWM (Pulse Train) Input DIMENSIONS For PCB (circuit board) only, refer to page (+) Power Supply Red ( ) Power Supply Not Used Not Used PWM Gnd. PWM In Black Yellow/Red Stripe Yellow Yellow/Black Stripe Yellow/Blue Stripe Mounting Holes (4) (6.35) Dia Enable Frame Gnd. ( ) Coil (+) Coil Purple Shield Orange/Black Stripe Orange/Red Stripe Note: When Enable is connected to (+) Power or left open, the unit is enabled. When Enable is connected to ( ) Power, the unit will be disabled. Approx M INCH MILLIMETRE CONNECTIONS For Complete Set-Up Instructions, see page Basic Setup: Turn ramp screws fully counterclockwise to eliminate ramping. Use I-Min. screw to set minimum speed with minimum control input. Use I-Max. screw to set maximum speed with 100% of control input. PWM (Pulse Train) Control Supplied by User (+) Power ( ) Power Not Used Not Used PWM Gnd. PWM In Enable Frame Gnd. ( ) Coil (+) Coil Wire Color Red Black Yellow/Red Stripe Yellow Yellow/Black Stripe Yellow/Blue Stripe Purple Shield Orange/Black Stripe Orange/Red Stripe TO ORDER Part Number Output I-Min. Setting I-Max. Setting ma Max. 0 to 500 ma 600 to 2000 ma

24 Proportional Valve Controller DIN Rail Mount DESCRIPTION 0 5 VDC, 10K Pot or 0 20 ma Input A DIN rail-mount style control amplifier for controlling HydraForce proportional valves. OPERATION This control module uses closed-loop current control with superimposed dither to supply a proportional valve solenoid with a proportional control signal. The input signal to this controller can be from a 10K potentiometer, 0 5 VDC, 0 20 ma, or from other pre-set levels. FEATURES Adjustments and connections clearly labeled. LED indication of output power level, input level and power on/off. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. Can be disconnected from coil when powered. Maximum current adjustment does not affect minimum current setting. Independent ramp adjustments and internal supply for potentiometer. Filter eliminates electrical noise. Dither frequency and amplitude are adjustable for maximum valve performance. GENERAL SPECIFICATIONS Weight: 25 g (0.88 oz.) Connections: Screw terminals for AWG wire CSA Listing: CSA C22.2 No. 14-M91 RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal Options: 10K external potentiometer (accepts 5K to 50K pots), or 0 5 VDC signal, or 0 20 ma current signal (see connection diagrams) Input Resistance: Voltage: 250K Ohms; Current: 33 Ohms Output Current: up to 2000 ma (see ordering info.) Minimum Current Range: ma (adjustable; see ordering info.) Maximum Current Range: ma (adjustable; see ordering info.) Ramp Up and/or Down: seconds (independently adjustable) Dither Frequency: Hz (adjustable) Dither Amplitude: 0 10% of maximum current (adjustable) Operating Conditions: 20 to 85 C; 0 to 85% relative humidity SCHEMATIC POTENTIOMETER INPUT V PS + (9-32 VDC) +5 V REFERENCE VOLTAGE IN (0-5 VDC) CURRENT IN (0-20 ma) SIGNAL GND POWER GND ACTIVE REVERSE POLARITY PROTECTION VOLTAGE REFERENCE GENERATOR RAMP UP DITHER GENERATOR RAMP DOWN INDEPENDENT RAMP CONTROL FUNCTION DITHER FREQUENCY R D R DITHER I-MAX. DITHER AMPLITUDE STEP-DOWN CONVERTER V PS TO 5.5 V R MAX. I-MIN. +5 V +5 V R M R MIN. R DA STEP-UP DC/DC CONVERTER ERROR AMPLIFIER V 12 V VOLTAGE TO HIGH FREQUENCY PWM CONVERTER CURRENT SENSING AND SHORT CIRCUIT PROTECTION INPUT, OUTPUT AND POWER SUPPLY INDICATORS LOW PASS FILTER C F S 1 SOLENOID OUTPUT S 2 ENABLE

25 HYDRAFORCE 0 5 VDC, 10K Pot or 0 20 ma Input DIMENSIONS Ramp Up (Rising Edge) Ramp Down (Falling Edge) Dither Frequency Amplitude (Dither Level) I-Min., Zero I-Max., Span Screw Terminal Connections for AWG wire (+) Solenoid ( ) Solenoid (+) Power ( ) Power Analog Ground Voltage In Current In Not Used Enable +5V Reference INCH MILLIMETRE Note: When Enable is connected to (+) Power or left open, the unit is enabled. When Enable is connected to ( ) Power, the unit will be disabled. CONNECTIONS For Complete Set-Up Instructions, see page For Either 0 20 ma or 0 5 VDC Control: Turn ramp screws fully counterclockwise to eliminate ramping. Use I-Min. screw to set minimum speed with minimum control input. Use I-Max. screw to set maximum speed with 100% of control input. 10K Potentiometer (Pot.) Control Supplied by User Screw Terminal (+) Coil (+) Solenoid ( ) Coil ( ) Solenoid (+) Power (+) Power ( ) Power ( ) Power ( ) Pot. Analog Gnd. 10K Pot. Voltage In Not Used Current In Not Used Enable Enable (+) Pot +5V Ref. 0 to 20 ma Control Supplied by User Screw Terminal 0 to 5 VDC Control Supplied by User (+) Coil (+) Solenoid (+) Coil ( ) Coil ( ) Solenoid ( ) Coil (+) Power (+) Power (+) Power ( ) Power ( ) Power ( ) Power ( ) 0 20mA Analog Gnd. ( ) 0 5V Not Used Voltage In (+) 0 5V (+) 0 20mA Current In Not Used Not Used Enable Enable Enable Not Used +5V Ref. Not Used Screw Terminal (+) Solenoid ( ) Solenoid (+) Power ( ) Power Analog Gnd. Voltage In Current In Not Used Enable +5V Ref. TO ORDER Part Number Output I-Min. Setting I-Max. Setting ma Max. 0 to 500 ma 600 to 2000 ma

26 Proportional Valve Controller DIN Rail Mount DESCRIPTION 0 10 VDC Input A DIN rail-mount style control amplifier for controlling HydraForce proportional valves. Remote mounting in a protected enclosure is required. OPERATION This control module uses closed-loop current control with superimposed dither to supply a proportional valve solenoid with a proportional control signal. The input signal to this controller can be from a 0 10 VDC source. FEATURES Adjustments and connections clearly labeled. LED indication of output power level, input level and power on/off. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. Can be disconnected from coil when powered. Maximum current adjustment does not affect minimum current setting. Independent ramp adjustments. Filter eliminates electrical noise. Dither frequency and amplitude are adjustable for maximum valve performance. GENERAL SPECIFICATIONS Weight: 25 g (0.88 oz.) Connections: Screw terminals for AWG wire CSA Listing: CSA C22.2 No. 14-M91 RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal: 0 10 VDC Input Resistance: 250K Ohms Output Current: up to 2000 ma (see ordering info.) Minimum Current Range: ma (adjustable) Maximum Current Range: ma (adjustable) Ramp Up and/or Down: seconds (independently adjustable) Dither Frequency: Hz (±10%) Dither Amplitude: 0 10% of maximum current (adjustable) Operating Conditions: 20 to 85 C; 0 to 85% relative humidity SCHEMATIC V PS + (9-32 VDC) NOT USED POWER GND ACTIVE REVERSE POLARITY PROTECTION STEP-DOWN CONVERTER V PS TO 5.5 V +5 V STEP-UP DC/DC CONVERTER +12 V 12 V INPUT, OUTPUT AND POWER SUPPLY INDICATORS RAMP UP RAMP DOWN +5 V VOLTAGE IN (0-10 VDC) NOT USED ANALOG GND INDEPENDENT RAMP CONTROL FUNCTION DITHER FREQUENCY R D R DITHER DITHER GENERATOR I-MAX. R MAX. DITHER AMPLITUDE I-MIN. R M R MIN. R DA ERROR AMPLIFIER + VOLTAGE TO HIGH FREQUENCY PWM CONVERTER CURRENT SENSING AND SHORT CIRCUIT PROTECTION LOW PASS FILTER C F S 1 SOLENOID OUTPUT S 2 ENABLE

27 HYDRAFORCE 0 10 VDC Input DIMENSIONS Ramp Up (Rising Edge) Ramp Down (Falling Edge) Dither Frequency Amplitude (Dither Level) I-Min., Zero I-Max., Span Screw Terminal Connections for AWG wire (+) Solenoid ( ) Solenoid (+) Power ( ) Power Analog Ground Voltage In Not Used Not Used Enable Not Used INCH MILLIMETRE Note: When Enable is connected to (+) Power or left open, the unit is enabled. When Enable is connected to ( ) Power, the unit will be disabled. CONNECTIONS For Complete Set-Up Instructions, see page Basic Setup: Controller is shipped with ramp trim pots fully counterclockwise to eliminate ramping. Use I-Min. screw to set minimum speed with minimum control input. Use I-Max. screw to set maximum speed with 100% of control input. 0 to 10 VDC Control Supplied by User (+) Coil ( ) Coil (+) Power ( ) Power ( ) 0 10V (+) 0 10V Not Used Enable Not Used Screw Terminal (+) Solenoid ( ) Solenoid (+) Power ( ) Power Analog Gnd. Voltage In Current In Not Used Enable +5V Ref. TO ORDER Part Number Output I-Min. Setting I-Max. Setting ma Max. 0 to 500 ma 600 to 2000 ma

28 Proportional Valve Controller DIN Rail Mount GENERAL SPECIFICATIONS Weight: 25 g (0.88 oz.) Connections: Screw terminals for AWG wire CSA Listing: CSA C22.2 No. 14-M91 DESCRIPTION 4 20 ma Input A DIN rail-mount style control amplifier for HydraForce proportional valves. Remote mounting in a protected enclosure is required. This model is designed for circuits with long wire runs or where electrical interference is a problem. OPERATION This control module uses closed-loop current control with superimposed dither to supply a proportional valve solenoid with a proportional control signal. The input signal to this controller can be from a 4 20 ma source. FEATURES Adjustments and connections clearly labeled. LED indication of output power level, input level and power on/off. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. Can be disconnected from coil when powered. Maximum current adjustment does not affect minimum current setting. Current sensing circuit maintains output current regardless of changes in input voltage or coil resistance. Filter eliminates electrical noise; Independent ramp adjustments. Dither frequency and amplitude are adjustable for maximum valve performance. RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal: 4 20 ma current signal (see connection diagram) Input Resistance: 50 Ohms Output Current: up to 2000 ma (see ordering info.) Minimum Current Range: ma (adjustable) Maximum Current Range: ma (adjustable) Ramp Up and/or Down: seconds (independently adjustable) Dither Frequency: Hz (±10%) Dither Amplitude: 0 10% of maximum current (adjustable) Operating Conditions: 20 to 85 C; 0 to 85% relative humidity SCHEMATIC V PS + (9-32 VDC) NOT USED POWER GND ACTIVE REVERSE POLARITY PROTECTION STEP-DOWN CONVERTER V PS TO 5.5 V +5 V STEP-UP DC/DC CONVERTER +12 V 12 V INPUT, OUTPUT AND POWER SUPPLY INDICATORS RAMP UP RAMP DOWN +5 V CURRENT LOOP TRANSMITTER NOT USED CURRENT IN (4-20 ma) ANALOG GND INDEPENDENT RAMP CONTROL FUNCTION DITHER FREQUENCY R D R DITHER DITHER GENERATOR I-MAX. R MAX. DITHER AMPLITUDE I-MIN. R M R MIN. R DA ERROR AMPLIFIER + VOLTAGE TO HIGH FREQUENCY PWM CONVERTER CURRENT SENSING AND SHORT CIRCUIT PROTECTION LOW PASS FILTER C F S 1 SOLENOID OUTPUT S 2 ENABLE

29 HYDRAFORCE 4 20 ma Input DIMENSIONS Ramp Up (Rising Edge) Ramp Down (Falling Edge) Dither Frequency Amplitude (Dither Level) I-Min., Zero I-Max., Span Screw Terminal Connections for AWG wire (+) Solenoid ( ) Solenoid (+) Power ( ) Power Analog Ground Not Used Current In Not Used Enable Not Used INCH MILLIMETRE Note: When Enable is connected to (+) Power or left open, the unit is enabled. When Enable is connected to ( ) Power, the unit will be disabled. CONNECTIONS For Complete Set-Up Instructions, see page Basic Setup: Turn ramp screws fully counterclockwise to eliminate ramping. Use I-Min. screw to set minimum speed with minimum control input. Use I-Max. screw to set maximum speed with 100% of control input. 4 to 20 ma Control Supplied by User (+) Coil ( ) Coil (+) Power ( ) Power ( ) 4 20mA Not Used (+) 4 20mA Enable Not Used Screw Terminal (+) Solenoid ( ) Solenoid (+) Power ( ) Power Analog Gnd. Voltage In Current In Not Used Enable +5V Ref. TO ORDER Part Number Output I-Min. Setting I-Max. Setting ma Max. 0 to 500 ma 600 to 2000 ma

30 Proportional Valve Controller DIN Rail Mount GENERAL SPECIFICATIONS Weight: 25 g (0.88 oz.) Connections: Screw terminals for AWG wire DESCRIPTION PWM (Pulse Train) Input A DIN rail-mount style control amplifi er for controlling HydraForce proportional valves. Remote mounting in a protected enclosure is required. OPERATION This control module uses closed-loop current control with superimposed dither to supply a proportional valve solenoid with a proportional control signal. The input signal to this controller can be from a PWM (pulse train) source. FEATURES Adjustments and connections clearly labeled. LED indication of output power level, input level and power on/off. One unit covers supply voltages from 9 to 32 VDC. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. Can be disconnected from coil when powered. Maximum current adjustment does not affect minimum current setting. Current sensing circuit maintains output current regardless of changes in input voltage or coil resistance. Independent ramp adjustments. Filter eliminates electrical noise. Dither frequency and amplitude are adjustable for maximum valve performance. RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal: 250 to 5000 Hz PWM (pulse train); 5% to 95% duty cycle; Low < 1.5 volts; High > 3.5 volts; 50 volts maximum Input Resistance: 9.7K Ohms Output Current: up to 2000 ma (see ordering info.) Minimum Current Range: ma (adjustable) Maximum Current Range: ma (adjustable) Ramp Up and/or Down: seconds (independently adjustable) Dither Frequency: Hz (±10%) Dither Amplitude: 0 10% of maximum current (adjustable) Operating Conditions: 20 to 85 C; 0 to 85% relative humidity SCHEMATIC 24 V PS (9-32 VDC) + POWER GND ACTIVE REVERSE POLARITY PROTECTION CONTROL SECTION POWER SUPPLY & REFERENCE +10 V 10 V +5 V REF. DITHER FREQUENCY R 1 R 2 DITHER GENERATOR R8 R9 7.5 V R7 I-MIN. HIGH FREQUENCY PWM OUTPUT STAGE S 1 SOLENOID OUTPUT S AMPS OUT RAMP UP RAMP DOWN R5 ERROR AMPLIFIER + PWM INPUT PWM GND + INPUT SIGNAL NORMALIZATION AND PWM TO VOLTAGE CONVERSION INDEPENDENT RAMP CONTROL FUNCTION I-MAX. R3 R4 R 6 R 10 DITHER LEVEL CURRENT SENSING AND SHORT CIRCUIT PROTECTION ENABLE

31 HYDRAFORCE PWM (Pulse Train) Input DIMENSIONS Screw Terminal Connections for AWG wire PWM In Dither Freq. Dither Level I-Min. 5% I-Max. 95% Falling Ramp Rising Ramp Not Used 3. PWM Ground 4. (+) Power 5. Not Used 6. ( ) Power 7. Enable 8. Not Used 9. Enable Ground 10. (+) Solenoid 11. Not Used INCH MILLIMETRE Note: When Enable is left open, the unit is enabled. When Enable is connected to Enable Ground, the unit will be disabled. 12. ( ) Solenoid CONNECTIONS For Complete Set-Up Instructions, see page Basic Setup: Turn ramp screws fully counterclockwise to eliminate ramping. Use I-Min. screw to set minimum speed with minimum control input. Use I-Max. screw to set maximum speed with 100% of control input. PWM (Pulse Train) Control Supplied by User PWM Input Ground (+) Power ( ) Power Enable Ground (+) Coil ( ) Coil Screw Terminal PWM In Not Used PWM Ground (+) Power Not Used ( ) Power Enable Not Used Enable Ground (+) Solenoid Not Used ( ) Solenoid TO ORDER Part Number Output I-Min. Setting I-Max. Setting ma Max. 0 to 500 ma 600 to 2000 ma

32 Proportional Valve Controller Metal Housing GENERAL SPECIFICATIONS Metal Housing: Conformal coated Exterior; Potted Interior; IP65 rated Weight: 0.58 kg (1.28 lbs.) Connections: Flat, tab-style (22); mates with 0.25 inch female tab connector: Keystone part no. 4470; also accepts AWG wire. Model with screw terminals available. DESCRIPTION Dual Solenoid Multifunction Valve Driver A metal box-style control amplifier for controlling HydraForce proportional valves. The metal housing is potted and is IP65 rated. Remote mounting is required. This controller has seven outputs that provide accurate control of hydraulic proportional and directional valves for a variety of hydraulic functions. OPERATION This controller will accept inputs from a joystick potentiometer with or without center tap, from a standard potentiometer, or from commonly available control signals such as 0 5 VDC, ±5 VDC, 0 10 VDC, ±10 VDC, 0 20 ma, and ±20 ma. It is designed for circuits using dual solenoid proportional four-way valves, single solenoid proportional flow and pressure controls, single or dual solenoid on/off valves, or half-speed functions. FEATURES Adjustments easily accessible and clearly labeled. One unit covers supply voltages from 9 to 32 VDC. Current sensing circuit maintains output current regardless of changes in input voltage and coil resistance. High/Low range input provides reduced output for training or operation of equipment in tight spaces. No internal fuses; circuit limits current electronically. Short circuit proof and reverse polarity protected. User selectable Deadband Jump. Adjustable Min. and Max. current. Pump Enable output active only when joystick is active. Asymmetrical or symmetrical ramps user selectable using Dip Switch 2 Center Null feature accommodates joystick or potentiometer centering errors. RATINGS Supply Voltage: 9 32 VDC Coil rating must be matched with supply voltage: RCOIL (VSUPPLY 1.5 V) / I-Max. Control Input Signal Options: User selectable using Dip Switch 1: Voltage Inputs: 0 5 VDC (2.5 VDC=0); 0 10 VDC (5 VDC=0); ±5 VDC (0 VDC=0); ±10 VDC (0 VDC=0) Current Inputs: 0 20 ma (10 ma=0); ±20 ma (0 ma=0) Joystick Potentiometer Input: 10K potentiometer recommended; 5K to 50K pots can be used; The potentiometer connection provides a 5.0 VDC bias voltage as well as a 2.5 VDC center tap driving voltage. A remote joystick potentiometer with or without center tap can be used. Low Range Input (I-Max/2): Full speed unconnected; 50% speed activated by applying 9 32 VDC through an external switch. Input Resistance: Current Mode: 250 Ohms Voltage Mode: 0 5 VDC, 1.38M Ohms ±5 VDC, 750K Ohms 0 10 VDC, 750 K Ohms ±10 VDC, 1.75M Ohms Output Current: up to 2000 ma (see ordering info.) Minimum Current Range: ma (adjustable) Maximum Current Range: ma (adjustable) Ramp Up and/or Down: seconds (independently adjustable using Dip Switch 2) Dither Frequency: Hz (adjustable) Dither Amplitude: 0 10% of maximum current (adjustable) Operating Conditions: 40 to 85 C; 0 to 85% relative humidity

33 HYDRAFORCE Dual Solenoid Multifunction Valve Driver SCHEMATIC V PS + (9-32 VDC) REFERENCE +2.5 V +5 V +10 V VOLTAGE OR CURRENT IN (not used) DISABLE POWER GND SIGNAL GND ACTIVE REVERSE POLARITY PROTECTION PROTECTED REFERENCE VOLTAGE GENERATOR PROTECTED INPUT RANGE SELECTION A UP DITHER LEVEL DITHER FREQUENCY A DOWN B B UP DOWN SYMMETRICAL OR NON-SYMMETRICAL RAMP GENERATOR DITHER GENERATOR +5 V STEP-DOWN CONVERTER V PS TO 5.5 V Ap Ap Bp Bp I-MIN I-MAX I-MIN I-MAX SIGNAL PROCESSING DEADBAND AND CHANNEL SEPARATION STEP-UP DC/DC CONVERTER ERROR AMPLIFIER V 12 V VOLTAGE TO HIGH FREQUENCY PWM CONVERTER CURRENT SENSING AND SHORT CIRCUIT PROTECTION SHORT CIRCUIT PROTECTED DIGITAL OUTPUTS LOW PASS FILTER C F + Ad + Bd + ABd + Cd Bp Ap SOLENOID A SOLENOID B PROPORTIONAL OUTPUTS I-MAX/2 I-MAX/2 (LOW RANGE INPUT) DIMENSIONS Standard Model with Spade Connectors - Part No Model with Screw Terminals Part No SW1 SETTINGS SW2 SETTINGS SW1 SETTINGS SW2 SETTINGS POWER V + GND 5 SELECTS I or V INPUT SYM RAMPS 1 ON ±10V SOL A: 1 ON 2 OFF 2 ON ±5V or ±20mA SOL B: 3 ON 4 OFF NON-SYM RAMPS 3 ON 0 10V SOL A: 1 OFF 2 ON 4 ON 0 5V or 0 20mA SOL B: 3 OFF 4 ON 5 ON=I OFF=V JOYSTICK DEADBAND 5 ON=NO DEADBAND 5 OFF=DEADBAND DUAL SOLENOID DRIVER P/N: 40XXXXX SAH SAL SBH POWER V + GND 5 SELECTS I or V INPUT SYM RAMPS 1 ON ±10V SOL A: 1 ON 2 OFF 2 ON ±5V or ±20mA SOL B: 3 ON 4 OFF NON-SYM RAMPS 3 ON 0 10V SOL A: 1 OFF 2 ON 4 ON 0 5V or 0 20mA SOL B: 3 OFF 4 ON 5 ON=I OFF=V JOYSTICK DEADBAND 5 ON=NO DEADBAND 5 OFF=DEADBAND DUAL SOLENOID DRIVER P/N: 40XXXXX SAH SAL SBH SBL SBL DITHER DITHER LEVEL FREQUENCY SGND IN DISABLE I-MIN-A I-MAX-A I-MIN-B I-MAX-B I-MAX/2 A-UP A-DOWN B-UP B-DOWN PROPORTIONAL OUTPUT Ad+ Ad Bd+ Bd DITHER DITHER LEVEL FREQUENCY SGND IN DISABLE I-MIN-A I-MAX-A I-MIN-B I-MAX-B I-MAX/2 A-UP A-DOWN B-UP B-DOWN PROPORTIONAL OUTPUT Ad+ Ad Bd+ Bd SGND ABd+ SGND ABd+ +10V REF ABd +10V REF ABd +2.5V REF Cd+ +2.5V REF Cd+ +5V REF ON INPUT OFF ON ON SWITCH 1 SWITCH 2 ON OFF Cd DIGITAL OUTPUT INCH MILLIMETRE +5V REF ON INPUT OFF ON ON SWITCH 1 SWITCH 2 ON OFF Cd DIGITAL OUTPUT Mounting Holes (4) 0.25 (6.35) Dia All Dimensions for Reference Only

34 Proportional Valve Controller Metal Housing CONNECTIONS/ADJUSTMENTS Dual Solenoid Multifunction Valve Driver Dither Adjustments CW to Increase DITHER LEVEL 0 10% of rated I-Max. DITHER FREQUENCY Hz Power Input VDC Ground Control Inputs + GND POWER V SW1 SETTINGS SW2 SETTINGS 5 SELECTS I or V INPUT SYM RAMPS 1 ON ±10V SOL A: 1 ON 2 OFF 2 ON ±5V or ±20mA SOL B: 3 ON 4 OFF NON-SYM RAMPS 3 ON 0 10V SOL A: 1 OFF 2 ON 4 ON 0 5V or 0 20mA SOL B: 3 OFF 4 ON 5 ON=I OFF=V JOYSTICK DEADBAND 5 ON=NO DEADBAND 5 OFF=DEADBAND DITHER LEVEL DITHER FREQUENCY DUAL SOLENOID DRIVER P/N: 40XXXXX SAH SAL SBH SBL PROPORTIONAL OUTPUT Proportional Outputs Solenoid Ap (High) Solenoid Ap (Low) Solenoid Bp (High) Solenoid Bp (Low) Digital Outputs Signal In SGND IN Ad+ Ad Ad+ Ad (not used) Disable I-Max/2 Signal +10V Ref. +2.5V Ref. DISABLE I-MIN-A I-MAX-A I-MIN-B I-MAX-B I-MAX/2 SGND +10V REF +2.5V REF A-UP A-DOWN B-UP B-DOWN Bd+ Bd ABd+ ABd Cd+ Bd+ Bd ABd+ Pump Enable ABd Pump Enable Cd+ Latching +5V Ref. INPUT +5V REF ON OFF ON ON ON OFF DIGITAL OUTPUT Cd Cd Latching SWITCH 1 SWITCH 2 INPUT SELECTION OPTIONS Current=ON Voltage=OFF 0 5VDC or 0 20mA 0 10VDC ±5VDC or ±0 20mA ±10VDC Settings shown are for 0 10VDC input ON OFF ON ON SWITCH 1 SWITCH 2 SOLENOID 'A' RAMPS Symmetrical: 1=ON, 2=OFF Non-Symmetrical: 1=OFF, 2=ON SOLENOID 'B' RAMPS Symmetrical: 3=ON, 4=OFF Non-Symmetrical: 3=OFF, 4=ON JOYSTICK DEADBAND No Joystick Deadband: 5=ON Joystick Deadband: 5=OFF ON OFF NOTE: Do not change switch positions while unit is powered. Settings shown are for Symmetrical Up and Down Ramps for Solenoids 'A' and 'B'. Electronic Deadband is selected for Joystick Input or Control Signal. Proportional Adjustments amps CW to Increase I-MIN-A I-MAX-A I-MIN-B I-MAX-B Ramp Time Adjustments 0.01 to 5 seconds CW to Increase A-UP A-DOWN B-UP B-DOWN

