MoTeC PDM User Manual
Contents
1. Output o PDM Off ew Fast F Home L 0 Park o The wiper unit can be wired in a simple two switch arrangement one switch for power and the other to select fast or slow The PDM supplies power only Wiper motor braking is performed by the combination of the park switch and the on off switch This arrangement cannot perform intermittent operation since the wiper will not park if the PDM simply removes power The switches must be able to handle the wiper motor current typically 4 ampere 3 Relay Method Relay Control Output ANN Switches PDM swr eS p Output pon ees op F Home Park 0 Switch The two switch method can be modified for intermittent operation by replacing the on off switch with a relay The PDM controls the relay to perform the intermittent function This requires two PDM outputs one to supply power and the other to control the relay Motor braking is performed by the combination of the park switch and the relay switch The PDM must be configured with the appropriate logic to perform on off and intermittent operation based on the state of the control switches 8 Installation Slow operation can be achieved using the switch or using intermittent operation to give a similar effect which avoids the need for a high current switch The fast slow switch and on of2. 13 1 60 Uld 8 JOJ99UUOD Uld JOJ99UUOJ uld 92 JOJ99UUOD uld Z JOJ99UUOD 5 2 Hole 2x To suit M5 or 3 16 Max Washer or Head 10 6 34 Appendices PDM15 and PDM30 Cover power stud with insulating cap R5 5 107 5 15 5 4 Power Connection 5 2 Hole 3x To suit M5 or 3 16 Max Washer or Head 13 Connector MoTeC Appendices 35 Wiring Wire Specification M22759 16 Insulation Material Tefzel Conductor Tin Plated Copper Voltage Rating 600 V Maximum Temperature 150 C Current Rating Current Rating Resistance Resistance at 80 C ambient at 100 C ambient ohm m ohm 1000 ft 22 The current ratings above are an indication only and will not apply in all circumstances The actual maximum current rating is determined by the maximum allowed temperature for the wire 150 C The temperature of the wire is affected by many factors including the temperature of adjacent wires how the wires are bundled and covered the ambient temperature and the current current rating for a single wire in free air Recommended Wire Gauge Output 24 to 20 8 Amp outputs 20 to 16 20 Amp outputs 4 to 2 Battery pos 36 Appendices PC Connection Wiring The PDM connects to the USB port on the PC This requires a CAN connector in the loom for MoTeC s UTC USB to CAN adaptor and USB cable If the PDM does not connect to any other CAN device it can be
3. While every effort is taken to ensure correctness no responsibility will be taken for the consequences of any inaccuracies or omissions in this manual PN 63029 V3 1 August 2009 MoTeC Introduction 1 Introduction The PDMs replace conventional relays fuses and circuit breakers by providing electronically switched power to the various electrical systems in the vehicle including motors lamps ECUs and data systems This simplifies wiring and switch requirements while increasing reliability There are four PDM versions PDM16 PDM32 PDM15 and PDMS0 Throughout this manual all versions will be referred to as the PDM except where details specific to a particular version are discussed Features ME PDM16 PDM32 PDM15 PDM30 8 Amp Outputs 20 Amp Outputs Connectors Autosport Waterproof connectors M6 stud Case size Length Width Height e Each output is over current short circuit and thermal overload protected e Outputs are programmable in 1 A steps e Outputs are controllable via a combination of switch inputs CAN messages and logic functions e Switch inputs are ranging from 0 to 51 V resolution 0 2 V e Performing up to 200 logic operations using operators like Flash Pulse Set Reset Hysteresis Toggle And Or Less than Greater than Not equal to Equal to True False etc e Performing functions such as flashing indicator lights and controlling thermofan and fuel pump e Using logic funct