35 HYDRAFORCE Dual Solenoid Multifunction Valve Driver APPLICATION INTERFACE INFORMATION Input Specifications: For proper operation, match the power supply voltage with the rating of the coil. Operating this driver with a supply voltage lower than the coil s rated voltage may result in reduced maximum current output. Output Specifications: All outputs are capable of operating a 2 amp solenoid or relay. Each output can withstand an indefinite short cicuit to power or ground. Each output is protected from over voltage with a recirculating diode. For proper operation of this driver, the solenoid coils should have no polarity or protection diodes. The maximum current output of this driver should not exceed the current rating of the coil. Joystick Deadband: Deadband is the zone of the joystick or threshold of the control signal where no action is generated by movement of the joystick or application of the control signal. Deadband Jump will be provided by safety microswitches if they are installed on the joystick. This feature can be enabled or disabled using Dip Switch 2. Joystick Center Null: If the joystick does not have safety microswitches installed, this effect can be achieved by external connections to the input side of this driver. Connect the joystick potentiometer to the +5V Reference and connect the midpoint terminal to the +2.5V Reference. This ensures that the mechanical and electrical centers of the joystick are consistent with each other. CONTROL SIGNAL INTERFACE POTENTIOMETER INTERFACE POWER V POWER V VEHICLE POWER SUPPLY Safety Enable Supplied by Customer + GND VEHICLE POWER SUPPLY Safety Enable Supplied by Customer + GND SGND SGND CONTROL SIGNAL External Switch Supplied by Customer IN DISABLE (not used) I-MAX/2 External Switch Supplied by Customer IN DISABLE (not used) I-MAX/2 SGND SGND Control Signal Input Options: 0 to 5V, 0 to ±5V 0 to 10V, 0 to ±10V 0 to 20mA, 0 to ±20mA Select Current or Voltage Input and Value on Dip Switch 1 INPUT +10V REF +2.5V REF +5V REF 10K to 50K Pot Select Current or Voltage Input and Value on Dip Switch 1 (0 5 VDC example shown) INPUT +10V REF +2.5V REF +5V REF

36 Proportional Valve Controller Metal Housing TYPICAL APPLICATIONS Dual Solenoid Multifunction Valve Driver Application A Application E Directional 2-Position 4-Way Control Valve Dual Solenoid 4-Port Proportional Valve Ap Bp Dual Solenoid Multifunction Valve Driver Ad Dual Solenoid Multifunction Valve Driver ABp Application B Directional 3-Position 4-Way Control Valve Single Solenoid 2-Port Proportional Flow Control Valve Ad Bd Dual Solenoid Multifunction Valve Driver ABp Application C Directional 3-Position 4-Way Control Valve Single Solenoid 2-Port Proportional Valve Application H Directional 2-Position 4-Way Control Valve Ad Bd Dual Solenoid Multifunction Valve Driver ABp Cd Dual Solenoid Multifunction Valve Driver Bypass Proportional Flow Control Valve Application F2 Application F1 Directional 2-Position 2-Way Control Valve Directional 2-Position 2-Way Control Valve Ad Bd Dual Solenoid Multifunction Valve Driver Directional 3-Position 3-Way Control Valve Ad Bd Dual Solenoid Multifunction Valve Driver ABp ABp Single Solenoid 2-Port Proportional Flow Control Valve Single Solenoid 2-Port Proportional Flow Control Valve

37 HYDRAFORCE Dual Solenoid Multifunction Valve Driver TYPICAL APPLICATIONS Application D Directional 3-Position 4-Way Control Valve Application G Directional 2-Position 2-Way Control Valve Ad Bd Dual Solenoid Multifunction Valve Driver ABp ABd Directional 2-Position 2-Way Control Valve Ad Bd Dual Solenoid Multifunction Valve Driver ABp Single Solenoid 2-Port Proportional Flow Control Valve Relief Valve Pump Enable Valve Relief Valve Pump Variable Displacement Pump Single Solenoid 2-Port Proportional Flow Control Valve Application I Application J EHPR Electro-Proportional Reducing/Relieving Valve PExx Proportional Pilot-Operated, 3-Position, 4-Way, Spring-Centered Directional Valve EHPR Electro-Proportional Reducing/Relieving Valve SPxx-47 Direct-Acting, Proportional, 3-Position, 4-Way, Spring-Centered Directional Valve Bp Ap Dual Solenoid Multifunction Valve Driver Relief Valve Ap Bp Dual Solenoid Multifunction Valve Driver Relief Valve

38 Proportional Valve Controller Metal Housing JOYSTICK MOTION Dual Solenoid Multifunction Valve Driver Typical Examples of Analog and Digital Output vs. Various Types of Input Voltage Current 2 Amp 0 Amp 2 Amp 0 Amp 2 Amp 0 Amp 2 Amp 0 Amp 2 Amp 0 Amp 2 Amp 0 Amp Ap Solenoid A Proportional Output Bp Solenoid B Proportional Output ABp (See Note Below) Solenoids A & B Proportional Output Ad Solenoid A Digital Output On/Off Bd Solenoid B Digital Output On/Off ABd (Pump Enable; Ad or Bd ON) Solenoids A & B Digital Output On/Off 2 Amp Cd Latching 0 Amp Digital Output On/Off Note: The ABp signal can be used to drive a single solenoid: Externally short the SAL and SBL terminals, and connect the solenoid to SBL and either SAH or SBH. Typical Joystick Motion Correlated to Output Signal Single Axis with Seven Outputs and ±7.5 Electronic Deadband Illustrated (other values are available)

39 HYDRAFORCE Dual Solenoid Multifunction Valve Driver JOYSTICK MOTION Typical Joystick Outputs: The Dual Solenoid Driver has multiple outputs available to support a variety of hydraulic circuits. The diagram on the previous page shows the outputs of the Driver as they relate to the movement of a remote joystick, with the Deadband function selected (dipswitch setting on Driver). The joystick has its own potentiometer which senses movement and signals the Driver to automatically activate its additional outputs. The potentiometer output will signal the Driver, causing the Ad, Bd and Abd signals to be generated electronically. The Dual Solenoid Driver can be used to replace joystick outputs that might otherwise be generated by microswitches or trigger switches. Problems normally encountered with mechanical switches can be eliminated because the Driver produces its outputs electronically. Some typical mechanical push-button and joystick-actuated microswitches are illustrated below. Signal Gnd. Ad 2.5V Ref. +5V Bd Signal Common Push Button Microswitch Actuated by Joystick Movement Abd Common TO ORDER Dual Solenoid Drivers Part Number Control Input I-Min. Setting I-Max. Setting With Spade Connectors VDC, 10 VDC 0 to 2000 ma 0 to 2000 ma With Screw Terminals VDC, 10 VDC 0 to 2000 ma 0 to 2000 ma

40 Proportional Valve Controllers Set-up Instructions SETUP INSTRUCTIONS Preparation Make sure that the controller/amplifier is connected to an operating proportional valve. For the coil mount version, use a small screwdriver to loosen the mounting screw and remove the transparent cover. Use a jeweler s size screwdriver (slotted 1.5) to make adjustments to the trim pots. For the metal box style, use a screwdriver to remove the metal cover. Use a small screwdriver to make adjustments to the trim pots. Interaction Between Maximum Current (I-Max.) and Minimum Current (I Min.) Adjustments Adjusting the maximum current (I-Max.) does not affect the minimum current (I-Min.) setting. Adjusting the minimum current (I-Min.) will shift the maximum current (I-Max.) setting. Factory Setting: I-Max. = 100%; I-Min. = 0% Adjustment to I-Max. = 50%; I-Min. remains at 0% Solenoid Current (amps) 2 1 Input Voltage/Current Solenoid Current (amps) 100% Input Offset = I-Min Slope = I-Max Voltage/Current Setting the Minimum Current (I Min.) The minimum setting can be used to take into account the mechanical valve deadband and provide desired offsets from zero to allow full control within the functional range of the specific valve. 1. Set the minimum current before setting the maximum current. 2. Apply appropriate minimum input (4mA, 0V or potentiometer, 0V or 0A). 3. The factory setting for the I-Min. trim pot is zero, fully counterclockwise (CCW). 4. If the desired minimum current is greater than zero, adjust the trim pot clockwise (CW) until the desired current is achieved. Setting the Maximum Current (I Max.) 1. Apply appropriate maximum control (20mA, 5V or control pot at maximum, 10V) 2. Factory setting for the I-Max. trim pot is 100% or fully clockwise (CW). 3. Turn the trim pot counterclockwise (CCW) to adjust the current downwards to the desired maximum. The maximum current setting is adjusted to match the customer s working pressure or flow range to the full scale signal input range. This provides maximum control for a specific application. Setting the Ramp Times 1. The factory setting for ramp times is the minimum (0.01 seconds) or fully CCW. 2. If the ramp time settings are not needed, leave the settings at the minimum value. (The Economy version controller has no ramps.) 3. To change the ramp times, adjust the trim pot CW to increase the time. 4. Rising (ramp up) and falling (ramp down) times are independent. Ramp times are application dependent. They limit the rate of change or how fast the operation happens. Note: If the input signal is not applied long enough for the ramp time that has been set, the desired solenoid current will not be reached. Input Signal Solenoid Current On Rise Time Solenoid Current Off Fall Time Setting the Dither Amplitude 1. The factory setting for dither amplitude is 0% (CCW). 2. To adjust dither amplitude, turn the trim pot clockwise until small changes in the input signal register similar changes in current output. 3. Choose the smallest effective dither amplitude. (The Economy version controller has no dither amplitude adjustment.) Dither amplitude is adjustable from 0 to 10% of rated maximum current. Dither amplitude and frequency are dependent on the specific valve. The effects of static friction on the operation of the solenoid are reduced by the application of a small AC current. The hysteresis and repeatability of the valve are improved by this practice. The optimum dither amplitude is attained when small input signal changes register similar changes in current output (pressure or flow through the valve). Setting the Dither Frequency 1. The factory setting for dither frequency is the minimum or 0% (CCW). 2. To adjust dither frequency, turn the trim pot clockwise until the desired frequency is set. 3. For the dither rating of a particular valve, refer to the HydraForce catalog. Start Up Procedures 1. Make sure that all components, such as the cover, compression washer, O-ring and base gasket, are correctly in place (necessary for IP65 protection). 2. Attach the proportional valve amplifier to the load. 3. Switch on the power supply to the controller/amplifier and apply a control signal

41 Proportional Valve Controllers Glossary ELECTRONIC TERMS & DEFINITIONS 1. Ohms Law: Current = Voltage Resistance (I = E R) 2. Current: The flow of electrons in a conductor. It is normally measured in amperes (A) or milli-amperes (ma). Calculations and electrical diagrams sometimes use the abbreviation I to symbolize current. 3. Voltage: The potential for current flow in an electrical circuit. It is measured in volts, and is sometimes abbreviated (V or E). Generally, higher voltage will induce higher current. 4. Resistance: Anything that causes an opposition to the flow of electrical current. It is used to control the amount of voltage and/or amperage in a circuit. Everything in a circuit, including wire, causes some resistance. Resistance is measured in units called Ohms and is sometimes abbreviated R or Ω (Greek letter omega). 5. Hysteresis: The measurement of the difference in output when current in a device is increasing vs. when current is decreasing. It is normally expressed as a percentage of the total change in input. 6. Proportional Controller/Amplifier: A device that converts a low-power input signal into an output signal that is capable of operating the valve. This output signal can be modified to include PWM, ramping, or dither. 7. PWM (Pulse Width Modulation): An efficient technique to control current. A PWM-switched signal pulses on and off to achieve the current flow required. PWM frequency can be low (100 to 400 Hz) or high (over 5000 Hz). High frequency produces a more constant ripple-free amperage output. 8. Ramping: The ability to control the rate of change of the output of an amplifier or controller. 9. Dither (Current Ripple): A rapid, small movement of the valve spool around the desired position. Dither keeps the spool moving to avoid stiction and to help average-out hysteresis. 10. I-Min. and I-Max.: The minimum and maximum control current induced into a proportional valve coil. 11. No Load Power: The power consumed by the amplifier or proportional controller when there is no output to the valve coil. 12. Maximum Control Current: The point where increasing current input no longer results in an increase in valve flow. 13. Threshold Current: The amount of current required to reach the point where increasing current input causes flow from the valve to begin to increase (normally closed valve) or decrease (normally open valve). 14. Compensator: A hydraulic device that maintains a fixed pressure drop across a fixed or variable orifice by restricting or bypassing flow. HYDRAFORCE

42 Electronics in the Mobile Equipment Industries ELECTRONIC CONTROL OF HYDRAULIC SYSTEMS As mobile equipment becomes more technologically sophisticated, the need for electronic control of hydraulic systems is growing. Electronic components have become more reliable and rugged. They can now withstand the harsh environmental conditions required for mobile equipment applications. Sophisticated electronic controllers normally supply only low power control signals. Amplification of the control signal is usually required to actuate solenoid-operated hydraulic valves. Electronic controllers that are designed for hydraulic applications will normally include the required amplification functions. Why Pulse Width Modulation (PWM)? When voltage is applied to a valve coil, the current flowing through it creates a magnetic field which provides the force to shift the valve s spool or poppet. The input voltage divided by the resistance of the coil equals the current draw. This is very straightforward when used with on/off valves, but proportional valves are only useful if the spool position can be precisely controlled by varying the input current. A simple potentiometer can be used to vary the resistance, which then varies the input current. This is an inefficient method of control, and is not practical when high currents are required. Also, when an infinitely variable DC signal is used to operate a proportional valve solenoid, the output transistor of the amplifier functions like a variable resistor. It drops the power supply voltage down to the level required by the solenoid coil at a particular time. The full coil current, which may be several amps, needs to pass through this output transistor. The result is that the transistor builds up heat which requires a large heat sink to dissipate. Pulse Width Modulation (PWM) is a control technique which can overcome the problems described above. With PWM, the output transistor is used as an on/off switch, feeding the solenoid coil with a series of on/off pulses at a constant voltage. The pulses are set at a constant frequency, typically 400 to Hz. The signal level is determined by varying the duration of the on pulses relative to the off pulses. The advantage of this technique is that during the off pulse, the output transistor is not passing any current, and during the on pulse, there is virtually no voltage drop across the transistor and therefore very little heat is created. In practice, there will be a small voltage drop across the transistor during the on pulses, and it takes a finite amount of time to switch on and off, so a small amount of heat is created. However, the amount of heat is much smaller than would be produced by a conventional DC output signal. PWM has become the standard for all valve amplifiers in order to reduce amplifier size and power waste. No modifications are required to the valve solenoid in order to use this technique. PWM is an efficient way to control current to a proportional valve coil. It allows the use of electronics for current regulation, dither, ramping, short circuit protection, and the elimination of deadband. How PWM Works A PWM signal is not constant, it is on for a period of time and off for a period of time (see Fig. 1). Voltage D 1 Hz 50% On 25% On 1 Hz 1 Hz = 1 Cycle per Second Fig. 1 1 Hz 75% On The duty cycle D refers to the on portion of the cycle. The duty cycle can be anywhere from 0 (signal always off) to 1 (signal always on). A 50% D results in a perfect square wave. The PWM signal frequency can be low (100 to 400 Hz) or high (over 5000 Hz). High frequency PWM is more desirable because it produces a more constant ripple-free amperage output. Coil Inductance Inductance is the characteristic of a circuit that opposes the starting, stopping or changing of current flow. Inductance in an electrical system is similar to inertia in a mechanical system. Its effect is to introduce a time lag into the duty cycle wave form. In theory the wave form is perfectly rectangular, rising immediately when current is applied, and falling immediately when current is withdrawn. Because of the effects of inductance, the actual wave form rises and falls more gradually (see Fig. 2). Voltage D 50% Amps 1 Hz Fig. 2 1 Hz = 1 Cycle per Second

43 HYDRAFORCE ELECTRONIC CONTROL OF HYDRAULIC SYSTEMS (cont d) PWM Current Characteristics At 25% signal, D is shorter than the time it takes the current to reach its maximum value (see Fig. 3). This results in reduced current output to the valve coil, and therefore a reduced hydraulic output from the valve. If the PWM frequency is low enough, the current will fall to zero during the off time. This is described as discontinuous current. Voltage Amps D 25% 1 Hz Dither (Current Ripple) Fig. 3 1 Hz = 1 Cycle per Second Stiction and hysteresis can make the behavior of a hydraulic proportional valve seem erratic and unpredictable. Stiction keeps the valve spool from moving when input signal changes are small. When the signal finally becomes large enough to initiate movement, the spool will tend to overshoot the position required for accurate control. Hysteresis is the tendency for the spool shift to be different depending on whether the change is increasing or decreasing, even when the control signal input value is identical. Dither is a rapid, small movement of the spool around the desired position. It is intended to keep the spool moving to avoid stiction and average-out hysteresis. Dither amplitude must be large enough and the frequency slow enough for the spool to respond, and yet small and fast enough to avoid creating a noticeable pulsation in the hydraulic output of the valve. Dither is caused by coil current ripples current variations around the desired control signal value. Due to inertia, the valve spool will follow low frequency ripples better than it will follow high frequency ripples. The amplitude of the ripples determines if, or how far, the spool will move at a given frequency. Low Frequency PWM Low Frequency PWM, typically less than 400 Hz, generates dither (current ripple) as a by-product of the PWM process (see Fig. 4). The PWM frequency is low enough so that the current has time to decay before the next rise begins. The amount of dither (ripple) changes as the average coil current changes. Dither is maximum at 50% D. Dither decreases to zero at 0% and 100% D. This can result in too much dither at some current levels and not enough at others. The dither current amplitude at a given average current is a function of coil inductance and PWM frequency. The inductance of a coil is largely a function of its rated voltage and wattage. A low wattage coil will usually have more inductance thus less by-product dither for a given PWM frequency than a high wattage coil. Different valve designs will have differing responses to the same dither frequency and amplitude. Changing the PWM frequency will allow adjusting the dither, but the amplitude and frequency of the dither cannot be set independently as may be required by various valve designs. High Frequency PWM 200 to 300 Hz Fig. 4 Inherent Ripple When the PWM frequency is high enough, typically above 5000 Hz, the coil current will be constant for all practical purposes (see Fig. 5). No by-product dither will be produced by high frequency PWM. Over 5000 Hz Fig

44 Electronics in the Mobile Equipment Industries ELECTRONIC CONTROL OF HYDRAULIC SYSTEMS (cont d) The advantage of using high frequency PWM is that dither can be generated separately and then superimposed on top of the output current (see Fig. 6). This allows the user to independently control the current level, as well as the dither frequency and amplitude. The dither will therefore be constant for any current level, and its frequency and amplitude can be set by the user to optimize the function of the particular hydraulic valve. Ramps Frequency Hz Superimposed Dither Fig. 6 Amplitude 10% of 2 Amps Max. Ramps are used to slow down the response of the valve driver to a changing command input. This results in a smooth transition when an abrupt change of the command input signal occurs. Ramps have no effect if the input signal change is slower than the ramp setting. Ramps can be fixed or adjustable, symmetrical or independent, and single or dual. Adjustable ramps usually operate in the zero to eight second range and are controlled by a potentiometer. Single-side ramps are usually used in slow-shift controls where only acceleration is a concern. Symmetrical ramps (see Fig. 7) are controlled by a single potentiometer that adjusts the increasing and decreasing ramps identically. + Input Signal 0 Symmetrical Ramps Ramp Time Fig. 7 Ramp Independent ramps (see Fig. 8) have separate potentiometers for the increasing and decreasing sides, allowing acceleration and deceleration to be set independently of one another. + Input Signal 0 Independent Ramps Ramp Time Fig. 8 Dual-coil bi-directional valve drivers offer two independent ramps per coil, for a total of four independently controlled ramps (see Fig. 9). + Input Signal 0 Input Signal Gain or I-Max. Ramp Ramp Time Ramp Ramp Dual Solenoid Driver with Independent Ramps Fig. 9 The gain of an amplifier is the ratio of its large output signal (to the valve) to its small control input signal. Gain = Output Signal Input Signal The gain is usually adjusted by a potentiometer on the amplifier. This adjustment is usually called I-Max. Adjusting the I-Max. adjusts the amplifier gain. This can be used to adjust the maximum output of the amplifier (which controls the valve setting) for full input signal. Enable/Disable Some control/amplifiers incorporate an Enable function. This is a safety feature that requires a specific voltage to be present at the enable connection before the output of the controller will operate. Enable can be used for an emergency stop switch or other safety interlock device. While it is possible to place an emergency stop switch in the power supply, this is not recommended because stored charges in capacitors can maintain the valve signal for a period of time after the switch is opened. Ramp

45 HYDRAFORCE ELECTRONIC CONTROL OF HYDRAULIC SYSTEMS (cont d) Deadband/I-Min. Spool-type proportional valves will normally have a certain amount of spool overlap which produces deadband. For pressure and flow controls this deadband will occur at the start of spool movement. For directional valves the deadband will occur around the center position. Spool overlap reduces leakage in the null position and also provides a greater degree of safety in power failure or emergency stop situations. The effect of spool overlap requires that a certain minimum signal level has to be present at the solenoid coil before any noticeable result occurs in the system. If this characteristic is undesirable, deadband can be eliminated or reduced (for pressure and flow controls) by setting a minimum current (I-Min.) on the controller/amplifier. When I-Min. is adjusted above the zero point, the valve spool will immediately jump to this setting when power is appled, eliminating the deadband. Please note that the I-Min. adjustment will affect the I-Max. setting, so it should always be set first. When controlling directional valves using a multifunction/dual solenoid driver, the deadband elimination function is normally activated using a dip switch. The amount of deadband jump is typically factory-set, and is application-specific. Current Feedback When a current passes through a solenoid coil, heat is generated. This heat increases the resistance of the coil. For example, a coil may have a resistance of seven ohms at 20 C, and a resistance of nine ohms at 100 C. This increased resistance causes a reduction in coil power which results in a lower valve setting. To compensate for temperature induced changes, some controller/amplifiers have a function known as Current Feedback. A current feedback resistor is added to the circuit in series with the solenoid coil. This allows the solenoid current to be proportional to the input signal voltage, and independent of the solenoid resistance. Power supply voltage must be sufficient to overcome the increased resistance

46 Electronic Control Requirements EVDR-Type Controllers are valve drivers that relate a specifi c input to a specifi c output using a mathematically modeled signal. Logic capabilities are limited. The higher-level ECU controllers should be used for logic applications where multiple inputs are used to regulate a common output, or where sensors, displays, or other system components are integrated into the system for control and feedback purposes. CAN-compatible EVDR controllers can communicate with ECU products as sub-system or expansion devices. EVDR1, EFDR1, and ETDR1 Programmable Valve Drivers Software for EVDR1, ETDR1 and EFDR1 is provided on a single CD. The software is downloadable to a PC. The interface between the PC and all ExDR plug-in modules is via a custom RS-232 confi guration cable. The software is graphic display style with point and click menus for programmable functions including input type, ramp rates, i-min, i-max settings, etc. The EFDR1 Fan Drive allows for the programming of dual-ramping and fan-reversal options. The ETDR1 Transmission Controller has customizable clutch fi ll, engagement pressure and inching features. The ExDR1 products are not capable of communicating on a CAN network. To Order ExDR1 for System Programming: Model EVDR1 Dual/Single Valve Driver: Part No Model EFDR1 Fan Control Valve Driver: Part No Model ETDR1 Dual/Single Transmission Control Valve Driver: Part No RS232 Confi guration Cable: Part No ExDR1 Confi guration Software: Part No Mating Connector: Part No (1 req d.) To Order ExDR1 Connectors for System Integration: Mating Connectors: Part No (1 req d.); Part No (1 req d.) EVDR4 Valve Drivers EVDR4 software is very similar to that used for the EVDR1, however the device controls a larger number of input and output selections, and can provide diagnostic capabilities through a machine service harness. The EVDR4 is not capable of communicating on a CAN network. Connection is via a standard RS232 cable. To Order EVDR4 for System Programming: Model EVDR4 Controller: Part No Confi guration Connector Kit: Part No EVDR4 Confi guration Software: Part No To Order EVDR4 Connector Kits for System Integration: J1, DTM06-12A Kit, Grey: Part No J2, DTM06-12B Kit, Black: Part No EVDR4 Configuration Software and Diagnostic Tool (shown above) EVDR5, 6, 7, 9 and 10 Controllers The EVDR5, 6, 7, 9 and 10 (and future CAN-capable products) are programmed using the Electronic Assistant software and communications adapter, both of which are provided together in a single package. The software is text-menu-based PC software that connects to the system using a USB to CAN Converter. After connecting to the CAN network, the program identifi es all EVDR controllers on the CAN Network and allows the programmer to establish operating parameters for the identifi ed controller. The software disc also contains the CAN Assistant Visual Tool which provides real-time J1939 CAN Bus information for troubleshooting, and the CAN Assistant Scope which allows you to view real-time J1939 message data off of the CAN Bus. All CAN output from the controller requires a CAN Bridge connector assembly to communicate on the J1939 network bus. This is a network bridge that connects multiple electronic segments/components allowing the traffi c of digital information across the adjacent electronic components and is required for programming and system integration. To Order EVDR5 10 for System Programming: Models EVDR5 10 Controllers: see controller catalog pages Communication Adapter and Software Kit: Part No EVDR5 Confi guration Cables: Part No EVDR6 Confi guration Cables: Part No EVDR7, 9 & 10 Confi guration Cables: Part No ExDR1 Configuration Software (shown above)

47 HYDRAFORCE Electronic Control Requirements (cont d.) To Order CAN Bridge Components for Configuration and Integration: End Connection Model DT06-3S: Part No (2 req d. per component) Terminating Resistor: Part No (1 req d. per component) T-Splitter: Part No (1 req d. per component) To Order Connector Kits for System Integration: J1, DTM06-12A Kit, Grey: Part No J2, DTM06-12B Kit, Black: Part No EVDR5 10 Electronic Assistant Configuration Software (shown above) ECU MS, MM, and ML Main ECUs The ECU controllers are programmable, multi-function, robust processors that can relate specifi c or multiple inputs to a specifi c output for total machine control. Logic capabilities are available and used to regulate feedback loops and to program input and output relationships between sensors, displays and various system components and output devices. ECU software is used for Machine System and Hydraulic Function Control confi guration. Caterpillar Composer Software is the ECU programming tool sold by HydraForce. The software is copyright protected and regulated through Caterpillar Electronics. It is available in two forms: 1) CAT Composer Software Engineer (Part No ) is the complete software package which includes both program development and diagnostic capabilities. This tool has a software key that is enabled via connection to the internet. The user can check-out the license key from the internet for a period of two weeks to allow for onsite development work. After the fi rst calendar year, the customer pays a yearly maintenance fee to keep the license active. CAT Composer Software Engineer is not compatible with MS Vista operating systems. 2) CAT Composer Service Technician (Part No ) is the diagnostics program which allows limited adjustment of predetermined service parameters, real-time monitoring of service points and the ability to monitor and access the machine s diagnostic log. This is a stand- alone tool and requires a software key that is enabled via connection to the internet. The user can check-out the license key from the internet for a period of two weeks to allow for onsite trouble-shooting. The user simply needs to register the PC serial number with the license server. CAT Composer Service Technician is not compatible with MS Vista operating systems. Composer Software is a function block diagram development tool. Programs are developed in stages, using pick-and-drop Windows-type boxes which can be individually opened into text boxes for detailed specifi cations, logic structures, calculations, etc. First, each component in the system must be specifi ed with its input/output parameters. Second, the links between inputs and outputs are established. Finally the logic structure and mathematical relationships are defi ned within the programming tool. Training is required in order to use the software tool, and personnel selected for training must be experienced in system confi guration and engineering. While the Composer interface operates in a similar fashion to other MS Windows based software, the tool is not suitable for casual users. The training schedule is driven by request. The software is PC-operated and is connected to the system using a communications adapter which communicates through the CAN bus. A compact, lower-function communications adapter is also available for fi eld service and support. As with the EVDR product, all CAN outputs from the controller require a CAN Bridge connector assembly to permit CAN communications on the J1939 Network Bus. To Order Main ECUs for System Programming: ECU Controllers: see controller catalog pages CAT Composer Software Engineer : Part No CAT Composer Service Technician : Part No Programmer Communication Adapter: Part No Service Technician Communication Adapter: Part No Communication Adapter, Female End Connector: Part No To Order CAN Bridge Components for Configuration and Integration: End Connection Model DT06-3S: Part No (2 req d. per component) Terminating Resistor: Part No (1 req d. per component) T-Splitter: Part No (1 req d. per component) CAT Composer Software (shown above)

48 EVDR-TYPE VALVE CONTROLLERS SELECTION GUIDE HYDRAFORCE PLUG-IN STYLE SEPARATE MOUNTING General Purpose Control Transmission Control General Purpose Control Multi-I/O Model EVDR1 Model ETDR1 Model EVDR4 Model EVDR5 Model EVDR6 Model EVDR7 Model EVDR9 Model EVDR10 Model EVDR18 Cat. pg Cat. pg Cat. pg Cat. pg Cat. pg Cat. pg Cat. pg Cat. pg Cat. pg Valve Driver Valve Driver Multi-I/O Multi-I/O Multi-I/O Multi-I/O Multi-Output Multi-Input Slave Multi-Input Slave Stand-Alone Stand-Alone Stand-Alone Stand-Alone Slave Module Module Module Controller Controller and/or Controller and/or Controller and/or Slave Module Slave Module Slave Module Slave Module Power: 8 to 36 VDC Power: 8 to 36 VDC Power: 8 to 36 VDC Power: 8 to 36 VDC Power: 9 to 36 VDC Power: 8 to 60 VDC Power: 8 to 80 VDC Power: 8 to 96 VDC Power: 8 to 32 VDC Communications: Communications: Communications: Communications: Communications: Communications: Communications: Communications: Communications: Proprietary Proprietary RS232 J1939 Confi guration J1939 Confi guration J1939 Confi guration J1939 & RS232 J1939 Confi guration J1939 Confi guration Confi guration Only Confi guration Only Confi guration Only & Networked & Networked & Networked Confi g. & Networked & Networked & Networked Inputs: 1) Analog Inputs: 1) Analog Inputs: 4) Analog Inputs: 4) Analog Inputs: 2) Analog Inputs: 4 Inputs: Inputs: Inputs: 2) Digital 2) Digital 3) Digital CAN Network 10) Analog/Digital 18) Digital Input Types: Input Types: Input Types: Input Types: Input Types: Input Types: Input Types: Input Types: 0 to 5 VDC 0 to 5 VDC 0 to 5 VDC 0 to 5VDC 0 to 5 VDC 0 to 1, 2.5, 5, 0 to 5VDC 8) PWM or Hz/RPM or 0 to 10 VDC or 0 to 10 VDC or 0 to 10 VDC or 0 to 10 VDC 0(4) to 20mA 10 VDC 0(4) to 20mA or 16-bit CTR 0 to 5K ohms 0 to 5K ohms 0(4) to 20mA 0(4) to 20mA PWM or Hz/RPM 0(4) to 20mA PWM or Hz/RPM 10) Digital Hi/Lo 0(4) to 20mA 0(4) to 20mA PWM PWM or 16-bit CTR 30 to 250K ohms or 16-bit CTR PWM PWM or Digital Hi/Lo or Digital Hi/Lo or 16-bit CTR PWM or Hz/RPM or Digital Hi or Digital Hi Outputs: 2) PWM Outputs: 2) PWM Outputs: 1) 5Vref Outputs: 2) 5Vref Outputs: Outputs: Outputs: Outputs: Outputs: 4) PWM 4) PWM 6) Confi gurable, 2) Confi gurable 9) Confi gurable, CAN Network CAN Network 1) On/Off 1) On/Off 6A total 4) 5Vref 6A total Output Types: Output Types: Output Types: Output Types: Output Types: Output Types: Output Types: PWM: 0 to 2A PWM: 0 to 2A 5Vref@50mA 5Vref@50mA PWM@2A 2) PWM@2A On/Off; PWM: 0 to 2A PWM: 0 to 2A On/Off; Pulsed; 4) 5Vref.@100mA Hot Shot@2A On/Off: 5A max. On/Off: 5A max. Timed@5A 2) PWM On/Off@2A Voltage/Amps; Proportional@2A PWM@2A

49 EVDR1 Dual/Single Valve Driver, Plug-In Style DESCRIPTION A convenient, plug-mounted microprocessor-based controller for use on a hydraulic proportional valve coil. The input signal to the controller can be confi gured as voltage, current, resistive, or PWM. OPERATION The EVDR1 can be confi gured for a SINGLE or DUAL OUTPUT control based on a single input signal. A single output would be used to control a single solenoid proportional valve coil for fl ow or pressure control. It could be confi gured to increase or decrease the output current as the input increases. All input and output endpoints and breakpoints can be adjusted via a PC interface and confi guration software. A dual output would be used to control a dual solenoid proportional valve. For a dual control the input would be a joystick that is spring loaded to the center position where both outputs would be OFF. As the joystick is stroked in one direction the corresponding output would increase to adjust the valve and the other output would remain OFF. When the joystick is stroked the opposite direction the other output will respond. Again all input and output endpoints and breakpoints are adjustable and the dual slope will have a center deadband width that is also adjustable. DIAGNOSTIC FEATURES Any input below 9 VDC or above 32 VDC for a duration of 100mS will cause the controller to default to safe mode of "valve off." Any absence of an input signal caused by an open or short will cause the controller to default to safe mode of "valve off." Any no-current (open) output condition or over-current (short) will cause the controller to default to safe mode of "valve off." When a fault is corrected the controller will return to a proper operating mode. RATINGS Operating Temperature: 40 C to +85 C ( 40 C to +185 F) Molded Enclosure Dimensions: 35.1mm(W) x 72.9mm(H) x 42.67mm (D); 1.38 in.(w) x 2.87 in. (H) x 1.68 in. (D) Mating Connectors: Deutsch DT06-6S and DT04-2P Solenoid Connector: Integral HF DR 2-Pin Power Requirements: 9 to 32 VDC Control Inputs: Voltage: 0 to 5 or 0 to 10 VDC Current: 0 to 20 or 4 to 20 ma Resistive: 0 to 5K ohms PWM: 5 to 95% Duty Cycle, Low<1.5V to High>3.5V (50V max.), 100 Hz to 10 KHz min. Control Outputs: 50 to 2000 ma Dither: 50 to 400 Hz; 0 to 50% of I-Max Ramp Time: 0.0 to 10.0 seconds; I-Min to I-Max Sealing: IP67 rated; Materials: Polyester, 15% glass with silicone seals CONFIGURATION EXAMPLE

50 HYDRAFORCE EVDR1 Dual/Single Valve Driver, Plug-In Style CONNECTIONS & WIRING Description Interface I/O Pin Connector Battery Power+ A/0 4 DT04-6P Power Pgnd 5 Voltage Control Voltage in A/1 3 Signal Gnd Agnd 2 Current Control 0 to 20 ma in A/1 3 Signal 4 to 20 ma in A/1 3 Gnd Agnd 2 Resistive Radj in A/1 3 Control Signal Gnd Agnd 2 PWM Control PWM in A/1 3 Signal Gnd Agnd 2 External Sol B+ AO2 6 Solenoid Sol B AO3 1 Integral Sol A+ AO1 1 DT06-2S Solenoid Sol A Pgnd 2 External Connection (not present for single valve controller) Sol B+ Sol B Power Power + Internal Connection Sol A+ Pin 1 Sol A Plug-In Valve Driver Wiring Pin 1 Signal Lo Signal Hi DT06-2S or similar provided by customer DT04-6P Integral Mating DT06-6S DT06-2S Integral Mates to ER/DR Coil DIMENSIONS & MOUNTING INCH MILLIMETRE MOUNTING CONSIDERATIONS When installing the coil on a horizontal plane, the controller should be orientated as closely as possible to verticle alignment with the coil, as shown in Fig 1. When mounted in this position, the controller will withstand the vibration test profile described on HydraForce catalog page (Test No. 4). Avoid mounting the controller on a horizontal axis with the coil, as shown in Fig. 2. UP Typical single-valve inline housing. FIG. 1: CORRECT INSTALLATION FIG. 2: INCORRECT INSTALLATION TO ORDER Dual/Single Valve Driver Model EVDR1 Part No Configuration Cable for ExDR1 Part No Configuration Software for EVDR1 Part No

51 EFDR1 Valve Driver, Fan Control, Plug-In Style DESCRIPTION A convenient, plug-mounted microprocessor-based controller intended for use on a TSxx-21 or TSxx-27 hydraulic proportional valve for fan control applications. The input signal to the controller can be a temperature sensor, PWM, voltage, or current. OPERATION This fan drive controller can be confi gured for a single or dual output control based on a single input signal. A single output would be used to control a single solenoid proportional valve coil for fl ow or pressure control. As the temperature increases the current decreases. All input and output endpoints and breakpoints can be adjusted via a PC interface and confi guration software. There are two modes of automatic operation: On/Off and Proportional. There is also a Reversing feature which allows the operator to blow any debris out of the radiator by reversing the direction of fan rotation. DIAGNOSTIC FEATURES Any input below 9 VDC or above 32 VDC for a duration of 100mS will cause the controller to default to safe mode of "valve off." Any absence of an input signal caused by an open or short will cause the controller to default to safe mode of "valve off max. pressure." Any no-current (open) output condition or over-current (short) will cause the controller to default to safe mode of "valve off max. pressure." When a fault is corrected the controller will return to a proper operating mode. RATINGS Operating Temperature: 40 C to +85 C ( 40 C to +185 F) Molded Enclosure Dimensions: 35.1mm(W) x 72.9mm(H) x 42.67mm (D); 1.38 in.(w) x 2.87 in. (H) x 1.68 in. (D) Mating Connectors: Deutsch DT06-6S and DT04-2P Solenoid Connector: Integral HF DR 2-Pin Power Requirements: 9 to 32 VDC Control Inputs: Voltage: 0 to 5 or 0 to 10 VDC; Current: 4 to 20 ma; Negative or Positive Temperature Coeffi cient (NTC or PTC) sensor; Resistive: 60 to 6500 ohms; PWM: 5 to 95%, 1.5V to 3.5V, 100 Hz to 10 KHz Control Outputs: 50 to 2000 ma Dither: 50 to 400 Hz; 0 to 50% of I-Max Ramp Time: 0.0 to 10.0 seconds; I-Min to I-Max Sealing: IP67 rated DIMENSIONS INCH MILLIMETRE MOUNTING CONSIDERATIONS When installing the coil on a horizontal plane, the controller should be orientated as closely as possible to verticle alignment with the coil, as shown in Fig 1. When mounted in this position, the controller will withstand the vibration test profile described on HydraForce catalog page (Test No. 4). Avoid mounting the controller on a horizontal axis with the coil, as shown in Fig. 2. UP Typical single-valve inline housing. FIG. 1: CORRECT INSTALLATION FIG. 2: INCORRECT INSTALLATION

52 EFDR1 Valve Driver, Fan Control, Plug-In Style CONNECTIONS & WIRING Description Interface I/O Pin Connector Battery Power+ A/0 4 DT04-6P Power Pgnd 5 Control Input Temperature Signal A/1 3 T emperature Return Agnd 2 Solenoid B Reverse Solenoid B+ AO2 6 Solenoid B Pgnd 1 Solenoid A Control Solenoid A+ AO1 1 DT06-2S Solenoid A Pgnd 2 HYDRAFORCE Reversing Control B+ B DT06-2S connector or similar provided by customer. External Connection (not present for single valve controller) Pin 1 DT04-6P Integral. Mating: DT06-6S DPDT Momentary Switch for Reversing Internal Connection Power Power + Fan Control A+ Pin 1 A DT06-2S Integral. Mates to ER/DR Coil. Gnd. Input N.C. N.O. N.C. N.O. Temperature Sensor 50 Ohm Recommended Model ERT150 HF Part No Plug-In Fan Control Wiring CONTROL MODES (based on default values) ON/OFF with hysteresis PROPORTIONAL CURRENT ma FAN SPPED % CURRENT ma FAN SPPED % 30 C 40 C 50 C 60 C 70 C Low High Set Pt. Set Pt. Low High Break Pt. Break Pt. 30 C 40 C 50 C 60 C 70 C Low Set Pt. High Set Pt. Low Break Pt. High Break Pt. TO ORDER EFDR1 Fan Control Valve Driver Part No Configuration Cable for ExDR1 Part No Configuration Software for ExDR1 Part No Recommended Temperature Sensor, Model ERT150 Part No

53 EFDR2 Valve Driver, Fan Control, Multi-Input, DESCRIPTION The EFDR2 multi-input fan drive controller provides precise, repeatable control of one proportional valve coil and one on/off solenoid valve coil. The controller accepts up to three thermistor inputs for fan control along with a single switch input for manual activation of the fan reversal function. Controller input signals can be from a resistive temperature sensor, or analog switch inputs. The EFDR2 setup parameters are confi gured using a PC, or the Application Confi guration Programmer (ACP) serial interface, which allows for infrared programming and fi eld adjustment of the controller. This multi-input fan drive controller is suitable for a wide range of heavy duty industrial, marine, and mobile off-highway equipment applications requiring proportional fan control. RATINGS POWER REQUIREMENTS: Power Required: 10 to 32 VDC INPUT SUPPLY CURRENT: One: 200 ma Quiescent All input and output characteristics are confi gurable with the Application Confi guration Programmer (ACP) software. FEATURES Complete Closed-Loop System Controller. Settings by pre-written PC program. CE Compliant for global application. PC Data Logging feature for trend analysis. Visible diagnostics with LED system error blink code warning. Alarm output for integrated system interface/shutdown options. Fully protected against shorts, opens, and reverse connections. Fan Start-up Delay feature to prevent excessive cooling. Flame-proof resin encapsulation. Reversing can be initiated manually or automatically. Various password levels ensure that characteristics cannot be changed without proper authority. Suitable for on- or off-road use. Industry-standard, sealed, Weatherpack or two-part polarized connectors. Fan Noise Test feature for demonstrating the proper noise level of a forward driven fan. INPUTS Three Command Inputs: Three discrete thermistor inputs: OHMS only (Max. Temp. = 50; Min. Temp. = 2M) Note: a thermistor input reaching Overtemp will result in ramping to full fan speed. One Reversing Input: Digital: Active High Dither Frequency: ~30 to 250Hz (menu selectable) OUTPUTS Two Control Outputs: Operating Current: Max. load for proportional valve One, On/Off Sourcing Driver: (3A) One, Proportional: (3.3A) Proportional and Directional Coils: 8-14VDC: Use 12V coil; 20-36VDC: Use 24V Coil ENVIRONMENTAL RATINGS: Operating Temp. Range: 30 C to +75 C; Storage Temp. Range: 40 C to +85 C Humidity Tolerance: % Non-Condensing Moisture Leakage (sealant pressure tolerance): ±0.35 bar (5 psi) against water and water vapor; immersion resistant in 3 ft. (1 meter) of water; meets IP68 standards. MATERIALS: Housing: Polycarbonate with fl ame resistant, two-part Epoxy Resin

54 HYDRAFORCE Thermisor Input w/usb Interface DIMENSIONS Label Dimension A 3.77 in./96.0 mm B 1.89 in./48.0 mm C in./5.0 mm Dia. D 3.82 in./97.0 mm E 3.10 in./78.8 mm F 0.46 in./12.0 mm G 3.25 in./82.6 mm H 0.64 in./16.5 mm I 0.26 in./6.5 mm Dimensions are for reference only. PINOUT Connector 1 Connector 2 Pin Function 1 Thermistor 3 Sig 2 Thermistor 3 Gnd 3 Thermistor 2 Sig 4 Thermistor 2 Gnd 5 Thermistor 1 Sig 6 Thermistor 1 Gnd Pin Function 1 Reverse I/P+ 2 +V Power I/P 3 +Prop Valve O/P 4 +Reverse Valve O/P 5 Reverse Valve O/P 6 Alarm O/P 7 Prop Valve O/P 8 0V Power I/P Notes: The engine Coolant Sensor must be connected to Thermistor 1 input. The Charge Air Sensor must be connected to Thermistor 2 input. TO ORDER EFDR2 Fan Control Valve Driver Part No Connector Kit for EFDR2 Part No Configuration Kit for EFDR2 Includes Application Confi guration Programmer (ACP), and USB Cable Part No Software GUI Part No Recommended Temperature Sensor Part No Mating Connector for Recommended Temperature Sensor Part No

55 ETDR1 Dual/Single Transmission Valve Driver, Plug-In DESCRIPTION A convenient, plug-mounted microprocessor-based controller for use on a hydraulic proportional valve coil. The input signal to the controller can be confi gured as voltage, current, resistive, or PWM. OPERATION The ETDR1 can be confi gured to provide a smooth clutch operation on a transmission. The controller will output the required current to fi ll the clutch, hold the output and then ramp the current output to full engagement of the shift. This will happen under a confi gurable preset timed function when the neutral to in gear is required. See Clutch Engagement Profi le graph below. Once the transmission is engaged the controller will also operate in the inch/troll which will allow slow precise control based on the amplitude of the input signal. The input signal can originate from a joystick type device with PWM, Voltage, or Resistance output. The two outputs of the ETDR1 provide for both forward and reverse control. DIAGNOSTIC FEATURES Any input below 9 VDC or above 32 VDC for a duration of 100mS will cause the controller to default to safe mode of "valve off." Any absence of an input signal caused by an open or short will cause the controller to default to safe mode of "valve off." Any no-current (open) output condition or over-current (short) will cause the controller to default to safe mode of "valve off." When a fault is corrected the controller will return to a proper operating mode. RATINGS Operating Temperature: 40 C to +85 C ( 40 C to +185 F) Molded Enclosure Dimensions: 35.1mm(W) x 72.9mm(H) x 42.67mm (D); 1.38 in.(w) x 2.87 in. (H) x 1.68 in. (D) Mating Connectors: Deutsch DT06-6S and DT04-2P Solenoid Connector: Integral HF DR 2-Pin Power Requirements: 9 to 32 VDC Control Inputs: Voltage: 0 to 5 or 0 to 10 VDC; Current: 0 to 20 or 4 to 20 ma Resistive: 0 to 5K ohms; PWM: 5 to 95%, 1.5V to 3.5V, 100 Hz to 10 KHz Control Outputs: 50 to 2000 ma Dither: 70 to 350 Hz; 0 to 10% of I-Max Ramp Time: 0.0 to 5.0 seconds; I-Min to I-Max Sealing: IP67 rated Materials: Polyester, 15% glass with silicone seals RAMP PROFILE EXAMPLES (Output A shown with default settings) 800 CLUTCH ENGAGEMENT PROFILE 800 INCH/TROLL PROFILE 700 Max. Current 700 Max. Current Output Current (ma) Fill Time Fill Current Hold Time Hold Current Ramp Time Output Current (ma) Disengage Max. Deadband Inch/Troll Current Functional Range Hold Current Inch/Troll Range Engage Inch/Troll Signal Max. Signal Error Range Time (ms) Input Signal (% of Full Signal)

56 ETDR1 Dual/Single Transmission Valve Driver, Plug-In CONNECTIONS & WIRING HYDRAFORCE Description Interface I/O Pin Connector Battery Power+ A/0 4 DT04-6P Power Pgnd 5 Voltage Control Voltage in A/1 3 Signal Gnd Agnd 2 Current Control 0 to 20 ma in A/1 3 Signal 4 to 20 ma in A/1 3 Gnd Agnd 2 Resistive Radj in A/1 3 Control Signal Gnd Agnd 2 PWM Control PWM in A/1 3 Signal Gnd Agnd 2 External Solenoid Sol B+ AO2 6 Reverse Sol B AO3 1 Integral Solenoid Sol A+ AO1 1 DT06-2S Forward Sol A Pgnd 2 External Connection (not present for single valve controller) Reverse Sol B+ Sol B Power Power + Internal Connection Forward Sol A+ Pin 1 Sol A Plug-In Valve Driver Wiring Pin 1 Signal Lo Signal Hi DT06-2S or similar provided by customer DT04-6P Integral Mating DT06-6S DT06-2S Integral Mates to ER/DR Coil DIMENSIONS & MOUNTING INCH MILLIMETRE MOUNTING CONSIDERATIONS When installing the coil on a horizontal plane, the controller should be orientated as closely as possible to verticle alignment with the coil, as shown in Fig 1. When mounted in this position, the controller will withstand the vibration test profile described on HydraForce catalog page (Test No. 4). Avoid mounting the controller on a horizontal axis with the coil, as shown in Fig. 2. UP Typical single-valve inline housing. FIG. 1: CORRECT INSTALLATION FIG. 2: INCORRECT INSTALLATION TO ORDER Dual/Single Transmission Control Valve Driver Model ETDR1 Part No Configuration Cable for ExDR1 Part No Configuration Software for ExDR1 Part No

57 EVDR4 Five-Valve Driver, Universal Input DESCRIPTION The EVDR4 valve driver provides precise, repeatable control of four proportional solenoid valve coils and one on/off solenoid valve coil. PWM input signals can be from a joystick, a PLC or Engine Control Module. Analog inputs and multiple switched inputs are optional to suit a range of applications. An onboard RS-232 port is used for user-confi guration and diagnostics via PC. This versatile, multi-function controller is suitable for a wide range of heavy duty industrial, marine, and mobile off-highway equipment applications, such as transmission controls, vehicle traction controls, and drive-by-wire control systems. RATINGS POWER REQUIREMENTS: Power Required: 9 to 32 VDC Operating Current: 7 amp maximum load Non-Destructive Voltage: 32 to +36 VDC FEATURES Microprocessor based control (standard software or OEM software on request). Standard hardware and software adapts to many applications including interface to a joystick PWM command or proportional signals. Independent outputs for four proportional valves (0 2A) and 1on/off valve (< 2 A). Interfaces to up to 2 PWM signal inputs (interface to a 2 axis joystick). Up to four voltage or current analog inputs: 0-5V, 0-10V, 4-20 ma or 0-20 ma. Digital inputs for interface to switches, etc., (up to 6). Robust 8 36VDC power supply interface with reverse polarity protection. One, +5V reference voltage to power input devices. Thermal overload and overvoltage protection provided. Rugged IP67-rated packaging with IP69K-rated plug-in connections. Operational from -40 to 85 C (-40 to 185 F). RS232 interface to PC or laptop for user confi guration and diagnostics. SENSOR POWER SUPPLY: One, 5V Sensor Supply: 50 ma DC PROCESSING and MEMORY: Motorola Microprocessor: MC56F8346 Flash ROM: 128 KByte SRAM: 4 KByte EEPROM: 8 KBytes All input and output characteristics are configurable with ACP (Application Configuration Programmer). INPUTS: PWM/Digital: 2 inputs 5 to 36 VDC; 0 to 100% DC; 50 Hz to 10 KHz; or Digital Active High/Low Input Analog/Digital: 4 inputs 0 to 20 ma; 4 to 20 ma, 0 to 5V or 0 to 10V; or Digital Active High or Low OUTPUTS: On/Off High Side Driver (2A): 1 PWM Driver, High Side (2A): 4; PWM Drivers can be confi gured for On/Off or Proportional Communications: RS-232 ENVIRONMENTAL RATINGS: Operating Temperature Range: 40 C to +85 C Storage Temperature Range: 50 C to 125 C Humidity Tolerance: 115% of nominal system voltage at 90% relative humidity over operating temperature range Salt Spray Tolerance: 115% of nominal system voltage with 5% salt spray for 48 hours at 35 C Chemical Splash Immunity: Diesel Fuel, engine/machine oil, SAE J1455 chemical agents Vibration (Shock-isolated components): 7.4 Grms random vibration from 24 Hz to 2 KHz in three orthagonal planes Moisture Leakage (sealant pressure tolerance): ±0.35 bar (5 psi) against water and water vapor; immersion resistant in 3 ft. (1 meter) of water; meets IP67 standards. Radiated Immunity: 10 V/M; 80 MHz to 1.0 GHz Electrostatic Environment: Zero damage during exposure to electrostatic painting process (IEC ) Materials: Housing: Thermoplastic with silicone elastomer seals. Contacts: Tin-plated copper alloy