4. 2 m 7 ft long then a single termination resistor may be used The resistor should be placed at the opposite end of the CAN bus to the CAN connector 38 Appendices CAN Output Messages The PDM transmits the following messages at 20 Hz Note only relevant messages get transmitted Cat Suel Channei Scalng lo 4 7 Compound Id 0 jo o Input1 State Input 2 State Input 3 State Base ld 0 nput 4 State 0 Inactive nput 5 State 1 Active nput 6 State Base ld 0 Base ld 0 7 PDM Internal Oto 125 0 C to 125 C Temperature 1 C steps nput 7 State 0 to 255 0 V to 31 V PDM Battery Voltage 0 1216 V steps 0 0K 3 0 7 Global Error Flag 1 one or more outputs is in Base ld 0 either Fault or Over Current error nput 10 State nput 11 State nput 12 State 0 Inactive nput 13 State 1 Active nput 14 State nput 15 State nput 16 State Compound Id 2 Input 17 State Input 18 State Input 19 State nput 20 State nput 21 State nput 22 State nput 23 State Compound Id 3 0 Inactive 1 Active A A Oh N N N o 3 6 4 6 o 0 2 6 o nput 8 State 4 0 7 Total Current 0 to 255 0 to 255A 1 A steps Compound Id 1 nput 9 State 0 to 255 0 V to 15 68 V 9 5V internal rail 0 0615 V steps voltage Should read close to 9 5 V when the Battery voltage is gt 10 5 V 6 0 7 ResetSource LI MoTeC Appendices 39 Cap Byie BR og Seating ooo Bas
5. V 0 2 V steps Base Id 5 Base ld 5 0 to 255 0 to 51 V 0 2 V steps 0 to 255 0 to 51 V 0 2 V steps Compound ld 3 Input 22 Voltage 0 to 255 0 to 51 V 0 Input 23 Voltage 0 2 V steps 44 Appendices Windows Keyboard Shortcuts When using a laptop in and around a car it is often not practical to use a mouse to navigate through the program Using the keyboard to select options is easier Main Menu File Edit View Online Tools Help MoTecC I A RAC MOLON lt To access the main menu press ALT the key for the underlined letter in the menu followed by the underlined letter of the item in the drop down menu E g ALT F N for File New Alternatively press and release ALT select the desired menu item using the arrow keys press ENTER to activate it Closing a Window Press ENTER for OK or Close only when the OK or Close button has a bold line around it Press ESC to Cancel or Close MoTeC Appendices 45 Selecting an ltem in a Window Setup Channels Channel Name Levels Polarity Active Low v Channel is false when input voltage is above 4 2 a Y for 0 10 as Channel is true when input voltage is below 28 a Y for 0 10 as To access the various items in a window press ALT the key for the underlined letter of the item of interest e g to select Polarity press ALT P Alternatively use the TAB key to move through the dialog box use SHIFT TAB t
6. Xenon HID Lamps Xenon lamps are also used in headlights and are more efficient than Tungsten and Halogen lamps Xenon lamps have a long duration inrush current that peaks at about 4 times the steady state current The inrush current decays over a period of MoTeC Configuration 21 about 10 seconds This puts a high load on the PDM output during start up To avoid Over Current Shutdown during start up it may be necessary to set a higher Maximum Current than normal particularly if the battery voltage is low For example a Xenon lamp with a steady state current of 3 ampere may need a Maximum Current setting of 6 to 8 ampere The wire should also be rated at this current Unlike other lamps Xenon lamps draw more current as the battery voltage decreases At 10 volt the lamp will draw 40 more current than at 14 volt For example a lamp that draws 3 ampere at 14 volt will draw 4 2 ampere at 10 volt This must be allowed for when setting the Maximum Current To ensure that the Maximum Current is set appropriately check that the Output Load value stays safely below 100 during turn on when the battery is at 12 volt not charging Motors Electric motors draw additional current during start up Typically the start up current is 3 to 5 times the steady state current and it dies out in less than a second This start up current is largely ignored by the PDM due to the Output Load filtering The current in a motor increases with incr