58 9 EVDR4 Five-Valve Driver, Universal Input DIMENSIONS HYDRAFORCE BOTTOM VIEW Allow 2.00/50.8 Clearance for Mating Connector Installation INCH MILLIMETRE Dimensions are for reference only. Mounting Holes 0.29 (7.4) Dia., 2 Places Mating Plug Assemblies: See To Order section below Overall Thickness CONNECTOR VIEW (not to scale) X X J1 Grey J2 Black Center to Center NOTE: Use dielectric grease on pins when installing the connectors. PINOUT Connector J1 Grey Pin Function 1 Power + 2 Proportional Solenoid 1+ 3 Proportional Solenoid 2+ 4 Proportional Solenoid 3+ 5 Proportional Solenoid 4+ 6 Digital Solenoid + 7 Digital Solenoid 8 Proportional Solenoid 4 9 Proportional Solenoid 3 10 Proportional Solenoid 2 11 Proportional Solenoid 1 12 Power Pinout Notes: To ground a PWM input use an analog GND connection pin. Active high digital inputs can be connected to the +5V reference. Active low inputs can be grounded to the analog GND connection pin. Joystick commands X and Y axes affect solenoids depending on how the joystick is wired to the controller. X and Y mentioned here may not correspond to the wiring chosen in a particular application. Use RS232 cable with the following pinout to make this connection: J2 Black, Pin 7 -> TXD -> female DB-9 Pin 2 J2 Black, Pin 8 -> RXD -> female DB-9 Pin 3 J2 Black, Pin 9 -> GND -> female DB-9 Pin 5 Connector J2 Black Pin Function 1 CAN-H 2 CAN-L 3 Analog In 1 / Digital In 1 (Controls the digital output when PWM command type is selected.) 4 Analog In 2 / Digital In 2 (ENABLE control when PWM command type is selected.) 5 Analog In 3 / Digital In 3 (Not used in standard software.) 6 Analog In 4 / Digital In 4 (Not used in standard software.) 7 RS232 Transmit (See Notes.) 8 RS232 Receive (See Notes.) 9 Analog Ground (and RS232 Ground) 10 +5V Reference 11 PWM In 1 / Digital In 5 (Controls the digital output when analog command type is selected; See notes.) 12 PWM In 2 / Digital In 6 (ENABLE control when analog command type is selected; See Notes.) TO ORDER Controller: Model EVDR4; Part No Connector Kits: J1, DTM06-12A Kit, Grey: J2, DTM06-12B Kit, Black: Configuration Software: Configuration Cable:

59 EVDR5 Five-Valve Driver, Universal Input w/j1939 DESCRIPTION The EVDR5 valve driver provides precise, repeatable control of four proportional solenoid valve coils and one on/off solenoid valve coil. PWM input signals can be from a joystick, a PLC or Engine Control Module. Analog inputs and multiple switched inputs are optional to suit a range of applications. The CAN J1939 communications port, along with the USB-to-CAN adapter, allow the EVDR5 setup parameters to be confi gured using a PC. Also, the CAN port can be set up to provide communications and control with other devices on the network. This versatile, multi-function controller is suitable for a wide range of heavy duty industrial, marine, and mobile off-highway equipment applications, such as transmission controls, vehicle traction controls, and drive-by-wire control systems. RATINGS POWER REQUIREMENTS: Power Required: 9 to 36 VDC Operating Current: 6 amp maximum load Non-Destructive Voltage: 32 to +36 VDC FEATURES Microprocessor based control (standard software or OEM software on request). Standard hardware and software adapts to many applications including interface to a joystick PWM command or proportional signals. Independent outputs for four proportional valves (0 2A) and 1on/off valve (< 2 A). Interfaces to up to 2 PWM signal inputs (interface to a 2 axis joystick). Up to four voltage or current analog inputs: 0-5V, 0-10V, 4-20 ma or 0-20 ma. Digital inputs for interface to switches, etc., (up to 6). Robust 8 36VDC power supply interface with reverse polarity protection. Two, +5V reference voltage to power input devices. Thermal overload and overvoltage protection provided. Rugged IP67-rated packaging with IP69K-rated plug-in connections. Operational from -40 to 85 C (-40 to 185 F). CAN for networking capability, user confi guration and diagnostics SENSOR POWER SUPPLY: Two, 5V Sensor Supplies: 50 ma DC each PROCESSING and MEMORY: Motorola Microprocessor: MC56F8346 Flash ROM: 128 KByte SRAM: 4 KByte EEPROM: 8 KBytes All input and output characteristics are configurable with ACP (Application Configuration Programmer). INPUTS: PWM/Frequency/Digital: 2 inputs 5 to 36 VDC; 0 to 100% DC; 50 Hz to 10 KHz; or Digital Active High/Low Input Analog/Digital: 4 inputs 0 to 20 ma; 4 to 20 ma, 0 to 5V or 0 to 10V; or Digital Active High or Low OUTPUTS: On/Off High Side Driver (2A): 1 PWM Driver, High Side (2A): 4; PWM Drivers can be confi gured for On/Off or Proportional Communications: CAN J1939; RS-232 ENVIRONMENTAL RATINGS: Operating Temperature Range: 40 C to +85 C Storage Temperature Range: 50 C to 125 C Humidity Tolerance: 115% of nominal system voltage at 90% relative humidity over operating temperature range Salt Spray Tolerance: 115% of nominal system voltage with 5% salt spray for 48 hours at 35 C Chemical Splash Immunity: Diesel Fuel, engine/machine oil, SAE J1455 chemical agents Vibration (Shock-isolated components): 7.4 Grms random vibration from 24 Hz to 2 KHz in three orthagonal planes Moisture Leakage (sealant pressure tolerance): ±0.35 bar (5 psi) against water and water vapor; immersion resistant in 3 ft. (1 meter) of water; meets IP67 standards. Radiated Immunity: 10 V/M; 80 MHz to 1.0 GHz Electrostatic Environment: Zero damage during exposure to electrostatic painting process (IEC ) Materials: Housing: Thermoplastic with silicone elastomer seals. Contacts: Tin-plated copper alloy.

60 9 EVDR5 Five-Valve Driver, Universal Input w/j1939 DIMENSIONS HYDRAFORCE BOTTOM VIEW Allow 2.00/50.8 Clearance for Mating Connector Installation INCH MILLIMETRE Dimensions are for reference only. Mounting Holes 0.29 (7.4) Dia., 2 Places Mating Plug Assemblies: See To Order section below Overall Thickness CONNECTOR VIEW (not to scale) X X J1 Grey J2 Black Center to Center NOTE: Use dielectric grease on pins when installing the connectors. PINOUT Connector J1 Grey Pin Function 1 Power + 2 Proportional Solenoid 1+ 3 Proportional Solenoid 2+ 4 Proportional Solenoid 3+ 5 Proportional Solenoid 4+ 6 Digital Solenoid + 7 Digital Solenoid 8 Proportional Solenoid 4 9 Proportional Solenoid 3 10 Proportional Solenoid 2 11 Proportional Solenoid 1 12 Power Pinout Notes: To ground a PWM input use an analog GND connection pin. Active high digital inputs can be connected to the +5V reference. Active low inputs can be grounded to the analog GND connection pin. Joystick commands X and Y axes affect solenoids depending on how the joystick is wired to the controller. X and Y mentioned here may not correspond to the wiring chosen in a particular application. Connector J2 Black Pin Function 1 CAN-H 2 CAN-L 3 Analog In 1 / Digital In 1 4 Analog In 2 / Digital In 2 5 Analog In 3 / Digital In 3 6 Analog In 4 / Digital In 4 7 Analog Ground V Reference 2 9 Analog Ground V Reference 1 11 PWM In 1 / Frequency / Digital In 5 (Controls the digital output when analog command type is selected; see notes.) 12 PWM In 2 / Frequency / Digital In 6 (ENABLE control when analog command type is selected; see notes.) TO ORDER Controller Model EVDR5; Part No Connector Kits: J1, DTM06-12A Kit, Grey: J2, DTM06-12B Kit, Black: Configuration Kit Includes Converter, Cable and Software: CAN Flashing Cable: Part No

61 EVDR6 Six-Valve Driver, Universal Input, w/j1939, DESCRIPTION The EVDR6 valve driver provides precise, repeatable control of six on/off solenoid valve coils that draw up to 5 amps each. It also accepts two analog and three digital inputs. CAN bus communications offer control system networking capabilty and user confi guration. This versatile, multi-function controller is suitable for a wide range of heavy duty industrial, marine, and mobile off-highway equipment applications, such as transmission controls, vehicle traction controls, and drive-by-wire control systems. FEATURES Microprocessor based control (standard software or OEM software on request). Standard hardware and software adapts to many applications. Robust 9 to 36VDC power supply interface with reverse polarity protection. Six on/off outputs capable of driving 5 amps each. Two analog confi gurable inputs: 5V, 20mA, PWM, Frequency/RPM, or Digital. Three digital confi gurable inputs: High, Low, or PWM Thermal overload and overvoltage protection provided. Rugged IP67-rated packaging with IP69K-rated plug-in connections. Operational from -40 to 85 C (-40 to 185 F). One CAN J1939 port CAN for networking capability, user confi guration and diagnostics. RATINGS POWER REQUIREMENTS: Power Required: 9 to 36 VDC Operating Current: 8 amp maximum load Non-Destructive Voltage: 32 to +80 VDC PROCESSING and MEMORY: Motorola Microprocessor: MC56F8346 Flash ROM: 128 KByte SRAM: 4 KByte EEPROM: 8 KBytes All input and output characteristics are configurable with ACP (Application Configuration Programmer). COMMUNICATION I/O: CAN J1939 Standard CANopen Consult Factory INPUTS: Analog: 2, Confi gurable as: 0 to 5VDC; 0(4) to 20mA; PWM, 0 to 100%, 5KHz maximum; Frequency/RPM, 1 to 65 KHz; 16-bit counter; Digital High Digital: 3, Confi gurable as: Digital, High/Low; PWM, 0 to 100%, 5KHz maximum; Frequency/RPM, 1 to 65KHz; 16-bit counter OUTPUTS: High Side ON/OFF Drivers: 6 Drivers can be confi gured for On/Off, Timed, Pulsed, Duty Cycle ENVIRONMENTAL RATINGS: Operating Temperature Range: 40 C to +85 C Storage Temperature Range: 50 C to 125 C Humidity Tolerance: 115% of nominal system voltage at 90% relative humidity over operating temperature range Salt Spray Tolerance: 115% of nominal system voltage with 5% salt spray for 48 hours at 35 C Vibration (Shock-isolated components): 7.4 Grms random vibration from 24 Hz to 2 KHz in three orthagonal planes Moisture Leakage (sealant pressure tolerance): ±0.35 bar (5 psi) against water and water vapor; immersion resistant in 3 ft. (1 meter) of water; meets IP67 standards. Radiated Immunity: 10 V/M; 80 MHz to 1.0 GHz Electrostatic Environment: Zero damage during exposure to electrostatic painting process (IEC ) Materials: Housing: Thermoplastic with silicone elastomer seals. Contacts: Tin-plated copper alloy

62 9 HYDRAFORCE PWM and CAN Inputs EVDR6 DIMENSIONS BOTTOM VIEW Allow 2.00/50.8 Clearance for Mating Connector Installation INCH MILLIMETRE Dimensions are for reference only. Mounting Holes 0.29 (7.4) Dia., 2 Places Mating Plug Assemblies: See To Order section below Overall Thickness CONNECTOR VIEW (not to scale) X X J1 Grey J2 Black Center to Center NOTE: Use dielectric grease on pins when installing the connectors. PINOUT Connector J1 Grey Pin Function 1 Ground 6 2 Ground 5 3 Ground 4 4 Ground 3 5 Ground 2 6 Ground 1 7 Output 1 8 Output 2 9 Output 3 10 Output 4 11 Output 5 12 Output 6 Connector J2 Black Pin Function 1 BATT + 2 CAN Hi 3 Factory Use 4 Factory Use 5 Input 1 Analog 6 Input 2 Analog 7 Ground 8 Input 5 Digital 9 Input 4 Digital 10 Input 3 Digital 11 CAN Lo 12 BATT TO ORDER Controller Model EVDR6; Part No Connector Kits: J1, DTM06-12A Kit, Grey: J2, DTM06-12B Kit, Black: Configuration Kit Includes Converter, Cable and Software: CAN Flashing Cable: Part No

63 EVDR7 Multi-I/O Controller and/or Slave Module FEATURES Microprocessor based control (standard software or OEM software on request). Standard hardware and software adapts to many applications. Independent outputs for one proportional valve (0 to 2A) and one on/off valve (2A). Up to four universal analog or digital inputs: voltage, current, resistive, PWM, frequency, or digital. Digital input (one) for interface to switch, etc. Priority control sensor, selectable. Robust 8-60 VDC power supply interface with reverse polarity protection. Four, +5V reference voltage-to-power input devices (100mA w/output to common ground). Thermal overload and overvoltage protection provided. Rugged IP67-rated packaging with IP69K-rated plug-in connections. Operational from -40 to 85 C (-40 to 185 F). CAN for networking capability, user confi guration and diagnostics. DESCRIPTION The EVDR7 multi-i/o controller provides precise, repeatable control of one proportional solenoid valve coil and one on/off solenoid valve coil. Controller input signals can be resistive temperature sensor, frequency, PWM, digital, voltage, or current. Analog inputs and multiple switched inputs are optional to suit a range of machine applications. The CAN J1939 communications port, along with the USB-to-CAN adapter, allows the EVDR7 setup parameters to be confi gured using a PC. Also, the CAN port can be set up to provide communications with other devices on the network. This multi-input controller is suitable for a wide range of heavy duty industrial, marine, and mobile off-highway equipment applications. RATINGS POWER REQUIREMENTS: Power Required: 8 to 60 VDC; Operating Current: 6 amp maximum load Non-Destructive Voltage: 32 to +80 VDC SENSOR POWER SUPPLY: Four, 5V Sensor Supplies: 100 ma DC each PROCESSING and MEMORY: Motorola Microprocessor: MC56F8346; Flash ROM: 128 KByte SRAM: 4 KByte; EEPROM: 8 KBytes All input and output characteristics are configurable with ACP (Application Configuration Programmer). INPUTS: Four universal inputs can be chosen in the following ranges: Voltage, current, or resistive analog inputs: 0-1V, 0-2.5V, 0-5V, 0-10V, 0-20 ma, 4-20 ma, or 30K to 300K ohms. PWM, frequency, or digital inputs: PWM: 0-100% D.C., 10 Hz to 1 KHz, or 100 Hz to 10 KHz Frequency: Two ranges, 10 Hz to 1 KHz, or 100 Hz to 10 KHz Digital: Active High OUTPUTS: Two control outputs: One, On/Off Sinking or Sourcing Driver (2A) One, High side grounded, mA confi gurable as: Discrete: On/Off; Current: PWM Closed Loop; Duty Cycle: PWM Open Loop ENVIRONMENTAL RATINGS: Operating Temp. Range: 40 C to +85 C; Storage Temp. Range: 50 C to 125 C Humidity Tolerance: 115% of nominal system voltage at 90% relative humidity over operating temperature range. Salt Spray Tolerance: 115% of nominal system voltage with 5% salt spray for 48 hours at 35 C. Chemical Splash Immunity: Diesel fuel, engine/machine oil, SAE J1455 chemical agents. Vibration (Shock-isolated components): 7.4 Grms random vibration from 24 Hz to 2 KHz in three orthagonal planes. Moisture Leakage (sealant pressure tolerance): ±0.35 bar (5 psi) against water and water vapor; immersion resistant in 3 ft. (1 meter) of water; meets IP67 standards. Materials: Housing: Thermoplastic with silicone elastomer seals. Contacts: Tin-plated copper alloy

64 9 HYDRAFORCE Universal Input, w/j1939, EVDR7 DIMENSIONS BOTTOM VIEW Allow 2.00/50.8 Clearance for Mating Connector Installation INCH MILLIMETRE Dimensions are for reference only. Mounting Holes 0.29 (7.4) Dia., 2 Places Mating Plug Assemblies: See To Order section below Overall Thickness CONNECTOR VIEW (not to scale) X X J1 Grey J2 Black Center to Center NOTE: Use dielectric grease on pins when installing the connectors. PINOUT Connector J1 Grey Pin Function 1 CAN_SH 2 Not Used 3 Output 2 Return 4 Output 1 Return 5 BATT 6 BATT 7 BATT + 8 BATT + 9 Output 1 Driver 10 Output 2 Driver 11 CAN Hi 12 CAN Lo Connector J2 Black Pin Function 1 5 Vref 1 2 Input 1 3 Analog Ground 4 Analog Ground 5 Input Vref Vref 3 8 Input 3 9 Analog Ground 10 Analog Ground 11 Input Vref 4 Pinout Notes: To ground a PWM input use an analog GND connection pin. Active high digital inputs can be connected to the +5V reference. Active low inputs can be grounded to the analog GND connection pin. TO ORDER Controller Model EVDR7; Part No Connector Kits: J1, DTM06-12A Kit, Grey: Part No J2, DTM06-12B Kit, Black: Part No Configuration Kit Includes Converter, USB Cable and Software: Part No CAN Flashing Cable: Part No

65 EVDR9 Nine-Valve Driver with CAN Input DESCRIPTION The EVDR9 valve driver provides precise, repeatable control of nine proportional solenoid valve coils. CAN bus communications offer control system networking capabilty and user confi guration. This versatile, multi-function controller is suitable for a wide range of heavy duty industrial, marine, and mobile off-highway equipment applications, such as transmission controls, vehicle traction controls, and drive-by-wire control systems. FEATURES Microprocessor based control (standard software or OEM software on request). Standard hardware and software adapts to many applications. Robust 8 to 80VDC power supply interface with reverse polarity protection. Thermal overload and overvoltage protection provided. Rugged IP67-rated packaging with IP69K-rated plug-in connections. Operational from -40 to 85 C (-40 to 185 F). CAN for networking capability, user confi guration and diagnostics. RATINGS POWER REQUIREMENTS: Power Required: 8 to 80 VDC Operating Current: 8 amp maximum load Non-Destructive Voltage: 32 to +80 VDC PROCESSING and MEMORY: Motorola Microprocessor: MC56F8346 Flash ROM: 128 KByte SRAM: 4 KByte EEPROM: 8 KBytes All input and output characteristics are configurable with ACP (Application Configuration Programmer). COMMUNICATION I/O: CAN J1939 Standard CANopen Consult Factory OUTPUTS: PWM Driver, High Side (2A): 9; PWM Drivers can be confi gured for On/Off or Proportional ENVIRONMENTAL RATINGS: Operating Temperature Range: 40 C to +85 C Storage Temperature Range: 50 C to 125 C Humidity Tolerance: 115% of nominal system voltage at 90% relative humidity over operating temperature range Salt Spray Tolerance: 115% of nominal system voltage with 5% salt spray for 48 hours at 35 C Vibration (Shock-isolated components): 7.4 Grms random vibration from 24 Hz to 2 KHz in three orthagonal planes Moisture Leakage (sealant pressure tolerance): ±0.35 bar (5 psi) against water and water vapor; immersion resistant in 3 ft. (1 meter) of water; meets IP67 standards. Radiated Immunity: 10 V/M; 80 MHz to 1.0 GHz Electrostatic Environment: Zero damage during exposure to electrostatic painting process (IEC ) Materials: Housing: Thermoplastic with silicone elastomer seals. Contacts: Tin-plated copper alloy

66 9 HYDRAFORCE EVDR9 Nine-Valve Driver with CAN Input DIMENSIONS BOTTOM VIEW Allow 2.00/50.8 Clearance for Mating Connector Installation INCH MILLIMETRE Dimensions are for reference only. Mounting Holes 0.29 (7.4) Dia., 2 Places Mating Plug Assemblies: See To Order section below Overall Thickness CONNECTOR VIEW (not to scale) X X J1 Grey J2 Black Center to Center NOTE: Use dielectric grease on pins when installing the connectors. PINOUT Connector J1 Grey Pin Function 1 Ground 5 2 Ground 4 3 Ground 3 4 Ground 2 5 Ground 1 6 BATT 7 BATT + 8 Output 1 9 Output 2 10 Output 3 11 Output 4 12 Output 5 Connector J2 Black Pin Function 1 Output 6 2 Output 7 3 Output 8 4 Output 9 5 Factory Use 6 CAN HI 7 CAN LO 8 Factory Use 9 Ground 9 10 Ground 8 11 Ground 7 12 Ground 6 TO ORDER Controller Model EVDR9; Part No Connector Kits: J1, DTM06-12A Kit, Grey: J2, DTM06-12B Kit, Black: Configuration Kit Includes Converter, Cable and Software: CAN Flashing Cable: Part No

67 EVDR10 Ten Analog Input Module with J1939 FEATURES Microprocessor based control (standard software or OEM software on request). Standard hardware and software adapts to many applications. Robust 8 to 96VDC power supply interface with reverse polarity protection. Thermal overload and overvoltage protection provided. Rugged IP67-rated packaging with IP69K-rated plug-in connections. Operational from -40 to 85 C (-40 to 185 F). CAN for networking capability, user confi guration and diagnostics. DESCRIPTION The EVDR10 Analog Module measures up to 10 inputs and sends the data over a CAN network. The 10 inputs can be confi gured for 0 to 5VDC, 0(4) to 20 ma, PWM/Frequency/Counter, and Digital (High). CAN bus communications offer control system networking capabilty and is used for confi guration. This versatile, multi-function module is suitable for a wide range of heavy duty industrial, marine, and mobile off-highway equipment applications, such as transmission controls, vehicle traction controls, and drive-by-wire control systems. RATINGS POWER REQUIREMENTS: Power Required: 8 to 96 VDC Operating Current: 0.35 amps maximum, typically less than 2W Non-Destructive Voltage: 32 to +96 VDC PROCESSING and MEMORY: Motorola Microprocessor: DSP56F8346 Flash ROM: 128 KByte SRAM: 4 KByte EEPROM: 8 KBytes All input and output characteristics are configurable with ACP (Application Configuration Programmer). COMMUNICATION I/O: CAN J1939 Standard CANopen Consult Factory Inputs, 10 configurable: Type Range Accuracy Voltage 0 to 5 VDC ±7mV Current 0(4) to 20mA ±0.1mA PWM 0 to 100%, 50Hz to 10KHz, 96Vp-p ±2.0% RPM 0 to 100%, 50Hz to 10KHz, 96Vp-p ±0.3% Counter 0 to 96 VDC, 10KHz Digital 0 to 96 VDC, 10KHz ENVIRONMENTAL RATINGS: Operating Temperature Range: 40 C to +85 C Storage Temperature Range: 50 C to 125 C Humidity Tolerance: 115% of nominal system voltage at 90% relative humidity over operating temperature range Salt Spray Tolerance: 115% of nominal system voltage with 5% salt spray for 48 hours at 35 C Vibration (Shock-isolated components): 7.4 Grms random vibration from 24 Hz to 2 KHz in three orthagonal planes Moisture Leakage (sealant pressure tolerance): ±0.35 bar (5 psi) against water and water vapor; immersion resistant in 3 ft. (1 meter) of water; meets IP67 standards. Radiated Immunity: 10 V/M; 80 MHz to 1.0 GHz Electrostatic Environment: Zero damage during exposure to electrostatic painting process (IEC ) Materials: Housing: Thermoplastic with silicone elastomer seals. Contacts: Tin-plated copper alloy

68 9 EVDR10 Ten Analog Input Module with J1939 DIMENSIONS HYDRAFORCE BOTTOM VIEW Allow 2.00/50.8 Clearance for Mating Connector Installation INCH MILLIMETRE Dimensions are for reference only. Mounting Holes 0.29 (7.4) Dia., 2 Places Mating Plug Assemblies: See To Order section below Overall Thickness CONNECTOR VIEW (not to scale) X X J1 Grey J2 Black Center to Center NOTE: Use dielectric grease on pins when installing the connectors. PINOUT Connector J1 Grey Pin Function 1 Ground 5 2 Ground 4 3 Ground 3 4 Ground 2 5 Ground 1 6 BATT 7 BATT + 8 Input 1 9 Input 2 10 Input 3 11 Input 4 12 Input 5 Connector J2 Black Pin Function 1 Input 6 2 Input 7 3 Input 8 4 Input 9 5 Input 10 6 CAN HI 7 CAN LO 8 Ground 10 9 Ground 9 10 Ground 8 11 Ground 7 12 Ground 6 TO ORDER Controller Model EVDR10; Part No Connector Kits: J1, DTM06-12A Kit, Grey: J2, DTM06-12B Kit, Black: Configuration Kit Includes Converter, Cable and Software: CAN Flashing Cable: Part No

69 EVDR18 Eighteen Digital Input Module with J1939 FEATURES Microprocessor based control (standard software or OEM software on request). Standard hardware and software adapts to many applications. Robust 8 to 32VDC power supply interface with reverse polarity protection. Thermal overload and overvoltage protection provided. Rugged IP67-rated packaging with IP69K-rated plug-in connections. Operational from -40 to 85 C (-40 to 185 F). CAN for networking capability, user confi guration and diagnostics. DESCRIPTION The EVDR18 Input Module measures up to 18 inputs and sends the data over a CAN network. The 10 inputs can be confi gured for Digital (High or Low). The remaining 8 inputs can be confi gured for Digital (High or Low), PWM, Freq/RPM, or Counter. CAN bus communications offer control system networking capabilty and is used for confi guration. This versatile, multi-function module is suitable for a wide range of heavy duty industrial, marine, and mobile off-highway equipment applications, such as transmission controls, vehicle traction controls, and drive-by-wire control systems. RATINGS POWER REQUIREMENTS: Power Required: 8 to 32 VDC Operating Current: 0.10 amps maximum, typically less than 2W Non-Destructive Voltage: 32 to +75 VDC PROCESSING and MEMORY: Motorola Microprocessor: DSP56F8346 Flash ROM: 128 KByte SRAM: 4 KByte EEPROM: 8 KBytes All input and output characteristics are configurable with ACP (Application Configuration Programmer). COMMUNICATION I/O: CAN J1939 Standard CANopen Consult Factory Inputs: Type Range Accuracy PWM 0 to 100%, 1Hz to 10KHz, 32Vp-p ±1.25% RPM 50Hz to 10KHz, 50mV to 3V RMS ±1.0% Counter 0 to 32 VDC, 10KHz Digital 0 to 32 VDC, 2.5V Threshold ENVIRONMENTAL RATINGS: Operating Temperature Range: 40 C to +85 C Storage Temperature Range: 50 C to 125 C Humidity Tolerance: 115% of nominal system voltage at 90% relative humidity over operating temperature range Salt Spray Tolerance: 115% of nominal system voltage with 5% salt spray for 48 hours at 35 C Vibration (Shock-isolated components): 7.4 Grms random vibration from 24 Hz to 2 KHz in three orthagonal planes Moisture Leakage (sealant pressure tolerance): ±0.35 bar (5 psi) against water and water vapor; immersion resistant in 3 ft. (1 meter) of water; meets IP67 standards. Radiated Immunity: 10 V/M; 80 MHz to 1.0 GHz Electrostatic Environment: Zero damage during exposure to electrostatic painting process (IEC ) Materials: Housing: Thermoplastic with silicone elastomer seals. Contacts: Tin-plated copper alloy

70 9 EVDR18 Eighteen Digital Input Module with J1939 DIMENSIONS HYDRAFORCE BOTTOM VIEW Allow 2.00/50.8 Clearance for Mating Connector Installation INCH MILLIMETRE Dimensions are for reference only. Mounting Holes 0.29 (7.4) Dia., 2 Places Mating Plug Assemblies: See To Order section below Overall Thickness CONNECTOR VIEW (not to scale) X X J1 Grey J2 Black Center to Center NOTE: Use dielectric grease on pins when installing the connectors. PINOUT Connector J1 Grey Pin Function 1 CAN HI 2 CAN LO 3 CAN_SH 4 GND 5 Power 6 Power + 7 Input 6 8 Input 5 9 Input 4 10 Input 3 11 Input 2 12 Input 1 Connector J2 Black Pin Function 1 Input 7 2 Input 8 3 Input 9 4 Input 10 5 Input 11 6 Input 12 7 Input 18 8 Input 17 9 Input Input Input Input 13 TO ORDER Controller Model EVDR18; Part No Connector Kits: J1, DTM06-12A Kit, Grey: J2, DTM06-12B Kit, Black: Configuration Kit Includes Converter, Cable and Software: CAN Flashing Cable: Part No

71 ECU-ML Heavy-Duty Machine Controller DESCRIPTION The ECU-ML Machine Control is a heavy-duty general-purpose programmable controller designed to withstand the extreme environmental demands of the agricultural, marine, mining and construction industries. Based on a 32-bit MPC555 microprocessor running at 40MHz, the ECU-ML is a monitor and controller for use as a stand alone system, or for working together in a large complex network with other devices using its onboard CAN communications. ECU-ML is equipped with ample inputs and outputs to interface with HydraForce joysticks, sensors, displays and valves. There are 72 inputs consisting of digital switch to both ground and battery, analog signals, PWM signals, and frequency/speed types. A total of 26 outputs consist of sinking drivers of 300mA, sourcing drivers of 2.0 Amps, a neutral start driver, and PWM drivers of 2.0 Amps. Note: Refer to ECU Technical Reference pages for specifi c data and ratings of individual inputs and outputs. FEATURES Advanced electronic design for reliability and accuracy. Reliable operation in extreme temperature conditions from -40 to +85 C. Ruggedly designed, fully-sealed aluminum housing. Inputs and Outputs have both protection and diagnostics. Regulated power supplies are provided for external sensors. No special power is required. No external cooling or heat dissipation required. Low cost/compact size. Fully programmable for application versatility. Software developed with Composer TM. RATINGS POWER REQUIREMENTS: Operating Voltage: 9 to 32 VDC Battery is internally monitored by the CPU Operating Current: 450 ma + 30 Amp Maximum Load Non-Destructive Voltage: 32 to +80 VDC SENSOR POWER SUPPLIES: One 5V Sensor Supply: 200 ma DC One 8V Sensor Supply: 400 ma DC One 10V Sensor Supply: 3A COMMUNICATION: J1939 (CAN) Data Link PROCESSING and MEMORY: MPC555 Microprocessor: 40 MHz Flash ROM: 2 MByte SRAM: 256 KByte EEPROM: 32 KBytes INPUTS: Switch to Ground: 35 Switch to Battery: 3 Key Switch (+Batt): 1 Neutral Start Input: 1 Analog Inputs: 5 PWM / Frequency Input: 20 Speed Input: 6 Alternator Input: 1 Internal Battery Monitor: 1 OUTPUTS: On/Off Sinking Driver (0.5 to 300 ma): 8 On/Off Sourcing Driver (10 ma to 2A): 5 On/Off Neutral START Driver (10 ma to 2A): 1 PWM Driver (50 ma to 2A): 12 Note: Diagnostic current of 20 ma may prevent solenoid valve from turning off. ENVIRONMENTAL RATINGS: Operating Temperature Range: 40 C to 85 C Radiated Immunity: 15.0 KHz to 1.0 GHz at 100 V/M Storage Temperature Range: 50 C to 120 C Humidity Tolerance: 115% of nominal system voltage at 90% relative humidity over operating temperature range Salt Spray Tolerance: 115% of nominal system voltage with 5% salt spray for 48 hours at 35 C Chemical Splash Immunity: Diesel Fuel, engine/machine oil, SAE J1455 chemical agents Vibration (Shock-isolated components): 8.0 Grms random vibration from 24 Hz to 2000 Hz in three orthagonal planes Moisture Leakage (sealant pressure tolerance): ±0.35 bar (5 psi) against water and water vapor; meets IP67 standards Electrostatic Environment: Zero damage during exposure to electrostatic painting process

72 HYDRAFORCE ECU-ML Heavy-Duty Machine Controller DIMENSIONS Clearance required to engage/ disengage connectors Grounding Strap Approx 4" (100 mm) Pin 1 Pin 13 Pin 1 Pin J2 Connector Pin 58 Pin 70 Pin 58 Pin 70 J1 Connector Dia. Mounting Holes 4 Places All Dimensions are for Reference Only INCH MILLIMETRE MOUNTING No restrictions on mounting angle when using this optional kit. See To Order section

73 ECU-ML Heavy-Duty Machine Controller J1 CONNECTOR PIN ASSIGNMENTS Pin No. J1 Connector Function Type 1 Key-on Input 2 Differential Speed 1 (+) Input 3 Differential Speed 1 (-) Input 4 Differential Speed 2 (+) Input 5 Differential Speed 2 (-) Input 6 Differential Speed 3 (+) Input 7 Differential Speed 3 (-) Input 8 Differential Speed 4 (+) Input 9 Differential Speed 4 (-) Input V Sensor PS 12 2A On/Off 6 Output 13 Battery (-) 14 Switch to Battery 1 Input 15 Differential Speed 5 (+) Input 16 Differential Speed 5 (-) Input 17 Differential Speed 6 (+) Input 18 Differential Speed 6 (-) Input 19 CAN Shield I/O V Sensor Return 22 Analog Passive 1 Input 23 Battery (-) 24 Switch to Battery 2 Input 25 Switch to Battery 3 Input 26 Switch to Ground 1 Input 27 Switch to Ground 2 Input 28 Switch to Ground 3 Input 29 Analog Passive 2 Input 30 Analog Passive 3 Input 31 Battery (+) 32 Switch to Ground 4 Input 33 Switch to Ground 5 Input 34 Switch to Ground 6 Input 35 Switch to Ground 7 Input Pin No. J1 Connector Function Type 36 Analog Active 1 Input 37 Analog Active 2 Input 38 Battery (+) 39 Battery (+) 40 Switch to Ground 8 Input 41 Switch to Ground 9 Input 42 Switch to Ground 10 Input 43 Switch to Ground 11 Input 44 8V Sensor PS 45 8V Sensor Return 46 Battery (+) 47 Battery (+) 48 PWM Driver 1 (+) Output 49 PWM Driver 2 (+) Output 50 PWM Driver Return 1-4 Output 51 PWM Driver 3 (+) Output 52 PWM Driver 4 (+) Output 53 Ground Pin 54 PWM Drvr 2-wire Return Output 55 PWM Driver Return 9-12 Output 56 Battery (-) 57 Battery (-) 58 PWM Driver 5 (+) Output 59 PWM Driver 6 (+) Output 60 PWM Driver Return 5-8 Output 61 PWM Driver 7 (+) Output 62 PWM Driver 8 (+) Output 63 Switch to Ground 12 Input 64 Switch to Ground 13 Input 65 PWM Driver 9 (+) Output 66 PWM Driver 10 (+) Output 67 PWM Driver 11 (+) Output 68 PWM Driver 12 (+) Output 69 10V Sensor PS 70 Battery (-)

74 HYDRAFORCE ECU-ML Heavy-Duty Machine Controller J2 CONNECTOR PIN ASSIGNMENTS Pin No. J2 Connector Function Type 1 Neutral Start Input 2 2A On/Off 1 Output 3 2A On/Off 2 Output 4 2A Load Return 1 Output 5 2A On/Off 3 Output 6 2A On/Off 4 Output 7 2A On/Off 5 Output 8 2A Load Return 2 Output 9 300mA Sink 1 Output mA Sink 2 Output mA Sink 3 Output mA Sink 4 Output mA Sink 5 Output 14 Alternator Monitor Input 15 PWM High Res 1 Input 16 PWM High Res 2 Input 17 PWM High Res 3 Input 18 PWM High Res 4 Input mA Sink 6 Output mA Sink 7 Output mA Sink 8 Output 22 Digital Return 23 Switch to Ground 14 Input 24 PWM In 5 Input 25 PWM In 6 Input 26 PWM In 7 Input 27 PWM In 8 Input 28 Switch to Ground 15 Input 29 Switch to Ground 16 Input 30 Switch to Ground 17 Input 31 Switch to Ground 18 Input 32 PWM In 9 Input 33 PWM In 10 Input 34 PWM In 11 Input 35 PWM In 12 Input Pin No. J2 Connector Function Type 36 Switch to Ground 19 Input 37 Switch to Ground 20 Input 38 Switch to Ground 21 Input 39 Switch to Ground 22 Input 40 PWM In 13 Input 41 PWM In 14 Input 42 PWM In 15 Input 43 PWM In 16 Input 44 Switch to Ground 23 Input 45 Switch to Ground 24 Input 46 Switch to Ground 25 Input 47 Switch to Ground 26 Input 48 PWM In 17 Input 49 PWM In 18 Input 50 PWM In 19 Input 51 PWM In 20 Input 52 Switch to Ground 27 Input 53 Switch to Ground 28 Input 54 Switch to Ground 29 Input 55 Switch to Ground 30 Input 56 Ground Pin 57 Ground Pin 58 Switch to Ground 31 Input 59 Switch to Ground 32 Input 60 Switch to Ground 33 Input 61 Switch to Ground 34 Input 62 Switch to Ground 35 Input 63 Ground Pin 64 CAN B (+) I/O 65 CAN B (-) I/O 66 CAN B Shield I/O 67 CAN A (+) I/O 68 CAN A (-) I/O 69 CAN A Shield I/O 70 Ground Pin TO ORDER Controller Model ECU-ML Composer TM Software: Part No Pin Connectors: J2 Part No J1 Part No Harness Hood Part No Socket Part No Seal Plug Part No Mounting Kit Part No

75 ECU-MM Heavy-Duty Machine Controller DESCRIPTION The ECU-MM Machine Control is a heavy-duty general-purpose programmable controller designed to withstand the extreme environmental demands of the agricultural, marine, mining and construction industries. Based on a 32-bit MPC555 microprocessor running at 40MHz, the ECU-MM is a monitor and controller for use as a stand alone system, or for working together in a large complex network with other devices using its onboard CAN communications. ECU-MM is equipped with ample inputs and outputs to interface with HydraForce joysticks, sensors, displays and valves. There are 44 inputs consisting of digital switch to ground, analog signals, PWM signals, and frequency/speed types. A total of 20 outputs consist of sinking drivers of 300mA, sourcing drivers of 2.0 Amps, a neutral start driver, and PWM drivers of 2.0 Amps. Note: Refer to ECU Technical Reference pages for specifi c data and ratings of individual inputs and outputs. FEATURES Advanced electronic design for reliability and accuracy. Reliable operation in extreme temperature conditions from -40 to +85 C. Ruggedly designed, fully-sealed aluminum housing. Inputs and Outputs have both protection and diagnostics. Regulated power supplies are provided for external sensors. No special power is required. No external cooling or heat dissipation required. Low cost/compact size. Fully programmable for application versatility. Software developed with Composer TM. RATINGS POWER REQUIREMENTS: Operating Voltage: 9 to 32 VDC Battery is internally monitored by the CPU Operating Current: 450 ma + 30 Amp Maximum Load Non-Destructive Voltage: 32 to +80 VDC SENSOR POWER SUPPLIES: One 5V Sensor Supply: 200 ma DC One 8V Sensor Supply: 400 ma DC COMMUNICATION: J1939 (CAN) Data Link PROCESSING and MEMORY: MPC555 Microprocessor: 40 MHz Flash ROM: 2 MByte SRAM: 256 KByte EEPROM: 32 KBytes INPUTS: Switch to Ground: 21 Key Switch (+Batt): 1 Neutral Start Input: 1 Analog Inputs: 5 PWM / Frequency Input: 11 Speed Input: 4 Alternator Input: 1 Internal Battery Monitor: 1 OUTPUTS: On/Off Sinking Driver (0.5 to 300 ma): 8 On/Off Sourcing Driver (10 ma to 2A): 3 On/Off Neutral START Driver (10 ma to 2A): 1 PWM Driver (50 ma to 2A): 8 Note: Diagnostic current of 20 ma may prevent solenoid valve from turning off. ENVIRONMENTAL RATINGS: Operating Temperature Range: 40 C to 85 C Radiated Immunity: 15.0 KHz to 1.0 GHz at 100 V/M Storage Temperature Range: 50 C to 120 C Humidity Tolerance: 115% of nominal system voltage at 90% relative humidity over operating temperature range Salt Spray Tolerance: 115% of nominal system voltage with 5% salt spray for 48 hours at 35 C Chemical Splash Immunity: Diesel Fuel, engine/machine oil, SAE J1455 chemical agents Vibration (Shock-isolated components): 8.0 Grms random vibration from 24 Hz to 2000 Hz in three orthagonal planes Moisture Leakage (sealant pressure tolerance): ±0.35 bar (5 psi) against water and water vapor; meets IP67 standards Electrostatic Environment: Zero damage during exposure to electrostatic painting process

76 HYDRAFORCE ECU-MM Heavy-Duty Machine Controller DIMENSIONS Clearance required to engage/ disengage connectors Grounding Strap Approx 4" (100 mm) Pin 1 Pin 13 Pin 1 Pin J2 Connector Pin 58 Pin 70 Pin 58 Pin 70 J1 Connector Dia. Mounting Holes 4 Places All Dimensions are for Reference Only INCH MILLIMETRE MOUNTING No restrictions on mounting angle when using this optional kit. See To Order section

77 ECU-MM Heavy-Duty Machine Controller J1 CONNECTOR PIN ASSIGNMENTS Pin No. J1 Connector Function Type 1 Key-on Input 2 Differential Speed 1 (+) Input 3 Differential Speed 1 (-) Input 4 Differential Speed 2 (+) Input 5 Differential Speed 2 (-) Input 6 Differential Speed 3 (+) Input 7 Differential Speed 3 (-) Input 8 Differential Speed 4 (+) Input 9 Differential Speed 4 (-) Input V Sensor PS Battery (-) CAN Shield I/O V Sensor Return 22 Analog Passive 1 Input 23 Battery (-) Switch to Ground 1 Input 27 Switch to Ground 2 Input 28 Switch to Ground 3 Input 29 Analog Passive 2 Input 30 Analog Passive 3 Input 31 Battery (+) 32 Switch to Ground 4 Input 33 Switch to Ground 5 Input 34 Switch to Ground 6 Input 35 Switch to Ground 7 Input Pin No. J1 Connector Function Type 36 Analog Active 1 Input 37 Analog Active 2 Input 38 Battery (+) 39 Battery (+) 40 Switch to Ground 8 Input 41 Switch to Ground 9 Input 42 Switch to Ground 10 Input 43 Switch to Ground 11 Input 44 8V Sensor PS 45 8V Sensor Return 46 Battery (+) 47 Battery (+) 48 PWM Driver 1 (+) Output 49 PWM Driver 2 (+) Output 50 PWM Driver Return 1-4 Output 51 PWM Driver 3 (+) Output 52 PWM Driver 4 (+) Output Battery (-) 57 Battery (-) 58 PWM Driver 5 (+) Output 59 PWM Driver 6 (+) Output 60 PWM Driver Return 5-8 Output 61 PWM Driver 7 (+) Output 62 PWM Driver 8 (+) Output 63 Switch to Ground 12 Input 64 Switch to Ground 13 Input Battery (-)

78 HYDRAFORCE ECU-MM Heavy-Duty Machine Controller J2 CONNECTOR PIN ASSIGNMENTS Pin No. J2 Connector Function Type 1 Neutral Start Input 2 2A On/Off 1 Output 3 4 2A Load Return 1 Output 5 2A On/Off 3 Output 6 2A On/Off 4 Output 7 2A Neutral Start Output 8 2A Load Return 2 Output 9 300mA Sink 1 Output mA Sink 2 Output mA Sink 3 Output mA Sink 4 Output mA Sink 5 Output 14 R-terminal Input mA Sink 6 Output mA Sink 7 Output mA Sink 8 Output 22 Digital Return 23 Switch to ground 14 Input 24 PWM In 5 Input 25 PWM In 6 Input 26 PWM In 7 Input 27 PWM In 8 Input 28 Switch to ground 15 Input 29 Switch to ground 16 Input 30 Switch to ground 17 Input 31 Switch to ground 18 Input 32 PWM In 9 Input 33 PWM In 10 Input 34 PWM In 11 Input 35 PWM In 12 Input Pin No. J2 Connector Function Type 36 Switch to ground 19 Input 37 Switch to ground 20 Input 38 Switch to ground 21 Input 39 Switch to ground 22 Input 40 PWM In 13 Input 41 PWM In 14 Input 42 PWM In 15 Input CAN A (+) I/O 57 CAN A Shield I/O Ground Pin CAN A (-) I/O TO ORDER Controller Model ECU-MM Composer TM Software: Part No Pin Connector: J2 Part No J1 Part No Harness Hood Part No Socket Part No Seal Plug Part No Mounting Kit Part No

79 Info. shown in red is new or updated: June 24, 2010 ECU-MS Heavy-Duty Machine Controller DESCRIPTION The ECU-MS Machine Control is a heavy-duty general-purpose programmable controller designed to withstand the extreme environmental demands of the agricultural, marine, mining and construction industries. Based on a 32-bit MPC555 microprocessor running at 40MHz, the ECU-MS is a monitor and controller for use as a stand alone system, or for working together in a large complex network with other devices using its onboard CAN communications. The ECU-MS is equipped with 25 inputs and 13 or 21 outputs to interface with HydraForce joysticks, sensors, displays and valves. Note: Refer to ECU Technical Reference pages for specifi c data and ratings of individual inputs and outputs. FEATURES Advanced electronic design for reliability and accuracy. Reliable operation in extreme temperature conditions from -40 to +105 C. Ruggedly designed, fully-sealed aluminum housing. Inputs and Outputs have both protection and diagnostics. Regulated power supplies are provided for external sensors. No special power is required. No external cooling or heat dissipation required. Low cost/compact size. Fully programmable for application versatility. Software developed with Composer TM. RATINGS POWER REQUIREMENTS: Operating Voltage: 9 to 32 VDC Battery is internally monitored by the CPU. Operating Current: 450 ma +13 Amp Maximum Load. Non-Destructive Voltage: 32 to +80 VDC SENSOR POWER SUPPLIES: 2, confi gurable for 5 VDC or ma each. COMMUNICATION: J1939 (CAN) Data Link: 2 J1708 ATA: 1 INPUTS: Key Switch (+Batt): 1 Confi gurable SWG/SWB: 3 Confi gurable SWG: 3 PWM / Frequency/SWG: 6 Differential Frequency/PWM: 4 Active/Passive Analog: 8 OUTPUTS: 2A Confi gurable: 9 PWM Drivers, each of which can be used as 1 High Side and 1 Low Side On/Off Driver, for a total of 16 Drivers. No restrictions on the number of possible combinations. 2A Low-Side Drivers: 4 Note: Diagnostic current of 20 ma may prevent solenoid valve from turning off. PROCESSING and MEMORY: Microprocessor: MHz Flash ROM: 512 KByte SRAM: 128 KByte EEPROM: 8 KBytes ENVIRONMENTAL RATINGS: Operating Temperature Range: 40 C to 105 C Storage Temperature Range: 55 C to 125 C Radiated Immunity: 15.0 KHz to 1.0 GHz at 100 V/M Humidity Tolerance: 115% of nominal system voltage at 90% relative humidity over operating temperature range. Salt Spray Tolerance: 115% of nominal system voltage with 5% salt spray for 48 hours at 35 C. Chemical Splash Immunity: Diesel Fuel, engine/machine oil, SAE J1455 chemical agents. Vibration (Shock-isolated components): 8.0 Grms random vibration from 24 Hz to 2000 Hz in three orthagonal planes. Moisture Leakage (sealant pressure tolerance): ±0.35 bar (5 psi) against water and water vapor; meets IP68 standards. Electrostatic Environment: Zero damage during exposure to electrostatic painting process. Material: Aluminum Housing; Gold-Plated Contacts. Info. shown in red is new or updated: June 24,

80 HYDRAFORCE ECU-MS Heavy-Duty Machine Controller DIMENSIONS For Reference Only Pin 1 Pin 13 Pin Grounding Strap Approx 4" (100 mm) All Dimensions are for Reference Only Strain Relief HF Part No (Order Separately) Dia. Mounting Holes (4 Places) INCH MILLIMETRE MOUNTING No restrictions on mounting angle when using this optional kit. See To Order section

81 Info. shown in red is new or updated: June 24, 2010 ECU-MS Heavy-Duty Machine Controller CONNECTOR PIN ASSIGNMENTS Pin No. Connector Function Type 1 +Battery 2 -Battery 3 Key Switch Input 4 DRVR9 HS/LS Output 5 Differential Speed Sensor 1+ Input 6 Differential Speed Sensor 1- Input 7 SWG/SWB 1 Input 8 SWG/SWB 2 Input 9 SWG/SWB 3 Input 10 Drvr 1 LS (ON/OFF_DRVR_LS) Output 11 Drvr 2 LS (ON/OFF_DRVR_LS) Output 12 Drvr 3 LS (ON/OFF_DRVR_LS) Output 13 Drvr 4 LS (ON/OFF_DRVR_LS) Output 14 +Battery 15 -Battery 16 Extra Switch/Sensor Returns Input 17 Extra Switch/Sensor Returns Input 18 Differential Speed Sensor 2+ Input 19 SWG 1 Input 20 SWG 2 Input 21 SWG 3 Input 22 PWM/FREQ 1 Input 23 PWM/FREQ 2 Input 24 +Battery 25 -Battery 26 DRVR 1 HS Output 27 DRVR 1 LS Output 28 PWM/FREQ 3 Input 29 PWM/FREQ 4 Input 30 PWM/FREQ 5 Input 31 PWM/FREQ 6 Input 32 DRVR 2 HS Output 33 DRVR 2 LS Output 34 DRVR 3 HS Output 35 DRVR 3 LS Output Pin No. Connector Function Type 36 Active/Passive Analog 1 (AIN) Input 37 Active/Passive Analog 2 (AIN) Input 38 Active/Passive Analog 3 (AIN) Input 39 Active/Passive Analog 4 (AIN) Input 40 DRVR 4 HS Output 41 DRVR 4 LS Output 42 DRVR 5 HS Output 43 DRVR 5 LS Output 44 Active/Passive Analog 5 (AIN) Input 45 Active/Passive Analog 6 (AIN) Input 46 Active/Passive Analog 7 (AIN) Input 47 Active/Passive Analog 8 (AIN) Input 48 DRVR 6 HS Output 49 DRVR 6 LS Output 50 DRVR 7 HS Output 51 DRVR 7 LS Output 52 Differential Speed Sensor 2- Input 53 CAN A Shield (CAN A SHIELD) I/O 54 CAN B Shield (CAN B SHIELD) I/O 55 Sensor Return (VS_RETURN) Input 56 Sensor Return (VS_RETURN) Input 57 CAT Data Link+ (CDL_HI) 58 DRVR 8 HS Output 59 DRVR 8 LS Output 60 Differential Speed Sensor 3+ Input 61 Differential Speed Sensor 3- Input 62 Differential Speed Sensor 4+ Input 63 Differential Speed Sensor 4- Input 64 CAN A+ (CAN_A_HI) I/O 65 CAN A- (CAN_A_LO) I/O 66 CAN B+ (CAN_B_HI) I/O 67 CAN B- (CAN_B_LO) I/O 68 Sensor Power 1 (VS_5_8_330MA) Output 69 Sensor Power 2 (VS_5_8_330MA) Output 70 CAT Data Link- (CDL_LO) I/O TO ORDER Controller Model ECU-MS Composer TM Software: Part No Pin Connector: Part No Harness Hood: Part No Socket Part No Strain Relief Part No Seal Plug Part No Mounting Kit Part No Info. shown in red is new or updated: June 24,

82 Heavy-Duty 70-Pin Electrical Connectors HYDRAFORCE DESCRIPTION This 70-position connector is a heavy-duty plastic electrical connection system for use with in-line, bulkhead and device applications. FEATURES Serviceable with common tools. Uses common size 16 pin and socket terminals. HF Part No (Deutsch No ) Uses common sealing plugs for unused cavities. HF Part No (Deutsch No ) Optional wire dress cover for wire seal protection from spray wash. PC board mounted header connector for device applications such as engine control module. PC board header connector pins can be depopulated to accommodate specifi c applications. TO ORDER For ECU-ML, ECU-MM, Connector J1: Part No For ECU-ML, ECU-MM, Connector J2: Part No For ECU-MS, Connector Type A: Part No For ELD-02 Display, Connector: Part No Terminal: Part No (Deutsch No ) Sealing Plugs: Part No (Deutsch No ) 90 Harness Hood: Part No