7. available in the PDM The number of operations used is shown in the status line Tip A condition can also be configured in the output pin setup In this case the outcome of the logic function will not create a new channel but will be directly connected to the output channel MoTeC Configuration 17 To configure a Condition e Inthe Configuration Tree select Conditions e On the Edit menu click Add e Type a channel name and select settings as required Output Pins All outputs are high side type outputs they switch Batt to the output pin All outputs have hardware thermal overload protection fault logic and over current logic Paralleled Outputs When two or more output pins are connected in parallel they must be configured to use a common channel or an identical condition to activate them Note outputs that are connected in parallel must all be of the same type either all 8 Amp or all 20 Amp outputs Output Protection Over Current Shutdown An Over Current Shutdown occurs when the Output Load exceeds 100 which corresponds to the maximum current setting The Output Load value is filtered so that it normally increases and decreases slowly modelling how the temperature of a wire responds to the current flowing through it The resultant characteristic is very similar to a thermal circuit breaker which is often used in motorsport applications It is also similar to a slow blow fuse See Fuse Characteristics for deta
8. directly wired to the CAN connector If the wiring length is less than 2 m 7 ft the terminating resistor is recommended but not essential CAN Connector PDM Green 191 Gan Lo White 11 CAN HI These wires must be twisted Minimum one twist per 50 mm 2 in 100R Resistor Not essential if the wiring length is less than 2 m 7 ft UTC Connector Type Deltron 716 0 0501 Non latching Neutrik NC5FDL1 Latching CAN Bus Wiring Requirements The CAN bus should consist of a twisted pair trunk with 100R 0 25 watt terminating resistors at each end of the trunk The preferred cable for the trunk is 100R data cable but twisted 22 Tefzel is usually OK The maximum length of the bus is 16 m 50 ft CAN devices Such as MoTeC PDM M800 etc may be connected to the trunk with up to 500 mm 20 in of twisted wire The CAN Connector for the UTC may also be connected to the trunk with up to 500mm 20in of twisted wire and should be within 500mm of one end of the trunk If desired two CAN connectors may be used so that the UTC may be connected to either side of the vehicle Both connectors must be within 500mm of each end of the trunk MoTeC Appendices 37 CAN Connector st Kg 100R Terminating Resistors at each These wires must be twisted end of the CAN Bus Minimum one twist per 50 mm 2 in 500 mm 4 9 lt lt CAN Bus gt gt DEE lt d O CAN Device Short CAN Bus If the CAN Bus is less than
9. off this is clamped and absorbed by the PDM The amount of energy absorbed by the PDM depends on the inductance and current in the solenoid The PDM is capable of absorbing the energy of most normal solenoids in a vehicle MoTeC Installation 9 Two Stage Solenoids Some solenoids have two windings one is used to turn the solenoid on the other is used to hold it on once it has switched This ensures optimum turn on characteristics with minimum holding current The current drawn by the turn on winding may be higher than the current drawn by the holding winding Ensure the Output Load is well clear of 100 during turn on and during holding Starter Solenoids In many cases it is possible to run starter solenoids from a single 20 Amp output even though they typically draw more than 20 ampere possibly as much as 40 ampere The Over Current Shutdown feature allows excess current for a period of time This feature will shut down the output after about 10 to 20 seconds of cranking See the Over Current Shutdown section for details The wire can be rated for 20 ampere also ensuring that the starter motor does not overheat during excess cranking A larger wire gauge might be required if the voltage drop is not acceptable Alternatively two 20 Amp outputs may be paralleled allowing cranking for any period of time Subject to overheating of the starter motor Electronic Devices The PDM can supply power to electronic devices such as en