83 ECU-0710 Machine Controller DESCRIPTION The ECU-0710 Machine Control is a general-purpose programmable controller designed to withstand the real-world environmental demands of the off-highway mobile market. The ECU-0710 can be used as a stand-alone controller, or for integrating into a CAN network with other devices. Input confi guration can be set for up to 20 inputs consisting of Digital, Pulse, Current Measuring Feedback and Analog inputs. Output confi guration can be set for a total of 7 outputs consisting of up to 6 PWM or digital high-side drivers, and a single low-side driver. All outputs are capable of driving up to 3.0 Amps. Note: Refer to Input/Output table below for pin confi guration capability. Refer to ECU-0710 Technical Reference Manual for specifi c data and ratings of individual inputs and outputs. FEATURES Advanced electronic design for reliability and accuracy. Reliable operation in real-world temperature conditions from -40 to +70 C. Fully-sealed, compact cast-aluminum housing. Inputs and Outputs are protected against shorts. Outputs have diagnostic capability. No external cooling or heat dissipation required. Software developed with CoDeSys. 2.3 Programming Tool. RATINGS POWER REQUIREMENTS: Operating Voltage: 9 to 30 VDC Idle Power Consumption: approximately 1 Watt Operating Current: 10 Amp Max. continuous current, with full external load. Over-Voltage: 34 VDC maximum REFERENCE VOLTAGES: (1) 5 VDC Potentiometer Reference: 5 ma DC COMMUNICATION: (2) ISO CAN 2.0B Interfaces: CANopen, J1939, or user-programmable. PROCESSING and MEMORY: Microprocessor: 16-bit at 40 MHz Flash ROM: 254 Kbyte SRAM: 256 Kbyte EEPROM: 6200 bytes ENVIRONMENTAL RATINGS: Operating Temperature: 40 C to+70 C Storage Temperature: 50 C to +85 C Water Resistance: meets IP67 standards (per IEC ) Humidity Tolerance: Rel. Humidity > 90% from +25 C to +55 C (per IEC Test Db) Radiated Immunity: 20 to 2000 MHz at 30 V/m (per 2005/83/EC Annex IX) Vibration: 3.5Grms random from 10 to 500 Hz (per IEC Test Fh) Shock: 50g peak (per IEC and -29 Tests Ea and Eb) Corrosion: 50 g/l, NaCl for 24 hours at +35 C (per ISO 9227) INPUTS / OUTPUTS 20 Total Max. I/O Digital In Digital In Pulse Analog Current PWM Digital Out Digital Out Count (SWG) (SWB) Input Input Feedback (Source) (Source) (Sink) 6 X X X 2 X X 2 X X 3 X 6 X X 1 X X Note: The ECU-0710 has inputs and outputs that can be confi gured in multiple ways. For more information, consult the ECU-0710 Technical Reference Manual

84 HYDRAFORCE ECU-0710 Machine Controller DIMENSIONS and MOUNTING Mounting Holes 0.24 Dia. 6.2 All Dimensions for reference only. Weight: 1.11 lbs./0.5 kg Mounting on Horizontal Surface: Mounting Surface 1 ECU-0710 X / Mounting on Vertical Surface: Mounting Surface PIN ASSIGNMENTS Pin Connector 1 Pin Function Type 1 Digital Input/PWM Output/Digital Output I/O 2 Current Measuring Feedback FB 3 Digital Input/PWM Output/Digital Output I/O 4 Digital Input/PWM Output/Digital Output I/O 5 Current Measuring Feedback FB 6 Current Measuring Feedback FB 7 Digital Input/PWM Output/Digital Output I/O 8 Digital Input/PWM Output/Digital Output I/O 9 Digital Input/PWM Output/Digital Output I/O 10 Digital Input/Analog Input Input 11 Digital Input/Pulse Input, 2.2KΩ to +5VDC Input 12 Digital Input/Pulse Input, 2.2KΩ to +5VDC Input 13 Digital Input/Pulse Input, 10KΩ to GND Input 14 Digital Input/Pulse Input, 10KΩ to GND Input 15 Must be left open N/A VDC Reference (Ref 47Ω) 17 Digital Input/Analog Input Input 18 Digital Input/Digital Output I/O 19 Ground (Ref 47Ω) 20 Digital Input/Analog Input Input 21 Digital Input/Analog Input Input 22 Digital Input/Analog Input Input 23 Digital Input/Analog Input Input Pin Connector 2 Pin Function Type 1 Power Ground 2 CAN 1 HIGH I/O 3 Power Ground 4 V SUPPLY (+9 to 30 VDC) 5 V SUPPLY (+9 to 30 VDC) 6 CAN 1 LOW I/O 7 CAN 2 HIGH I/O 8 CAN 2 LOW I/O The mounting positions shown here will allow water or other potential contaminants to fall away from connectors. Allow 5 in./125 mm clearance from mounting surface for connector installation. For additional mounting information, consult the ECU-0710 Technical Ref. Manual. TO ORDER Controller: Model ECU-0710 Part No AmpSeal Connectors: 23-Pin Grey Part No ; 8-Pin Black Part No AmpSeal Socket/Plug: Sockets Gold (100 pc.) Part No ; Sealing Plugs (100 pc.) Part No Shock Cover Kit (optional): Part No CoDeSys Programming Software: available from 3S Software GmbH USB-CAN Adaptor: Part No , also available from Diagnostic Kit: Part No

85 ECU-2415 Machine Controller DESCRIPTION The ECU-2415 Machine Control is a general-purpose programmable controller designed to withstand the real-world environmental demands of the off-highway mobile market. The ECU-2415 can be used as a stand-alone controller, or for integrating into a CAN network with other devices. Input confi guration can be set for up to 39 inputs consisting of Digital, Pulse, Current Measuring Feedback and Analog inputs. Output confi guration can be set for a total of 24 outputs consisting of up to 24 PWM or digital high-side drivers. All outputs are capable of driving up to 3.0 Amps. Note: Refer to Input/Output table below for pin confi guration capability. Refer to ECU-2415 Technical Reference Manual for specifi c data and ratings of individual inputs and outputs. FEATURES Advanced electronic design for reliability and accuracy. Reliable operation in real-world temperature conditions from -40 to +70 C. Fully-sealed, compact cast-aluminum housing. Inputs and Outputs are protected against shorts. Outputs have diagnostic capability. No external cooling or heat dissipation required. Software developed with CoDeSys. 2.3 Programming Tool. RATINGS POWER REQUIREMENTS: Operating Voltage: 9 to 30 VDC Idle Power Consumption: approximately 1 Watt Operating Current: 10 Amp Max. continuous current, with full external load. Over-Voltage: 34 VDC maximum REFERENCE VOLTAGES: (1) 5 VDC Potentiometer Reference: 5 ma DC COMMUNICATION: (2) ISO CAN 2.0B Interfaces: CANopen, J1939, or user-programmable. PROCESSING and MEMORY: Microprocessor: 16-bit at 40 MHz; Flash ROM: 254 Kbyte SRAM: 256 Kbyte; EEPROM: 6200 bytes ENVIRONMENTAL RATINGS: Operating Temperature: 40 C to+70 C; Storage Temperature: 50 C to +85 C Water Resistance: meets IP67 standards (per IEC ) Humidity Tolerance: Rel. Humidity > 90% from +25 C to +55 C (per IEC Test Db) Radiated Immunity: 20 to 2000 MHz at 30 V/m (per 2005/83/EC Annex IX) Vibration: 3.5Grms random from 10 to 500 Hz (per IEC Test Fh) Shock: 50g peak (per IEC and -29 Tests Ea and Eb) Corrosion: 50 g/l, NaCl for 24 hours at +35 C (per ISO 9227) INPUTS / OUTPUTS 49 Total Max. I/O Digital In Digital In Pulse Analog Current PWM Digital Out Digital Out Count (SWG) (SWB) Input Input Feedback (Source) (Source) (Sink) 1 X 10 X 6 X X 8 X X 8 X X X 16 X X X Note: The ECU-2415 has inputs and outputs that can be confi gured in multiple ways. For more information, consult the ECU-2415 Technical Reference Manual

86 HYDRAFORCE ECU-2415 Machine Controller PIN ASSIGNMENTS Pin Connector 1 Pin Function Type 1 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 2 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 3 Current Measuring Feedback FB 4 Current Measuring Feedback FB 5 Current Measuring Feedback FB 6 Current Measuring Feedback FB 7 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 8 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 9 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 10 Current Measuring Feedback FB 11 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 12 Ground 13 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 14 Current Measuring Feedback FB 15 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 16 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 17 Current Measuring Feedback FB 18 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 19 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 20 Current Measuring Feedback FB 21 Current Measuring Feedback FB 22 Current Measuring Feedback FB 23 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O PIN ASSIGNMENTS Pin Connector 3 Pin Function Type VDC Reference (Ref 300 ma) 2 +5 VDC Reference (Ref 47Ω) 3 Digital Input/ Analog Input, 2.2KΩ to +5VDC Input 4 Digital I/P/ Analog I/P, 82kΩ to GND/ V, 220Ω GND/A Input 5 Digital I/P/ Analog I/P, 82kΩ to GND/ V, 220Ω GND/A Input 6 Digital I/P/ Analog I/P, 82kΩ to GND/ V, 220Ω GND/A Input 7 Digital I/P/ Analog I/P, 82kΩ to GND/ V, 220Ω GND/A Input 8 Digital Input/ Analog Input, 19.5kΩ to GND and +5VDC Input VDC Reference (Ref 300 ma) 10 Ground 11 Ground 12 Ground 13 Ground 14 Digital Input, 2.2KΩ to +5VDC Input 15 Must be left open N/A 16 Digital Input/ Pulse Input, 2.2KΩ to +5VDC Input 17 Digital Input/ Pulse Input, 2.2KΩ to +5VDC Input 18 Digital Input/ Pulse Input, 2.2KΩ to +5VDC Input 19 Digital Input/ Pulse Input, 2.2KΩ to +5VDC Input 20 Digital Input/ Pulse Input, 2.2KΩ to +5VDC Input 21 Digital Input/ Pulse Input, 2.2KΩ to +5VDC Input 22 Digital Input/ Pulse Input, 2.2KΩ to +5VDC Input 23 Digital Input/ Pulse Input, 2.2KΩ to +5VDC Input Pin Connector 2 Pin Function Type 1 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 2 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 3 Current Measuring Feedback FB 4 Current Measuring Feedback FB 5 Current Measuring Feedback FB 6 Current Measuring Feedback FB 7 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 8 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 9 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 10 Current Measuring Feedback FB 11 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 12 Ground 13 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 14 Current Measuring Feedback FB 15 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 16 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 17 Current Measuring Feedback FB 18 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 19 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 20 Current Measuring Feedback FB 21 Current Measuring Feedback FB 22 Current Measuring Feedback FB 23 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O Pin Connector 4 Pin Function Type 1 Power Ground 2 CAN 1 HIGH I/O 3 Power Ground 4 VSUPPLY (+9 to 30 VDC) 5 VSUPPLY (+9 to 30 VDC) 6 CAN 1 LOW I/O 7 CAN 2 HIGH I/O 8 CAN 2 LOW I/O Continued on following page

87 ECU-2415 Machine Controller DIMENSIONS and MOUNTING Mounting on Horizontal Surface: Mounting on Vertical Surface: Mounting Surface ECU-2xxx Mounting Surface 0.24 Dia. 6.2 Mounting Holes 0.38/9.5 The mounting positions shown here will allow water or other potential contaminants to fall away from connectors. Allow 5 in./125 mm clearance from mounting surface for connector installation. For additional mounting information, consult the ECU-2415 Technical Ref. Manual All Dimensions for reference only. Weight: 1.55 lbs./0.7 kg TO ORDER Controller: Model ECU-2415 Part No AmpSeal Connectors: 23-Pin Grey Part No ; 23-Pin Blue Part No Pin Black Part No ; 8-Pin Black Part No AmpSeal Socket/Plug: Sockets Gold (100 pc.) Part No ; Sealing Plugs (100 pc.) Part No Shock Cover Kit (optional): Part No CoDeSys Programming Software: available from 3S Software GmbH USB-CAN Adaptor: Part No , also available from Diagnostic Kit: Part No

88 ECU-2032 Machine Controller DESCRIPTION The ECU-2032 Machine Control is a general-purpose programmable controller designed to withstand the real-world environmental demands of the off-highway mobile market. The ECU-2032 can be used as a stand-alone controller, or for integrating into a CAN network with other devices. Input confi guration can be set for up to 52 inputs consisting of Digital, Pulse, Current Measuring Feedback and Analog inputs. Output confi guration can be set for a total of 20 outputs consisting of up to 8 PWM or 20 digital high-side drivers. All outputs are capable of driving up to 3.0 Amps. Note: Refer to Input/Output table below for pin confi guration capability. Refer to ECU-2032 Technical Reference Manual for specifi c data and ratings of individual inputs and outputs. FEATURES Advanced electronic design for reliability and accuracy. Reliable operation in real-world temperature conditions from -40 to +70 C. Fully-sealed, compact cast-aluminum housing. Inputs and Outputs are protected against shorts. Outputs have diagnostic capability. No external cooling or heat dissipation required. Software developed with CoDeSys. 2.3 Programming Tool. RATINGS POWER REQUIREMENTS: Operating Voltage: 9 to 30 VDC Idle Power Consumption: approximately 1 Watt Operating Current: 10 Amp Max. continuous current, with full external load. Over-Voltage: 34 VDC maximum REFERENCE VOLTAGES: (3) 5 VDC Potentiometer Reference: 10 ma DC (3) 12 VDC Potentiometer Reference: 200 ma DC COMMUNICATION: (2) ISO CAN 2.0B Interfaces: CANopen, J1939, or user-programmable. INTERNALLY REGULATED POWER SUPPLY: (1) 5 VDC: 250 ma maximum PROCESSING and MEMORY: Microprocessor: 16-bit at 40 MHz; Flash ROM: 254 Kbyte SRAM: 256 Kbyte; EEPROM: 6200 bytes ENVIRONMENTAL RATINGS: Operating Temperature: 40 C to+70 C; Storage Temperature: 50 C to +85 C Water Resistance: meets IP67 standards (per IEC ) Humidity Tolerance: Rel. Humidity > 90% from +25 C to +55 C (per IEC Test Db) Radiated Immunity: 20 to 2000 MHz at 30 V/m (per 2005/83/EC Annex IX) Vibration: 3.5Grms random from 10 to 500 Hz (per IEC Test Fh) Shock: 50g peak (per IEC and -29 Tests Ea and Eb) Corrosion: 50 g/l, NaCl for 24 hours at +35 C (per ISO 9227) INPUTS / OUTPUTS 52 Total Max. I/O Digital In Digital In Pulse Analog Current PWM Digital Out Digital Out Count (SWG) (SWB) Input Input Feedback (Source) (Source) (Sink) 1 X X 15 X X 16 X X 8 X X 8 X X X 4 X X Note: The ECU-2032 has inputs and outputs that can be confi gured in multiple ways. For more information, consult the ECU-2032 Technical Reference Manual

89 HYDRAFORCE ECU-2032 Machine Controller PIN ASSIGNMENTS Pin Connector 1 Pin Function Type 1 Analog Input, 10KΩ to +5VDC Input 2 Analog Input, 10KΩ to +5VDC Input 3 Analog Input, 10KΩ to +5VDC Input 4 Analog Input, 10KΩ to +5VDC Input 5 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 6 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 7 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 8 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 9 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 10 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 11 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 12 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 13 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 14 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 15 Ground VDC Reference (ref 200mA) 17 Ground 18 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 19 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 20 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 21 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 22 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 23 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O PIN ASSIGNMENTS Pin Connector 3 Pin Function Type 1 Analog I/P, 0-5VDC, 41kΩ to +2.5VDC Input 2 +5 VDC Regulated Power Supply (Ref 250mA) 3 Digital I/P/ Analog I/P, 0-5VDC or mA to +2.5VDC Input 4 +5 VDC Reference (Ref +47Ω) 5 Digital I/P/ Analog I/P, 0-5VDC or mA to +2.5VDC Input 6 +5 VDC Reference (Ref +47Ω) 7 Digital I/P/ Analog I/P, 0-5VDC or mA to +2.5VDC Input 8 +5 VDC Reference (Ref +47Ω) 9 Ground 10 Digital I/P/ Analog I/P, 0-5VDC or mA to +2.5VDC Input 11 Analog I/P, 0-5VDC, 41kΩ to +2.5VDC Input 12 Analog I/P, 0-5VDC or mA, to +5VDC Input 13 Analog I/P, 0-5VDC or mA, to +5VDC Input 14 Analog I/P, 0-5VDC or mA, to +5VDC Input 15 Must be left open VDC Reference (ref 200mA) 17 Ground (Ref -47Ω) 18 Analog Input, 2.2KΩ to +5VDC Input 19 Ground (Ref -47Ω) 20 Analog Input, 92KΩ to +46VDC Input 21 Ground (Ref -47Ω) 22 Analog Input, 2.2KΩ to +5VDC Input 23 Ground (Ref -47Ω) Pin Connector 2 Pin Function Type 1 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 2 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 3 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 4 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 5 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 6 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 7 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 8 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 9 Ground 10 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 11 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 12 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 13 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 14 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 15 Digital I/P/ Pulse I/P, 10KΩ or 5kHz to Ground Input 16 Digital I/P / Digital O/P (open detect.) I/O 17 Digital I/P / Digital O/P (open detect.) I/O 18 Digital I/P / Digital O/P (open detect.) I/O 19 Digital I/P / Digital O/P (open detect.) I/O 20 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 21 Digital I/P/ PWM O/P/ Digital O/P (open detect.) I/O 22 Ground VDC Reference (ref 200mA) Pin Connector 4 Pin Function Type 1 Power Ground 2 CAN 1 HIGH I/O 3 Power Ground 4 VSUPPLY (+9 to 30 VDC) 5 VSUPPLY (+9 to 30 VDC) 6 CAN 1 LOW I/O 7 CAN 2 HIGH I/O 8 CAN 2 LOW I/O Continued on following page

90 ECU-2032 Machine Controller DIMENSIONS and MOUNTING Mounting on Horizontal Surface: Mounting on Vertical Surface: Mounting Surface ECU-2xxx Mounting Surface 0.24 Dia. 6.2 Mounting Holes 0.38/9.5 The mounting positions shown here will allow water or other potential contaminants to fall away from connectors. Allow 5 in./125 mm clearance from mounting surface for connector installation. For additional mounting information, consult the ECU-2032 Technical Ref. Manual All Dimensions for reference only. Weight: 1.55 lbs./0.7 kg TO ORDER Controller: Model ECU-2032 Part No AmpSeal Connectors: 23-Pin Grey Part No ; 23-Pin Blue Part No Pin Black Part No ; 8-Pin Black Part No AmpSeal Socket/Plug: Sockets Gold (100 pc.) Part No ; Sealing Plugs (100 pc.) Part No Shock Cover Kit (optional): Part No CoDeSys Programming Software: available from 3S Software GmbH USB-CAN Adaptor: Part No , also available from Diagnostic Kit: Part No

91 ECU-2820 Machine Controller DESCRIPTION The ECU-2820 Machine Control is a general-purpose programmable controller designed to withstand the real-world environmental demands of the off-highway mobile market. The ECU-2820 can be used as a stand-alone controller, or for integrating into a CAN network with other devices. Input confi guration can be set for up to 52 inputs consisting of Digital, Pulse, Current Measuring Feedback and Analog inputs. Output confi guration can be set for a total of 28 outputs consisting of up to 24 PWM or digital high-side drivers and up to 4 digital low-side drivers. All outputs are capable of driving up to 3.0 Amps. Note: Refer to Input/Output table below for pin confi guration capability. Refer to ECU-2820 Technical Reference Manual for specifi c data and ratings of individual inputs and outputs. FEATURES Advanced electronic design for reliability and accuracy. Reliable operation in real-world temperature conditions from -40 to +70 C. Fully-sealed, compact cast-aluminum housing. Inputs and Outputs are protected against shorts. Outputs have diagnostic capability. No external cooling or heat dissipation required. Software developed with CoDeSys. 2.3 Programming Tool. RATINGS POWER REQUIREMENTS: Operating Voltage: 9 to 30 VDC Idle Power Consumption: approximately 1 Watt Operating Current: 10 Amp Max. continuous current, with full external load. Over-Voltage: 34 VDC maximum INTERNALLY REGULATED POWER SUPPLY: (1) 5 VDC: 250 ma maximum across both pins (1) 12 VDC: 200 ma maximum across both pins COMMUNICATION: (2) ISO CAN 2.0B Interfaces: CANopen, J1939, or user-programmable. PROCESSING and MEMORY: Microprocessor: 16-bit at 40 MHz; Flash ROM: 254 Kbyte SRAM: 256 Kbyte; EEPROM: 6200 bytes ENVIRONMENTAL RATINGS: Operating Temperature: 40 C to+70 C; Storage Temperature: 50 C to +85 C Water Resistance: meets IP67 standards (per IEC ) Humidity Tolerance: Rel. Humidity > 90% from +25 C to +55 C (per IEC Test Db) Radiated Immunity: 20 to 2000 MHz at 30 V/m (per 2005/83/EC Annex IX) Vibration: 3.5Grms random from 10 to 500 Hz (per IEC Test Fh) Shock: 50g peak (per IEC and -29 Tests Ea and Eb) Corrosion: 50 g/l, NaCl for 24 hours at +35 C (per ISO 9227) INPUTS / OUTPUTS 49 Total Max. I/O Digital In Digital In Pulse Analog Current PWM Digital Out Digital Out Count (SWG) (SWB) Input Input Feedback (Source) (Source) (Sink) 4 X 4 X 24 X X X 8 X X 4 X X 8 X X Note: The ECU-2820 has inputs and outputs that can be confi gured in multiple ways. For more information, consult the ECU-2820 Technical Reference Manual

92 HYDRAFORCE ECU-2820 Machine Controller PIN ASSIGNMENTS Pin Connector 1 Pin Function Type 1 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 2 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 3 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 4 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 5 Current Measuring Feedback FB 6 Current Measuring Feedback FB 7 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 8 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 9 Ground 10 Ground 11 Ground 12 Analog Input, 2.2KΩ to +5VDC or 220Ω to 22.7mA Input 13 Auxiliary VSUPPLY (3A max) for External Devices 14 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 15 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 16 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 17 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 18 Digital Input/ Digital Output (open detect.) I/O 19 Digital Input, 10KΩ to Ground Input 20 Digital Input, 10KΩ to Ground Input 21 Digital Input/ Digital Output (open detect.) I/O 22 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 23 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O PIN ASSIGNMENTS Pin Connector 3 Pin Function Type VDC Regulated Power Supply (max 200mA) 2 +5 VDC Regulated Power Supply (max 250mA) 3 Ground 4 Ground 5 Digital I/P/ Analog I/P, 82KΩ to GND/V, 220Ω to GND/A Input 6 Digital I/P/ Analog I/P, 82KΩ to GND/V, 220Ω to GND/A Input 7 Digital I/P/ Analog I/P, 82KΩ to GND/V, 220Ω to GND/A Input 8 Digital I/P/ Analog I/P, 82KΩ to GND/V, 220Ω to GND/A Input VDC Regulated Power Supply (max 200mA) VDC Regulated Power Supply (max 200mA) 11 Ground 12 Ground 13 Digital I/P/ Analog I/P, 82KΩ to GND/V, 220Ω to GND/A Input 14 Digital I/P/ Analog I/P, 82KΩ to GND/V, 220Ω to GND/A Input 15 Must be left open 16 Digital Input/ Pulse Input, 10KΩ or 5kHz to Ground Input 17 Digital Input/ Pulse Input, 10KΩ or 5kHz to Ground Input 18 Digital Input/ Pulse Input, 10KΩ or 5kHz to Ground Input 19 Digital Input/ Pulse Input, 10KΩ or 5kHz to Ground Input 20 Digital Input/ Pulse Input, 10KΩ or 5kHz to Ground Input 21 Digital Input/ Pulse Input, 10KΩ or 5kHz to Ground Input 22 Digital Input/ Pulse Input, 10KΩ or 5kHz to Ground Input 23 Digital Input/ Pulse Input, 10KΩ or 5kHz to Ground Input Pin Connector 2 Pin Function Type 1 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 2 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 3 Current Measuring Feedback FB 4 Current Measuring Feedback FB 5 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 6 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 7 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 8 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 9 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 10 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 11 Back-up VSUPPLY (+9 to 30 VDC) for CPU 12 Analog Input, 2.2KΩ to +5VDC or 220Ω to 22.7mA Input 13 Ground 14 Ground 15 Ground 16 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 17 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 18 Digital Input/ Digital Output (open detect.) I/O 19 Digital Input, 10KΩ to Ground Input 20 Digital Input, 10KΩ to Ground Input 21 Digital Input/ Digital Output (open detect.) I/O 22 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O 23 Digital I/P/ PWM O/P/ Digital O/P (no open detect.) I/O Pin Connector 4 Pin Function Type 1 Power Ground 2 CAN 1 HIGH I/O 3 Power Ground 4 VSUPPLY (+9 to 30 VDC) 5 VSUPPLY (+9 to 30 VDC) 6 CAN 1 LOW I/O 7 CAN 2 HIGH I/O 8 CAN 2 LOW I/O Continued on following page

93 ECU-2820 Machine Controller DIMENSIONS and MOUNTING Mounting on Horizontal Surface: Mounting on Vertical Surface: Mounting Surface ECU-2xxx Mounting Surface 0.24 Dia. 6.2 Mounting Holes 0.38/9.5 The mounting positions shown here will allow water or other potential contaminants to fall away from connectors. Allow 5 in./125 mm clearance from mounting surface for connector installation. For additional mounting information, consult the ECU-2820 Technical Ref. Manual All Dimensions for reference only. Weight: 1.55 lbs./0.7 kg TO ORDER Controller: Model ECU-2820 Part No AmpSeal Connectors: 23-Pin Grey Part No ; 23-Pin Blue Part No Pin Black Part No ; 8-Pin Black Part No AmpSeal Socket/Plug: Sockets Gold (100 pc.) Part No ; Sealing Plugs (100 pc.) Part No Shock Cover Kit (optional): Part No CoDeSys Programming Software: available from 3S Software GmbH USB-CAN Adaptor: Part No , also available from Diagnostic Kit: Part No

94 Electronic Control Units Technical Reference Technical Reference Information for Controller Models ECU-ML and ECU-MM PRODUCT OVERVIEW INPUTS/OUTPUTS User Liability and Safety OEM Responsibility Full responsibility for the safe and effective functioning of the equipment into which HydraForce electronic controls are installed is assumed by the OEM of the equipment. HydraForce assumes no responsibility for application performance, or for the consequences of improper application or equipment malfunction. An emergency stop function should be included on all safetycritical systems to switch off the main power supply for the output signals of the machine s electronic control system. The main supply voltage should be designed to switch off immediately when unsafe conditions are encountered. A manual emergency stop switch should be clearly visible and easily accessed by the machine or vehicle operator. Absolute Maximum Ratings Operating Temperature: 40 C to 85 C Storage Temperature: 50 C to 125 C Supply Voltage: 9 to 32 VDC Output Load Current per Channel: Up to 2 Amps Total Output Current: Varies by specifi c model CAN (Controller Area Networks) Ports All HydraForce machine controllers have CAN ports that conform to CAN 2.0b specifi cations, including CAN shield. Module Supply Voltage / Maximum Current Rating HydraForce machine controllers are designed to operate with a 9 to 32 VDC power supply, and are protected against reverse polarity. The voltage is internally monitored for Low/High Voltage and Load Dump. See individual product pages for maximum current ratings for specifi c models. Input/Output Types and Specifications HydraForce machine controllers include input and output pins for multiple I/O functions that are software-confi gurable by the OEM or the machine user. See individual product pages for details about each model s features and functions. Inputs General The controllers input pins support one or more of the following input types: Digital in: Switch to Ground and Battery Analog in: Voltage and Resistive Frequency in: Speed and PWM Communication General Model Dependent: CAN2.0 Key Switch Input The key switch input allows the power to be turned On or Off manually. After the power is applied, the software will have control of all the inputs and outputs. The software can also disable the function of the key switch input. Provide a method of resetting the entire ECU. Provide software option for key switch override. Allows low battery drain (10 ma) when ECU is asleep. Internal pull-down resistor is available for an external signal to turn off the key switch input. Input is protected from ESD and EMI. Key switch status is monitored by software. Inputs Digital Input voltage below minimum results in a non-damaging, non-latching reading saturated to the low limit. Input voltage above maximum results in a non-damaging, non-latching reading saturated to the high limit. Switch-to-Ground Features Switch-to-ground inputs are normally pulled high to +13 VDC through 2KΩ resistor when they are fl oating. Inputs are protected from ESD, EMI and short to +Battery faults. Fast response times. Specifications for Switch-to-Ground Inputs: Short ckt current: 10 ma DC maximum Maximum Resistance for On: 50Ω to Ground Minimum Resistance for Off: 4KΩ to Ground Non-Damaging Voltage Range: 0 to 32 VDC continuous Switch to +Battery Features Switch to battery inputs will detect a signal of +Batt 2V through a series resistance of 50Ω. Inputs have an internal pull-down resistor All inputs are protected from ESD, EMI, transients and short-to-ground faults. Specifications for Switch to +Battery Inputs: Activation Resistance: 50Ω maximum to +Batt De-Activation Resistance: 4KΩ minimum to +Batt Non-Damaging Voltage Range: 32 to +32 VDC continuous Note: for Controller Model ECU-MS, see pages

95 Electronic Control Units Technical Reference INPUTS/OUTPUTS (cont d.) HYDRAFORCE Technical Reference Information for Controller Models ECU-ML and ECU-MM Inputs Analog Voltage Input can measure voltage of analog sensors and can also serve as a current source with an internal 22KΩ pull-up resistor to +13 VDC. Input-open reads as 13 VDC; input short reads as 0 VDC. Protection for Short to +Batt and ground as well as ESD and EMI, provided internally. Specifications for Analog Inputs: Input Voltage: 0 to 5 VDC Input Accuracy: 2% Full Scale Pull-Up Resistance: 22KΩ to +13 VDC Analog to Digital Resolution: 5mV Sampling Rate: 2 msec. Inputs Analog Resistive (Temperature) Resistive or analog sensor input. Internal protection for short-to-battery or ground. ESD and EMI protected. Specifications for Resistive Sensor (Temperature) Inputs: Working Range: 0 to 5 VDC Pull-Up Resistance: 499Ω to +5 VDC Analog to Digital Resolution: 5mV Accuracy: ±50mV Inputs Frequency (Timing) Frequency inputs can be logic-level pulse pickup units (Hall Effect), Variable Reluctance (VR), PWM duty-cycle or frequency-encoded sensors, or switch-to-ground. Features for Variable Reluctance: Inputs are individually software-confi gurable as Passive (balanced) or Active (unbalanced) sensors. Adjacent input channels can be paired up as differential or single-ended to provide direction decoding. Diagnostic functions available through software confi guration are maximum frequency and maximum period faults. Direction and fault counter diagnostics are also available. Specifications for Variable Reluctance: Input Impedence: 20KΩ ±10% input to input. Input Measurable Limits: 0.5V to 120V p-p Frequency Range: 0.1 to 10 KHz programmable Frequency Accuracy: ±1% of actual Non-Damaging Voltage Range: 0.7 to 32 VDC Note: When using these inputs, best results will be obtained when a sensor is connected to the ECU with twisted shielded pair to reduce noise. The shield is then grounded to the Battery pin on the ECU. PWM Inputs: These inputs allow an interface to active PWM and speed sensors. The inputs can be confi gured to measure both duty cycle and frequency. Specifications for PWM Inputs: Input Low Threshold: <1.0 VDC Input High Threshold: >4.0 VDC Input Pull Up Resistance: 2 kω to +5 VDC Frequency Range: 0.6 Hz to 10 KHz Frequency Accuracy: ±1% for 0.6 Hz to 4 KHz; ±2% for 4 KHz to 10 KHz Timing Resolution: 1 µsec. Duty Cycle Range: 3% to 97% Duty Cycle Accuracy: ±1% Non-Damaging Voltage Range: 0.7 to 32 VDC Alternator Input: This input monitors the alternator frequency and voltage for proper operation. This can also be used for measuring engine speed. Frequency Range: 3 Hz to 10 KHz Accuracy and Resolution: 2% of input Voltage Range: 0.5 to 100 Vpeak Outputs General HydraForce machine controllers include factory-programmable output circuits confi gured via software. The controllers output pins support one or more of the following output types: Digital out: 2 Amp Sourcing, 300 milliamp Sinking PWM: 1-Wire and 2-Wire 2 Amp Drivers Outputs Digital 2 Amp Sourcing Driver Protection Driver: Outputs will survive shorts to +Bat, Bat through any impedance with no degradation in performance. If commanded ON, driver remains ON during 80V jump start and load dump unless current limit is exceeded during these events, in which case the driver is disabled and a short-toground diagnostic is reported. If driver protection feature disables driver during these events, the driver is allowed to retry within 10 ms. Protection Load: If commanded ON, driver remains ON during 80V jump start and load dump unless current limit is exceeded during these events. If commanded OFF, driver will not source more then 100 µa during 80V jump start and load dump. Diagnostics: Output fault detection reports short to battery or ground, as well as open circuits whether drivers are in ON or OFF state. Note: for Controller Model ECU-MS, see pages

96 Electronic Control Units Technical Reference Technical Reference Information for Controller Models ECU-ML and ECU-MM INPUTS/OUTPUTS (cont d) / RATINGS Specifications for 2 Amp Sourcing Driver: Output Voltage: +Battery 2.0 VDC minimum at rated current. Output Current: 2 Amps maximum. Leakage Current: 350 µa maximum. Idle Current: Less than 10 ma. Turn-On Time: Less than 1 ms from command to 90% of maximum output or voltage into resistive load at rated current. Maximum Switching Frequency for HydraForce Solenoids: Timing Resolution and Latency: Less than 1.25 ms. Return Connection: Separate return is NOT required for each driver. A total of two specifi c returns are assigned to all ON/OFF drivers. Spreading drivers evenly between the two return lines is recommended. System Reset Status: Drivers turn off during a system Reset. Specifications for 300 ma Sinking Outputs: Load Supply Voltage: 32 VDC maximum. Load Current: 300 ma (current limited at 400 ma). Leakage Current: 0.5 ma with Driver Off. Transition Time: 20 µsec. maximum. Maximum Switching Frequency for Non-Inductive Loads: Typical Loads: Lamps, LEDs > 0.50 ma, relays with maximum fl yback energy of 12 mj Outputs PWM Programmable control range of 50mA to 2A sourcing. Full-time diagnostics detect open or short to battery or ground; diagnostic limits for resistive, open circuit, leakage, or saturated driver faults. Software confi gurable for PWM, On/Off drivers, or Lamp drivers. One wire driver shares a common return with three other drivers. Two wire separate driver and return, both switch to avoid short to battery. Specifications for PWM Outputs: Output Current: Programmable from 0 to 2.0 AmpsDC. Controllable Current Range: 50mA to Imax. Output Current Resolution: 2mA. Output Voltage: +Battery 2.0 VDC minimum at maximum load. Leakage Current: 100 µa maximum at driver off. Switching Frequency: 1 KHz. Dither Period: Programmable 4 ms to 500 ms in 2 ms increments. Dither Amplitude: Programmable, 0 to 250 ma. Current Accuracy: For 50 ma to 80 ma: ±9% > 0 C, ±11% < 0 C For 80 ma to 150 ma: ±6% > 0 C, ±8% < 0 C For 150 ma to 400 ma: ±4% > 0 C, ±5% < 0 C For 400 ma to 2.0 A: ±2% > 0 C, ±3% < 0 C Frequency Response: 30 Hz or better. Sensor Power Supply Ratings Models that support sensor inputs include dedicated, regulated sensor power supplies and ground pins. See individual product pages for sensor power supply ratings. Diagnostics: Software controlled diagnostic functions executed every 15 ms. Short-to-Ground: Supply voltage is <95% of sensor voltage (5, 8 or 10 VDC) for two seconds minimum with ECU having been powered for three seconds minimum at fault detection. Short-to-Battery: Supply voltage is >105% of sensor voltage (5, 8 or 10 VDC) for two seconds minimum with ECU having been powered for three seconds minimum at fault detection. Specifications: Output Voltage: 5 VDC ±0.25 V Output Current: 200 ma minimum Output Short-Circuit Current: 250 ma maximum Specifications: Output Voltage: 8 VDC ±0.4 V Output Current: 400 ma minimum Output Short-Circuit Current: 450 ma maximum Specifications: Output Voltage: 10 VDC +1.0/ 3.0 V Output Current: 3 A minimum Output Short-Circuit Current: 3.5 A maximum General Ratings Reverse Polarity Protection: Controller will withstand reverse polarity at supply voltage up to -16V for 12V nominal systems and up to -32V for 24V nominal systems. Short-Circuit Protection: Inputs and outputs will withstand continuous short-circuit to all other leads including positive and negative terminals. When the short-circuit condition is ended, the controller will return to normal function. Other Voltage Protection: Up to 30V for a 12V system and 80V for a 24V system for 2 minutes. Automotive Electrical Transients Conformance to the Following Standards: ISO 7637; Road Vehicles: Electrical disturbance by conduction and Coupling. SAE J : Immunity to conducted transients on power leads. IEC : Immunity to electrical fast transient/burst IEC : Voltage dips and interruptions Note: for Controller Model ECU-MS, see pages

97 Electronic Control Units Technical Reference RATINGS (cont d) / WIRING GUIDELINES / COMMUNICATIONS EMC/EMI Modules conform to 89/336/EEC Directive ISO for Agricultural and Forestry machinery EMI Emission: Modules conform to the following standards: Near Field Radiated Emissions: 150 KHz to 50 MHz; SAE J : Limits and methods of measurement of radio disturbance characteristics of components and modules for the protection of receivers used on board vehicles. Near Field Radiated Emissions: 30 MHz to 1000 MHz: ISO 13766; Earth-Moving machinery; Electromagnetic compatibility. Far Field Radiated Emissions: 30 MHz to 1000 MHz: CISPR 11: ; Industrial, scientifi c and medical (ISM) radio frequency equipment; Electromagnetic disturbance characteristics; limits and methods of measurement. Conducted Emissions: 150 KHz to 108 MHz: CISPR 25: ; Radio disturbance characterisitcs for the protection of receivers used on board vehicles, boats, and on devices; limits and methods of measurement. EMC Immunity: Conforms to the following standards: SAE J : Electromagnetic compatibility measurement procedure for vehicle components; Part 21: Immunity to electromagnetic fi elds, 10 KHz to 18 GHz, absorber-lined chamber IEC Radiated Immunity 10V/M IEC Surge Immunity (Lightning 2KV) IEC Conducted RF Injection 150 KHz to 230 MHz IEC Power Frequency Magnetic Field 30 Amps/Meter SAE J Electromagnetic compatibility measurement procedure for Vehicle Components; Part 23: Immunity to Electromagnetic Fields, 10 KHz to 200 MHz, Strip Line Method. Electrostatic Discharge: Conforms to the following standards: IEC Electromagnetic Compatibility (ECM); Part 4-2: Testing and Measurement Techniques; Electrostatic Discharge Immunity Test SAE J Electromagnetic Compatibility Measurement Procedure for Vehicle Components; Part 13: Immunity to Electrostatic Discharge Machine Diagnostic Connector HydraForce recommends that a diagnostic connector be installed on machines controlled by HydraForce electronic controllers. The connector should be located to be convenient and readily accessible by the machine operator. Data communication between the controller and a personal computer is accomplished via the machine s CAN network. Teeing into the machine s CAN bus, the diagnostic connector should have the following connections: CAN+, CAN, CANshield, Battery+, Battery. HYDRAFORCE Technical Reference Information for Controller Models ECU-ML and ECU-MM Recommended Machine Wiring Guidelines Wherever possible, avoid running wires in hot areas. Where it is necessary to run wires in especially hot areas, use wire rated to 105 C. In general, wire rated to 85 C should always be used. Plastic or fl exible metal conduit is recommended to help prevent mechanical damage to wires. To help shield wires from EMI/RFI radiation, where possible run the wires next to or inside of metal machine surfaces. 18 AWG wire is recommended. Keep wires supported along their length. Avoid wire harness anchors that hold the wires rigid. Allowing the wires to fl oat is preferable. Use strain relief devices, and grommets for corner protection. Always protect wires from sharp metal parts and corners, and from moving or vibrating parts of the machine. Control wires and high-current-carrying wires should be separated from each other. Run sensor lines separately from digital and switching signals where possible. Twist sensor lines approximately one turn for every 10 mm (0.4 in.). For analog sensors, the ground wire should be connected to the sensor ground pin on the controller. Power to analog sensors should come from the controller s sensor power source. USB/CAN Communicator A USB/CAN connector allows the controller to exchange data with a PC. When connected to a PC, the controller functions as a USB slave; all electrical power is supplied by the PC; no other power source is required. The USB/CAN connector has internal CAN bus terminating resistors which the user can control using the controller s Service and Diagnostic tool. Refer to the controller s software manual for setup information. Refer to the USB/CAN Connector product information sheet for specifi cations and connector pin details. Note: for Controller Model ECU-MS, see pages

98 Electronic Control Units Technical Reference Technical Reference Information for Controller Model ECU-MS PRODUCT OVERVIEW INPUTS/OUTPUTS User Liability and Safety OEM Responsibility Full responsibility for the safe and effective functioning of the equipment into which HydraForce electronic controls are installed is assumed by the OEM of the equipment. HydraForce assumes no responsibility for application performance, or for the consequences of improper application or equipment malfunction. An emergency stop function should be included on all safetycritical systems to switch off the main power supply for the output signals of the machine s electronic control system. The main supply voltage should be designed to switch off immediately when unsafe conditions are encountered. A manual emergency stop switch should be clearly visible and easily accessed by the machine or vehicle operator. Absolute Maximum Ratings Operating Temperature: 40 C to 85 C Storage Temperature: 50 C to 125 C Supply Voltage: 9 to 32 VDC Output Load Current per Channel: Up to 2 Amps Total Output Current: 15 Amps CAN (Controller Area Networks) Ports All HydraForce machine controllers have CAN ports that conform to CAN 2.0b specifi cations, including CAN shield. Module Supply Voltage / Maximum Current Rating HydraForce machine controllers are designed to operate with a 9 to 32 VDC power supply, and are protected against reverse polarity. The voltage is internally monitored for Low/High Voltage and Load Dump. See individual product pages for maximum current ratings for specifi c models. Input/Output Types and Specifications HydraForce machine controllers include input and output pins for multiple I/O functions that are software-confi gurable by the OEM or the machine user. See individual product pages for details about each model s features and functions. Inputs General The controllers input pins support one or more of the following input types: Digital in: Switch to Ground and Battery Analog in: Voltage and Resistive Frequency in: Frequency and PWM Communication General Model Dependent: CAN2.0 Key Switch Input The key switch input allows the power to be turned On or Off manually. After the power is applied, the software will have control of all the inputs and outputs. The software can also disable the function of the key switch input. Provide a method of resetting the entire ECU. Provide software option for key switch override. Allows low battery drain (10 ma) when ECU is asleep. Internal pull-down resistor is available for an external signal to turn off the key switch input. Input is protected from ESD and EMI. Key switch status is monitored by software. Inputs Digital Input voltage below minimum results in a non-damaging, non-latching reading saturated to the low limit. Input voltage above maximum results in a non-damaging, non-latching reading saturated to the high limit. Switch-to-Ground Features Switch-to-ground inputs are normally pulled high to +10 VDC through 2KΩ resistor when they are fl oating. Inputs are protected from ESD, EMI and short to +Battery faults. Fast response times. Specifications for Switch-to-Ground Inputs: Short ckt current: 10 ma DC maximum Maximum Resistance for On: 50Ω to Ground Minimum Resistance for Off: 4KΩ to Ground Non-Damaging Voltage Range: 0 to 32 VDC continuous Switch to +Battery Features Switch to battery inputs will detect a signal of +Batt 2V through a series resistance of 50Ω. Inputs have an internal pull-down resistor All inputs are protected from ESD, EMI, transients and short-to-ground faults. Specifications for Switch to +Battery Inputs: Activation Resistance: 50Ω maximum to +Batt De-Activation Resistance: 4KΩ minimum to +Batt Non-Damaging Voltage Range: 32 to +32 VDC continuous Note: for Controller Models ECU-ML and ECU-MM, see pages

99 Electronic Control Units Technical Reference Technical Reference Information for Controller Model ECU-MS INPUTS/OUTPUTS (cont d.) HYDRAFORCE Inputs Analog Voltage Input can measure voltage of analog sensors and can also serve as a current source with an internal 16KΩ pull-up resistor to +10 VDC. Input-open reads as 10 VDC; input short reads as 0.2 VDC. Protection for Short to +Batt and ground as well as ESD and EMI, provided internally. Specifications for Analog Inputs: Input Voltage: 0.5 to 4.5 VDC Input Accuracy: 2% Full Scale Pull-Up Resistance: 16KΩ to +10 VDC Analog to Digital Resolution: 5mV, 10 bits Sampling Rate: 2 msec. Inputs Analog Resistive (Temperature) Resistive or analog sensor input. Internal protection for short-to-battery or ground. ESD and EMI protected. Specifications for Resistive Sensor (Temperature) Inputs: Working Range: 0 to 5 VDC Pull-Up Resistance: 499Ω to +5 VDC Analog to Digital Resolution: 5mV Accuracy: 2.5% Inputs Frequency (Timing) Frequency inputs can be logic-level pulse pickup units (Hall Effect), Variable Reluctance (VR), PWM duty-cycle or frequency-encoded sensors, or switch-to-ground. Features for Variable Reluctance: Inputs are individually software-confi gurable as Passive (balanced) or Active (unbalanced) sensors. Adjacent input channels can be paired up as differential or single-ended to provide direction decoding. Diagnostic functions available through software confi guration are maximum frequency and maximum period faults. Direction and fault counter diagnostics are also available. Specifications for Variable Reluctance: Input Impedence: 20KΩ ±10% input to input. Input Measurable Limits: 0.55V to 120V p-p Frequency Range: 0.1 to 10 KHz programmable Frequency Accuracy: ±1% of actual Non-Damaging Voltage Range: 0.7 to 32 VDC Note: When using these inputs, best results will be obtained when a sensor is connected to the ECU with twisted shielded pair to reduce noise. The shield is then grounded to the Battery pin on the ECU. PWM Inputs: These inputs allow an interface to active PWM and speed sensors. The inputs can be confi gured to measure both duty cycle and frequency. Specifications for PWM Inputs: Input Low Threshold: <1.0 VDC Input High Threshold: >4.0 VDC Input Pull Up Resistance: 2 kω to +5 VDC Specifications for Frequency Inputs: Frequency Range: 120 Hz to 1500 Hz Frequency Accuracy: ±1% Timing Resolution: 1 µsec. Duty Cycle Range: 3% to 97% Duty Cycle Accuracy: ±0.5% Non-Damaging Voltage Range: 0.7 to 32 VDC Outputs General HydraForce machine controllers include factory-programmable output circuits confi gured via software. The controllers output pins support one or more of the following output types: Digital out: 2 Amp Hi/Lo Driver, Sinking PWM: 2-Wire, 2 Amp Drivers Outputs Digital 2 Amp Low Side Driver Protection Driver: Outputs will survive shorts to +Bat, Bat through any impedance with no degradation in performance. If commanded ON, driver remains ON during 80V jump start and load dump unless current limit is exceeded during these events, in which case the driver is disabled and a short-tobattery diagnostic is reported. If driver protection feature disables driver during these events, the driver is allowed to retry within 10 ms. Diagnostics: Output fault detection reports short to battery or ground, as well as open circuits whether drivers are in ON or OFF state. Specifications for 2 Amp Sinking Outputs: Load Supply Voltage: 32 VDC maximum. Load Current: 2 Amps Leakage Current: 0.5 ma with Driver Off. Transition Time: 100 µsec. maximum. Note: for Controller Models ECU-ML and ECU-MM, see pages

100 Electronic Control Units Technical Reference Technical Reference Information for Controller Model ECU-MS INPUTS/OUTPUTS (cont d) / RATINGS Outputs PWM Hi/Lo Side Programmable control range of 50mA to 2A sourcing. Full-time diagnostics detect open or short to battery or ground; diagnostic limits for resistive, open circuit, leakage, or saturated driver faults. Software confi gurable for PWM, On/Off drivers, or Lamp drivers. One wire driver shares a common return with three other drivers. Two wire separate driver and return, both switch to avoid short to battery. Specifications for PWM Outputs: Output Current: Programmable from 0 to 2.0 Amps DC. Controllable Current Range: 50mA to full scale. Output Current Resolution: 1.5mA. Output Voltage: +Battery 2.8 VDC minimum at maximum load. Leakage Current: 100 µa maximum at driver off. Switching Frequency: 1 KHz. Dither Period: Programmable 4 ms to 500 ms in 2 ms increments. Dither Amplitude: Programmable, 0 to 250 ma. Current Accuracy: ±10%@25 C, ±15% Imax. Frequency Response: 30 Hz or better. Sensor Power Supply Ratings Models that support sensor inputs include dedicated, regulated sensor power supplies and ground pins. See individual product pages for sensor power supply ratings. Diagnostics: Software controlled diagnostic functions executed every 15 ms. Short-to-Ground: Supply voltage is <95% of sensor voltage (5, 8 or 10 VDC) for two seconds minimum with ECU having been powered for three seconds minimum at fault detection. Short-to-Battery: Supply voltage is >105% of sensor voltage (5, 8 or 10 VDC) for two seconds minimum with ECU having been powered for three seconds minimum at fault detection. Specifications: Output Voltage: 5 VDC ±0.25 V, or 8 VDC ±0.4 V Output Current: 330 ma minimum Output Short-Circuit Current: 360 ma maximum General Ratings Reverse Polarity Protection: Controller will withstand reverse polarity at supply voltage up to -16V for 12V nominal systems and up to -32V for 24V nominal systems. Short-Circuit Protection: Inputs and outputs will withstand continuous short-circuit to all other leads including positive and negative terminals. When the short-circuit condition is ended, the controller will return to normal function. Other Voltage Protection: Up to 30V for a 12V system and 80V for a 24V system for 2 minutes. Automotive Electrical Transients Conformance to the Following Standards: ISO 7637; Road Vehicles: Electrical disturbance by conduction and coupling. SAE J : Immunity to conducted transients on power leads. IEC : Immunity to electrical fast transient/burst IEC : Voltage dips and interruptions EMC/EMI Modules conform to 89/336/EEC Directive ISO for Agricultural and Forestry machinery EMI Emission: Modules conform to the following standards: Near Field Radiated Emissions: 150 KHz to 50 MHz; SAE J : Limits and methods of measurement of radio disturbance characteristics of components and modules for the protection of receivers used on board vehicles. Near Field Radiated Emissions: 30 MHz to 1000 MHz: ISO 13766; Earth-Moving machinery; Electromagnetic compatibility. Far Field Radiated Emissions: 30 MHz to 1000 MHz: CISPR 11: ; Industrial, scientifi c and medical (ISM) radio frequency equipment; Electromagnetic disturbance characteristics; limits and methods of measurement. Conducted Emissions: 150 KHz to 108 MHz: CISPR 25: ; Radio disturbance characterisitcs for the protection of receivers used on board vehicles, boats, and on devices; limits and methods of measurement. EMC Immunity: Conforms to the following standards: SAE J : Electromagnetic compatibility measurement procedure for vehicle components; Part 21: Immunity to electromagnetic fi elds, 10 KHz to 18 GHz, absorber-lined chamber IEC Radiated Immunity 10V/M IEC Surge Immunity (Lightning 2KV) IEC Conducted RF Injection 150 KHz to 230 MHz IEC Power Frequency Magnetic Field 30 Amps/Meter SAE J Electromagnetic compatibility measurement procedure for Vehicle Components; Part 23: Immunity to Electromagnetic Fields, 10 KHz to 200 MHz, Strip Line Method. Note: for Controller Models ECU-ML and ECU-MM, see pages