10. 17 V relative to Batt Maximum inductive load 1 5 J junction temperature 150 C load energy current 20 A 8 Amp Outputs Number of 8 A outputs e E TU 2 e Protection Short circuit and thermal overload lisa MIES ac Inductive load clamp voltage Output 9 0 7 V relative to Batt Other Outputs 42 V relative to Batt 0 3 J junction temperature 150 C load energy current 20 A Inputs Number of inputs PDM16 PDM382 PDM15 PDM30 12 16 16 23 Pull up resistor 10 kilo ohm to Batt Measurement Range of 0 to 51 V resolution 0 2 V 8 bits Calibration High and low trigger voltage high and low trigger times CAN Input Number of messages 4 messages 8 bytes per message CAN Output Message rate 20 Hz 26 Appendices Fuse Characteristics Trip time versus over current multiplier at 10A 100 00 Trip time s 10 00 F xo SS 1 00 E 0 10 1 2 3 4 5 6 7 8 Over current multiplier Trip time multiplier 75 rn a ie E 140 Example For 25 A current where max current setting is 5 A Over current multiplier 25A 5A 5 From Graph Trip time at 10 A is approx 1 second From Table Trip time multiplier at 5 A is approx 80 Trip time at 5 A 1 x 80 0 8 seconds MoTeC Appendices 27 Connectors and Pinout PDM16 26 pin Autosport 1 pin Autosport Mating connector 65040 Mating connector 68093 wire gauge 6 AWG 68094 wire ga
11. 3 19 0 7 Output 10 Voltage 0to255 0to 51 V 0 2 V steps 6 0 7 Output 13 Voltage lo oz Compound Id 2 Output 15 Voltage Base ld 3 Output 16 Voltage Base ld 3 Output 17 Voltage Base ld 3 8 0 7 Output20 Voltage 0 7 Output 24 Voltage 0 to 255 0 to 51 V 0 7 Output 25 Voltage 0 2 V steps 0 0 7 Output 26 Voltage Output 27 Voltage 0 7 Output 28 Voltage oe j 42 Appendices SANTO meint Channel Seating O Base ld 4 Base ld 4 Base Id 4 Base Id 4 o 6 7 Compoundld 0_________________ 9 9 8 Output 1 Status Output 2 Status 207 Joupa Satis A i e e 2 Output Over Current Error 4 Output Fault Error Output 6 Status om 7 Output 7 Status a 7 Output 8 Hz 19 id f Output 10 Status T Oupukon Ee E 2 Output Over Current Error Output 14 Status 14 Output 14 Status 4 Output Fault Error Output 18 Status a z a A 2 Output Over Current Error Output 22 Status 20 Output 22 Status 4 Output Fault Error Output 23 Status Output 24 Status 6 7 Compound Id 3 Ob Output 25 Status 0 7 Output 26 Status 1 Z Output on ia ees SR Status 2 Output Over Current Error 4 Output Fault Error N E cc olomlojo aa SiS 2 Y 2 A S fo SR 2 A 6 0 0 0 1 3 sp ojo Y MoTeC CAN ID Byte Bit Channel Scaling Base ld 5 Appendices 43 0 to 255 0to 51
12. Digital Switch Input 21 Digital Switch Input 22 Digital Switch Input 23 Not Connected Not Connected Not Connected Not Connected O O O0O N N N O O 0 J GC GA AION ch w al gt w N 8 A Output 13 Y 8AOutputso Z 8AOutpt3i Bo Batt 0 0 0 00 w w W w w 00 UY 0 0 0 0 D ZIZI XIS IO Tnm w w u W N lt gt lt MoTeC PDM32 continued Connector C 1 pin Autosport Mating connector 68093 wire gauge 6 AWG 68094 wire gauge 4 AWG Pin Function Connector D 8 pin Autosport Mating connector 68092 Function 20 A Output 1 Pin DB 20A Output 2 DD 20 A Output 3 20 A Output 4 20 A Output 5 D_E 20 A Output 6 D_G D SW 20 A Output 7 H 20 A Output 8 Appendices 29 30 Appendices PDM15 Connector A 34 pin waterproof connector Mating connector 65044 26 pin waterproof connector Mating connector 65045 Pin Function Pin Function A_1 20 A Output 1 with A10 B 1 Not used A 2 8 A Output 9 B2 Not used 20 A Output 2 with A12 B 3 20 A Output 6 with B9 A A 8 A Output 10 B 4 Not used B_6 Not used B 8 Not used b Not used B 12 Not used B 14 Not used B 16 Not used Not used B 19 Not used A_26 Battery Negative B_26 CAN High A_27 Digital Switch Input 1 A_28 OV A_29 Digital Switch Input 3 A 20 Digital Switch Input 5 Connector C Mating eyelet and M6 nut A_34 Digital S
13. MoTeC PDM User Manual Contents Juge Dei deu EE 1 FPL St lb lt ee tl 1 System OVEMVIEW srl isla 2 SENSU NATION id 3 Oe Le le peer cere ce Reet RENT 3 WY IMIG DEE 4 Batten Ee 4 Battery Nod Ves dc 5 CAN WIN Ra 5 die lee ME 5 OUTDUE Le Te arriero 6 TEE codicia 6 Windscreen Re 6 DO ON OMA ari 8 Electronic RE 9 PDM Manager Software Installation nsnnnnnneneeeeee eonenn etne nte renee eeee nene 10 Contigua rio 12 Configuration File tasasen r a ea E aa EAEN 12 n E Il 13 Config ration Re 14 Global Ue 14 el IS 14 CAN ll e 15 CAN OU IDU oie 16 Solaro ue 16 A A A A Aas seus sei Bottke 17 Operatl Merenrea a EE 22 Sending and Retrieving Configuration Files 22 Checking Oper Mini cid nnn reneeere reen 22 Sora NEE cdacete vite ee 23 Firmware Versions and Uodatmg nenene rennene 23 Password Protect bon 23 Standby Mode turis a 23 PDM User Manual PDDCINOICCS EE 24 SPOCMICA ION Sir td 24 FUSE EIER ee 26 Connectors and Pinout alaridos 27 AAA EE 27 Eege 28 PDs EE 30 PDMS A NS 31 Mounting Dimensions seriada ieioi ctas don oir 32 SET URL 32 Oe 33 PDI 1S and POMO nr sia 34 le Le E EE 35 WHEE SPECIES Macnee 35 PC Connection Wiring ii 36 CAN Bus Wiring Requirement cccccccccccccnncnnnanononcnccnonnnncnninanns 36 CAN Output Messages incor 38 Windows Keyboard Shortcuts E 44 EI 48 Copyright 2009 MoTeC Pty Ltd The information in this document is subject to change without notice
14. V pin Each input has an internal 10 kilo ohm pull up resistor to Batt If it is required to connect a switch that is wired to another system in the vehicle ensure that the voltage levels are set appropriately as there may be ground voltage variations between devices Tip If standby current is important wire the switches so that they are normally open during standby This will reduce the standby current Input Switch Connected to Battery When an input is driven from a device that switches to battery the switch should if possible be rearranged so that it switches to 0 V If the signal comes from an electronic device such as an ECU that has an output that can only switch to battery e g a signal that indicates when to turn the fuel pump on this might not be possible In this case an external pull down resistor is required The resistor should be 1500 ohm 0 25 watt and should be connected between the input pin and the 0 V pin The input trigger levels should be set to 4 V and 5 V to guarantee correct triggering for all possible battery voltages 6 Installation Output Wiring All outputs are high side type outputs they switch Batt to the output pin They all have hardware thermal overload protection fault logic and over current logic Paralleled Outputs Two or more output pins can be connected in parallel to increase current capacity Outputs that are connected in parallel must all be of the same type either all 8 Am
15. ch channel can only be generated once but may be used by multiple outputs and conditions Channel Names Each channel has a name to identify it By including a dot between parts of the channel name channels are arranged in a tree structure For example Indicators Left and Indicators Right would appear as Left and Right under a node called Indicators Search FA Indicators DIO Lett DIO Right 0101 CAN Timeout o L Constants Du Global Error H Input Voltages OO Internal DVD Ol Temperature DO Total Current The use of a dot between parts of the channel name is optional The channel list will be a simple flat list rather than a tree structure if it is not used 14 Configuration To rename a channel globally e Right click on the channel name in the Channels window and click Rename This