101 Electronic Control Units Technical Reference Technical Reference Information for Controller Model ECU-MS RATINGS (cont d) / WIRING GUIDELINES / COMMUNICATIONS Electrostatic Discharge: Conforms to the following standards: IEC Electromagnetic Compatibility (ECM); Part 4-2: Testing and Measurement Techniques; Electrostatic Discharge Immunity Test SAE J Electromagnetic Compatibility Measurement Procedure for Vehicle Components; Part 13: Immunity to Electrostatic Discharge Machine Diagnostic Connector HydraForce recommends that a diagnostic connector be installed on machines controlled by HydraForce electronic controllers. The connector should be located to be convenient and readily accessible by the machine operator. Data communication between the controller and a personal computer is accomplished via the machine s CAN network. Teeing into the machine s CAN bus, the diagnostic connector should have the following connections: CAN+, CAN, CANshield, Battery+, Battery. Recommended Machine Wiring Guidelines Wherever possible, avoid running wires in hot areas. Where it is necessary to run wires in especially hot areas, use wire rated to 105 C. In general, wire rated to 85 C should always be used. Plastic or fl exible metal conduit is recommended to help prevent mechanical damage to wires. To help shield wires from EMI/RFI radiation, where possible run the wires next to or inside of metal machine surfaces. 18 AWG wire is recommended. Keep wires supported along their length. Avoid wire harness anchors that hold the wires rigid. Allowing the wires to fl oat is preferable. Use strain relief devices, and grommets for corner protection. Always protect wires from sharp metal parts and corners, and from moving or vibrating parts of the machine. Control wires and high-current-carrying wires should be separated from each other. Run sensor lines separately from digital and switching signals where possible. Twist sensor lines approximately one turn for every 10 mm (0.4 in.). For analog sensors, the ground wire should be connected to the sensor ground pin on the controller. Power to analog sensors should come from the controller s sensor power source. HYDRAFORCE USB/CAN Communicator A USB/CAN connector allows the controller to exchange data with a PC. When connected to a PC, the controller functions as a USB slave; all electrical power is supplied by the PC; no other power source is required. The USB/CAN connector has internal CAN bus terminating resistors which the user can control using the controller s Service and Diagnostic tool. Refer to the controller s software manual for setup information. Refer to the USB/CAN Connector product information sheet for specifi cations and connector pin details. Note: for Controller Models ECU-ML and ECU-MM, see pages

102 CAN-Bus Keypads Eight-Key DESCRIPTION These soft-touch keypads are designed to be used with CAN-Bus J1939 network applications. They feature a black silicone overlay with custom legends and key groupings, and are available in an 8-key unit. The confi gurable keys are backlit and there are three amber indicator LEDs, which can be individually addressed via J1939 standards. FEATURES 8 buttons, 2 across x 4 high. Dash-mountable. SAE-J1939 compliant. CAN-Bus controllable LED indicators. Long life tested to 3 million activations. Custom legends and key combinations available (minimum order required, consult factory). Operating temperature: -40C to +85C. RATINGS Electrical and Environmental: Sealing: IP67 CE Rated Power: 8 to 32 2 amps maximum Operating and Storage Temperature: 40 to +85 C (-40 to 185 F) Humidity Tolerance at 115% of nominal voltage: 99% RH at 35 C for 240 hours EMC: 100 V/m using twisted pair J and J Fluid Compatibility: Diesel fuel, oil, unleaded gasoline, ethanol, coolant additive, battery fl uid with 37% sulfuric acid or KCH Vibration Rating: 5.3g random, three-axis; 3.5 sinusoidal Mechanical: Life Cycle: 3 million activations Backlighting: Green LED s, one per key Indicators: Amber LEDs; Qty: 24 for 8-key model; See dimension drawing for locations. Connector: 4-pin Deutsch DT Communications: J1939 CAN 2.0 Part B compliant Material: Silicone-based elastomer; Color: black

103 HYDRAFORCE CAN-Bus Keypads Eight-Key DIMENSIONS & MOUNTING 8 KEYS 2 x 4 Keypad Vertical Configuration Shown Mounting Shaded Areas Cut Out Dia Vent Do not obstruct Dia Dia M6 x 1.0mm Stud Dimensions Shown are for Reference Only INCH MILLIMETRE 4-PIN Deutsch DT Connector CAN_L Power CAN_H Ground TO ORDER CAN-Bus Keypad Model: 8-Key, 2 x4 Vertical Part No Mating Connector Kit for 8-Key Model Part No CAN Keypad User Manual for 8-Key Model Consult Factory

104 Heavy-Duty Pressure Sensors Models ERP345, ERP35 DESCRIPTION High-accuracy heavy-duty pressure sensors with 1% total error band accuracy accomplished by marrying a high performance ASIC to a very stable, fi eld-proven polysilicon, thin-fi lm pressure sensor. These sensors are intended for use in demanding industrial and off-highway equipment. FEATURES Advanced ASIC technology for reliability and accuracy. 1% total error band accuracy within -20 to 85 C temperature range. Long term active stability and repeatability. Broad temperature capability. All-welded pressure construction. Protected against EMI/RFI. IP67 ingress rated. Diagnostic rails. RATINGS PERFORMANCE: Pressure Range: ERP345: 0 to 345 bar (0 to 5000 psi) ERP35: 0 to 35 bar (0 to 500 psi) For alternate pressure ranges, consult factory. Durability: Tested to 50 million cycles Overpressure ERP345 (345 bar model): Proof 150%; Burst 500% Overpressure ERP35 (35 bar model): Proof 200%; Burst 1000% Proof Pressure: up to 10% intermittent duty cycle. Accuracy: ±1% of Span from -20 to 85 C ±1.5% of Span from -40 to -20 C ±1.5% of Span from 85 to 125 C Static Accuracy Class: ±0.25% of span (BFSL Method) including linearity, hysteresis, non-repeatability at reference temperature 21 C/72 F. Response Time: < 1 ms Supply Voltage ERP345: 0 to 5VDC Supply Voltage ERP35: 4.5 to 5.5VDC Supply Current: 3.5mA Ratiometric Output: VDC Reverse Polarity and Miswired Protected INSTALLATION & PHYSICAL SPECIFICATIONS Electrical Connection: Metri-Pack 150 Pressure Port Material: 304 Stainless Steel Sensor Material: 17-4PH SS Housing: 20% Glass Reinforced Nylon Install Torque: 27 Nm (20 ft-lbs) ENVIRONMENTAL RATINGS: Operating and Storage Temperature: 40 C to 125 C Vibration: 20 grms (10 hrs. each axis) Shock: 100gs, 6ms EMI / RFI Protection EN61326 (Heavy Industrial): 30 V/M 500 KHz to 1 GHz Weather Rating: IP67 TO ORDER 0 to 345 bar (5000 psi) Pressure Sensor Model No: ERP-345-RM-IM-06 Part No to 35 bar (500 psi) Pressure Sensor Model No: ERP-35-RM-IM-06 Part No Mating Connector: Metri-Pack 150 HF Part No DIMENSIONS SAE 6 9/16-18 UNF 2A Optional Mating Connector INCH MILLIMETRE Pin Metri-Pack Gnd. +5V Signal Dimensions are for reference only. NOTE: See following page ( ) for important Installation and Technical Reference Information

105 HYDRAFORCE Pressure Sensor Installation and Reference Info. TECHNICAL REFERENCE INFORMATION FOR ERP MODEL PRESSURE SENSORS WARNING- READ BEFORE INSTALLATION User Liability and Safety OEM Responsibility Full responsibility for the safe and effective functioning of the equipment into which HydraForce electronic controls are installed is assumed by the OEM of the equipment. HydraForce assumes no responsibility for application performance, or for the consequences of improper application or equipment malfunction. A failure resulting in injury or damage may be caused by excessive overpressure, excessive vibration or pressure pulsation, excessive instrument temperature, corrosion of the pressure containing parts, or other misuse. Consult HydraForce Inc., Lincolnshire, IL, USA before installing if there are any questions or concerns. 1. Overpressure: Pressure spikes in excess of the rated overpressure capability of the sensor may cause irreversible electrical and/or mechanical damage to the pressure measuring and containing elements. Fluid hammer and surges can destroy any pressure sensor and must always be avoided. A pressure snubber should be installed to eliminate the damaging hammer effects. Fluid hammer occurs when a liquid fl ow is suddenly stopped, as with quick closing solenoid valves. Surges occur when fl ow is suddenly begun, as when a pump is turned on at full power or a valve is quickly opened. Liquid surges are particularly damaging to pressure sensors if the pipe is originally empty. To avoid damaging surges, fl uid lines should remain full (if possible), pumps should be brought up to power slowly, and valves opened slowly. To avoid damage from both fl uid hammer and surges, a surge chamber should be installed. Symptoms of fluid hammer and surge's damaging effects: Pressure sensor exhibits an output at zero pressure (large zero offset). Pressure sensor output remains constant regardless of pressure In severe cases, there will be no output. 2. Freezing: Prohibit freezing of media in pressure port. Unit should be drained (mount in vertical position with electrical termination upward) to prevent possible overpressure damage from frozen media. 3. Static Electrical Charges: Any electrical device may be susceptible to damage when exposed to static electrical charges. To avoid damage to the sensor observe the following: Ground the body of the sensor BEFORE making any electrical connections. When disconnecting, remove the ground LAST! Note: The shield and drain wire in the cable (if supplied) is not connected to the sensor body, and is not a suitable ground. 4. Use in Life Support Devices HydraForce Inc. products are not authorized for use as critical components in life support devices or systems without the express written approval of the HydraForce Engineering Department. As used herein: Life support devices or systems are devices or systems which, (a) are intended for surgical implant into the body, or (b) support or sustain life, and whose failure to perform, when properly used in accordance with instructions for use provided in the labeling, can be reasonably expected to result in a signifi cant injury to the user. A critical component is any component of a life support device or system whose failure to perform can be reasonably expected to cause the failure of the life support device or system, or to affect its safety or effectiveness. DESCRIPTION The Hydraforce Model ERP pressure sensors are high performance instruments intended for use in off-highway and industrial applications where the process media is compatible with the 17-4PH stainless steel sensor material and the 304 SS process connection. Mechanical Installation Guidelines: Environmental The ERP pressure sensors can be stored and used within the temperature limits of 40 C to 125 C (-40 F to 257 F). Ingress protection ratings of the units are IP67 standard, but dependent on the electrical termination specifi ed for special models. Mounting The ERP pressure sensors require no special mounting hardware and can be mounted in any orientation with negligible position error. Although the units can withstand considerable vibration without damage or signifi cant output effects, it is always good practice to mount the sensor where there is minimum vibration. For units with NPT type pressure fi ttings, apply sealing tape or an equivalent sealant to the threads before installing. When installing or removing the unit apply a wrench to the hex wrench fl ats, located above the pressure fi tting. DO NOT tighten by using a pipe wrench on the housing. A 27mm (11 16 ) wrench can be used on the wrench fl ats of the hex. Electro-Magnetic Interference The circuitry of the ERP pressure sensors is designed to minimize the effect of electromagnetic and radio frequency interference. To minimize susceptibility to noise, avoid running the termination wiring in a conduit which contains high current AC power cables. Where possible avoid running the termination wiring near inductive equipment. Field Adjustments The ERP pressure sensors are precisely calibrated and temperature compensated at the factory to ensure long and stable performance. There are no fi eld accessible adjustments on the sensors. Electrical Installation Please refer to the performance ratings on the previous page for power supply requirements and for appropriate wiring protocol based on the particular output signal and electrical termination features of the unit being installed

106 HYDRAFORCE Thermistor Temperature Sensor Model ERT150 DESCRIPTION A thermistor style heavy-duty analog temperature sensor intended for use as a steady state temperature sensor for demanding industrial and off-highway equipment. FEATURES Thermistor technology for low cost and reliability. Rugged design for durability in harsh conditions. Pigtail with connector for installation in tight places. Stainless steel body. RATINGS PERFORMANCE: Sensing Temperature: 40 C to 150 C ( 40 F to 300 F) Output Signal: to ohms Accuracy: ±2 C from 30 to 70 C Sense Current: <10 ma at 25 C Response Time 10% to 90%: <15 sec. Nominal Output at 25 C: 1000 ohms Resistance (Ohms) TEMPERATURE vs. RESISTANCE CHARACTERISTCS TEMPERATURE ( C) Resistance of Thermistor at Key Temperature Points Temp C Resistance (Ohms) INSTALLATION REQUIREMENTS: Electrical Connection: Pigtail with Deutsch DT04-2P Mating Connector: Deutsch DT06-2S Port Size: SAE #6 Torque: 20 ±3 Nm (15 ±2 ft.-lb.) ENVIRONMENTAL RATINGS: Operating Pressure: 10 bar (145 psi) maximum Vibration: 20 grms (20 Hz to 20 KHz) Weather Rating: IP67 O-Ring Material: Fluorocarbon Short Circuit Protection: Short to +Batt may cause failure of the probe Error Handling: Device measuring will sense open or short (>100 ohms or <5 ohms) STEINHART-HART CONSTANTS: A = E-03 B = E-04 C = E-07 DIMENSIONS Best Sensitivity INCH / MILLIMETRE TO ORDER ACROSS FLATS Approx. 9/ Pins, Not Polarity 13.0 Sensitive; either 330 can be connected All Dimensions for reference only. to + or Temperature Sensor Model: ERT150-R-LD-06 Part No Mating Connector Deutsch Model: DT06-2S HF Part No

107 HYDRAFORCE Thermistor Temperature Sensor Model ERT120 DESCRIPTION A thermistor style heavy-duty analog temperature sensor with a padded resistor for improved linearity of the input curve. This steady-state sensor is intended for use in demanding industrial and off-highway equipment applications. FEATURES Thermistor technology for low cost and reliability. Rugged design for durability in harsh conditions. Pigtail with connector for installation in tight places. Stainless steel body. RATINGS PERFORMANCE: Sensing Temperature: 40 C to 150 C ( 40 F to 300 F) Output Signal: to ohms Accuracy: ±2 C from 30 to 70 C Sense Current: <10 ma at 25 C Response Time 10% to 90%: <30 sec. Nominal Output at 25 C: 4.9K ohms Resistance (Ohms) TEMPERATURE vs. RESISTANCE CHARACTERISTCS Temperature ( C) Resistance of Thermistor at Key Temperature Points Temp C Resistance (Ohms) INSTALLATION REQUIREMENTS: Electrical Connection: Pigtail with Deutsch DTM04-2P Mating Connector: Deutsch DTM06-2S Port Size: SAE #6 Torque: 48 ±5 Nm (35 ±3.5 ft.-lb.) ENVIRONMENTAL RATINGS: Operating Pressure: 10 bar (145 psi) maximum Vibration: 20 grms (20 Hz to 20 KHz) Weather Rating: IP67 O-Ring Material: Fluorocarbon Short Circuit Protection: Short to +Batt may cause failure of the probe Error Handling: Will sense open or short (>7K ohms or <400 ohms) DIMENSIONS Probe Dia. TO ORDER /16 18 INCH / MILLIMETRE ACROSS FLATS Polyolefin Shrink over Leads for Strain Relief and Sealing Approx All Dimensions for reference only. Deutsch DTM04-2P 2 Pins, Not Polarity-Sensitive. Connect either to + or Temperature Sensor Model: ERT120-R-LD-06 Part No Mating Connector Kit Deutsch Model: DTM06-2S HF Part No

108 Thermistor Temperature Sensor Model ERT130 DESCRIPTION A thermistor style heavy-duty analog temperature sensor intended for use as a steady state temperature sensor for demanding industrial and off-highway equipment. FEATURES Thermistor technology for low cost and reliability. Rugged design for durability in harsh conditions. Pigtail with connector for installation in tight places. Stainless steel body. RATINGS PERFORMANCE: Sensing Temperature: 40 C to 135 C ( 40 F to 275 F) Output Signal: to 46.6 ohms Accuracy: ±2 C from 30 to 70 C Sense Current: <10 ma at 25 C Response Time 10% to 90%: <15 sec. Nominal Output at 25 C: 1000 ohms Resistance of Thermistor at Key Temperature Points Temp C Resistance (Ohms) INSTALLATION REQUIREMENTS: Electrical Connection: Pigtail with Deutsch DTM04-2P Mating Connector: Deutsch DTM06-2S Port Size: SAE #6 Torque: 43 to 53 Nm (32 to 39 ft.-lb.) ENVIRONMENTAL RATINGS: Operating Pressure: 10 bar (145 psi) maximum Vibration: 20 grms (20 Hz to 20 KHz) Weather Rating: IP67 O-Ring Material: Fluorocarbon Short Circuit Protection: Short to +Batt may cause failure of the probe Error Handling: Device measuring will sense open or short >100K ohms or <5 ohms STEINHART-HART CONSTANTS: A = B = C = DIMENSIONS Probe Dia. 9/ ACROSS FLATS Deutsch DTM04-2P INCH / MILLIMETRE Polyolefin Shrink over Leads for Strain Relief and Sealing Approx All Dimensions for reference only. 2 Pins, Not Polarity-Sensitive. Connect either to + or TO ORDER Temperature Sensor Model: ERT130-R-LD-06 Part No Mating Connector Deutsch Model: DTM06-2S HF Part No

109 Series ELD-01 Heavy-Duty Display Unit Engine Speed Ground Speed **** RPM **** MPH DESCRIPTION The ELD-01 Series display is a monochrome, transfl ective graphical information display capable of displaying real-time operating information through two communication data links. Examples of some of the parameters that can be monitored are: temperature, motor speed, cylinder position, and fl ow. The information can be displayed as multilingual text or in one of several graphical formats. It is designed for use on heavy-duty vehicles and machines operating in adverse conditions. FEATURES Environmentally hardened for harsh heavy-duty off-road environments. Environmentally sealed up to ±5 psi against moisture. Vibration hardened to 9.8 Grms. Fully graphic, 64(h) x 240(w), positive image, transfl ective LCD for excellent visibility in all lighting conditions. Screen viewing area: 2.25 cm x 8.46 cm. White LED back-lighting for long life and sharp contrast. Dimmable via either external dimmer input or display keypad. 4 integral operator input buttons. HydraForce Screen Builder confi guration software available for custom designs. Out-of-Cab capable. RATINGS INPUTS: Keyswitch Input Dimmer Input: PWM COMMUNICATION: CAN SAE J1939 PROCESSING ELEMENTS: Processor: Mot MHz RAM/SRAM: 521 KBytes Flash Memory: 1 MByte EEPROM: 32 KBytes ELECTRICAL: Power Supply: 9 to 32 VDC at 3.0 Amps Maximum PHYSICAL SPECIFICATIONS: Dimensions: 120(w) x 61(h) x 66(d) mm (4.7 x 2.4 x 2.6 in.) Panel Thickness: 4.6 mm (0.18 in.) maximum Mounting: Front Panel Mount with Included Bracket; Panel Cutout: x 54.0 mm (4.44 x 2.13 in.) Optional Gimbal Mounting Bracket CONNECTOR: Deutsch DT06-8S ENVIRONMENTAL RATINGS: Operating Temperature Range: 35 C to 75 C ( 31 F to 167 F) Storage Temperature Range: 50 C to 85 C ( 58 F to 185 F) Vibration: 9.8g, 24 Hz to 2000 Hz Sealing/Protection: Sealed to ±0.35 bar, ±5 psi; IP67/NEMA 13 EMC: 55 V/M

110 HYDRAFORCE Series ELD-01 Heavy-Duty Display Unit DIMENSIONS Pin 1 Pin 8 All Dimensions for Reference Only. INCH MILLIMETRE PINOUT Pin Function 1 Battery 2 Ground 3 Keyswitch 4 PWM Input 5 Not Used 6 Not Used 7 CAN Hi 8 CAN Lo Connector J1939 DIAGNOSTIC SCREENS Built-In Diagnostics with Automatic Interrupt: Engine Messages: Fuel, Filters, Injectors, Coolant, Lubrication, Speed, RPM, Exhaust Transmission & Driveline Messages: Lubrication Electrical System Messages: Voltage, Load, Sensor Voltages Priority Messaging: Note that this display is programmed to present certain J1939 messages immediately when installed, and when sensors trigger a serious fault or imminent failure condition, ie. engine temperature, fuel system failure, et.al. These messages will displace any other active messages displayed at the time. This priority is preprogrammed into the display. For a list of these standard J1939 set messages, consult factory. TO ORDER Backlighting Software Part No. White None* Accessories: *Screen Builder Configuration Software: Part No Gasket: Part No Gimbal Mounting Bracket: Part No Mating Connector: Part No

111 ELD-06 2in. Backlighted LCD w/j1939 Data Link DESCRIPTION A heavy-duty, stand-alone, 2-inch, 2 x 8 character display module that can be connected to an SAE J1939 (CAN) data bus and is sealed to IP65 standards. Displayed data can originate with the vehicle s data bus. Backlighting is green/yellow and there are three status LEDs: green, red and amber. There are three, amber backlighted keys. This display unit is well-suited for use in mobile, heavy-duty and off-highway vehicles and equipment. FEATURES 2 x 8 character, backlighted, liquid crystal display. Addressable Keys and LEDs Three-button backlighted user interface buttons with tactile feel. Three LED warning indicators, hidden when off. Buzzer available for alert and high priority messages. 9 to 60 VDC operation. TO ORDER Model No: Configuration Kit: Part No Gasket: Part No Installation Cable for System Integration: Model M12-5 Cable with Harness Assembly, Part No Mating Connector, DTM04-6S: Part No Video Electronic 100-Style Mount (Industry Standard) RATINGS COMMUNICATION: CAN SAE J1939 ELECTRICAL: Power Supply: 9 to 60 VDC at 200 ma Protection: 24V Reverse Data Bus: SAE J1939 (CAN) Connector: M12, 5-Pin DISPLAY: Type: Positive, Transfl ective, FSTN Aperture: 1.375" W by 0.50" H Viewing Angle: 12:00 Icon Colors: Green, Red and Amber Screen Color: Green/Yellow Key Backlight Color: Amber ENVIRONMENTAL RATINGS: Operating Temperature: 20 C to +70 C Immersion: IP65 MATERIAL: Housing and Bezel: Black polycarbonate ABS Plastic DIMENSIONS DIA DIA DIA INCH 10 MILLIMETRE Recommended Panel Cutout All Dimensions for Reference Only Pin No Function Ground Vcc 9 to 60 VDC CAN Ground CAN_H CAN_L

112 HYDRAFORCE ELD-07 5in. Square LCD Display w/j1939 Data Link DESCRIPTION An all-purpose heavy-duty display unit with a 5-inch-square face. The programmable, graphical display can visualize data on the CAN bus. There are eight switches, a buzzer, LED backlight for the keyboard and a 320 x 240 color LCD display. Data can be exchanged via CAN bus. This display unit is well-suited for use in heavy-duty mobile, industrial and off-highway vehicles and equipment. FEATURES Programmable, graphical, backlighted LCD display. Addressable Keys and LEDs Eight backlighted user interface buttons. 9 to 60 VDC operation. TO ORDER Model No: Configuration Kit: Part No Installation Cable for System Integration: Model M12-5 Cable with Harness Assembly, Part No Mating Connector, DTM04-6S: Part No Video Electronic 100-Style Mount (Industry Standard) RATINGS COMMUNICATION: CAN SAE J1939 ELECTRICAL: Power Supply: 9 to 60 VDC Current Consumption: Less than 24 VDC Flash Memory: 4 MB; SRAM: 256 KB; EEPROM: 64 KB Data Bus: SAE J1939 (CAN) Connector: M12, 5-Pin DISPLAY: Type: Color LCD, 320 x 240 pixels (1/4 VGA) with dimmable backlighting LED: 1 LED Operator keys: Eight, LED illuminated switches ENVIRONMENTAL RATINGS: Operating Temperature: 30 C to +65 C Sealed against Contamination: IP67 MATERIAL: Housing: Aluminum; Bezel and Face: Black polycarbonate ABS Plastic DIMENSIONS Recommended Panel Cutout: Width: 5.945" ±0.008" 151mm ±0.2mm Height: 5.512" ±0.008" 140mm ±0.02mm Corner Radius: 0.04" 1mm INCH MILLIMETRE All Dimensions for Reference Only Pin No Function Ground Vcc 9 to 60 VDC CAN Ground CAN_H CAN_L

113 ELD in. Mono LCD Display w/j1939 Data Link DESCRIPTION A heavy-duty, stand-alone, 5.7-inch, monochrome LCD display module that can be connected to an SAE J1939 (CAN) data bus and is sealed to IP67 standards. Displayed data can originate with the vehicle s data bus. There are four backlit buttons. This display unit is well-suited for use in mobile, heavy-duty and off-highway vehicles and equipment. FEATURES 320 x 240 pixel, transfl ective, liquid crystal display. Four addressable backlit buttons. 9 to 60 VDC operation. TO ORDER Model No: Configuration Kit: Part No Installation Cable for System Integration: Model M12-5 Cable with Harness Assembly, Part No Mating Connector, DTM04-6S: Part No Video Electronic 100-Style Mount (Industry Standard) RATINGS COMMUNICATION: CAN SAE J1939 ELECTRICAL: Power Supply: 9 to 60 VDC; Current Consumption: 24 VDC Protection: 24V Reverse Data Bus: SAE J1939 (CAN) Memory: Program Flash: 256KB; Data Flash: 1MB; EEPROM: 64KB; SRAM: 256KB Connector: M12, 5-Pin DISPLAY: Type: Positive, Transfl ective, FSTN Viewing Angle: 12:00 Backlighting: Four Buttons ENVIRONMENTAL RATINGS: Operating Temperature: 20 C to +65 C Sealed against Contamination: IP67 MATERIAL: Housing and Bezel: Black polycarbonate ABS Plastic front; Aluminum Housing DIMENSIONS Recommended Panel Cutout: Width: 6.85"/174mm Height: 5.71"/145mm Corner Radius: 0.177"/4.5mm INCH MILLIMETRE All Dimensions for Reference Only Pin No Function Ground Vcc 9 to 60 VDC CAN Ground CAN_H CAN_L