will rename the channel where it is generated as well as in all the places where it is used Configuration Tree The Configuration Tree is used to configure the Global Setup Input Pins CAN Inputs Conditions and Output Pins The input and output pins will be numbered according to the PDM type selected Global Setup The Global Setup in the configuration tree is used to e Enter the PDM type and serial number e Set the base CAN address for incoming CAN communication e Enable outgoing CAN messages and set their base address e Seta Master Retry for all output pins Master Retry The Master Retry feature turns a
16. e ld 1 o 0 7 Compoundld 0____________________ OEO 0 to 255 0 to 127 5 A 0 5 A steps 5 0 7 Output5 Current f CEA 0 7 Output 7 Current Base ld 1 0 7 Compound ld 1 0 to 255 0 to 127 5 A 4 0 7 Output 11 Current___ 0 to 255 0 to 51 A 5 o7 ouput 2 Curen 0 2 A steps Output 13 Current Output 14 Current Base ld 1 Base ld 1 Base ld 1 Compound ld 2 Output 15 Current Output 16 Current Output 17 Current E E 5 0 7_ Output 19 Current O 6 o 7 Output 20 Current 0o 0 7 Compoundld 3 O 2 o 7 4 0 7 Output 25 Current 0 P A seps o Sech 7 0 7 Output 28 Current O 0 7 CompoundId 4 O S S 2 0 7 Output 30 Current 0 to 255 0 to 51 A 0 2 A steps 40 Appendices EOI EOS ECN A o o7 Compoundid 0 SSS EE E E 6 0 7 Output 6Load 7 0 7 Output 7 Load 0 7 Compound ld 1 0 s 6 0 7 Output 13 Load lo 0 7 Compound Id 2 Output 15 Load Base ld 2 Output 16 Load Base Id 2 Output 17 Load Jux 255 0 to 255 Base ld 2 E e 6 0 7 Outputzo Load 0 to 255 0 to 255 1 steps 7 i 0 to 255 0 to 255 1 steps ololo NIN MoTeC Appendices 41 SANTO Byie Bit Channel Sealing o 107 Compoundid 0 SS O Base u a 10 7 Output 3 Voltage 0to255 0to 51 V 0 2 V steps 6 0 7 Output 6 Voltage 7 0 7 Output 7 Voltage 0 7 Compound ld 1 0 Base ld
17. easing load on the motor A motor draws maximum current when it is stalled The Maximum Current setting should take this into account A motor may draw more current as it or the device that it is connected to ages this should be allowed for when setting the Maximum Current Note motor speed control is currently not supported 22 Operation Operation CAUTION The PDM may get very hot do not touch the PDM during operation To perform any of the activities in the Online menu the PC needs to communicate with the PDM When a configuration file is open in PDM Manager it will connect to the PDM with the matching serial number If there is no file open all connected PDMs will be displayed PDM Manager can be connected to a selected PDM Sending and Retrieving Configuration Files e On the Online menu click Send Configuration to send the currently open configuration file to the connected PDM e On the Online menu click Get Configuration to retrieve the current configuration file in the connected PDM Checking Operation Monitor Channels e On the Online menu click Monitor Channels Monitor Channels shows the value of each channel in the original tree structure Monitor PDM e On the Online menu click Monitor POM Monitor PDM shows the input output CAN input condition and PDM status channels in separate screen areas in an easy to view layout Test Outputs e On the Online menu click Test Outputs All outputs
18. er see Operation or transmitted via CAN to be logged Allow for sufficient time for the temperature to stabilise This may take 30 minutes or more If the internal temperature of the PDM exceeds the specified maximum values see Specifications cooling may be achieved by one or more of the following e relocating the PDM to a cooler mounting position e increasing air circulation around the PDM case e ducting cool air over the PDM case e fitting a heatsink to the back surface of the PDM case 4 Installation Wiring Gei ee Starter Isolator Motor Alternator Battery A Battery Input Switches gt E gt Inputs PDM CAN CAN Connector for UTC OV Outputs CAN Bus Ae LA A ECU Data Logger Other D Devices i Motors Lights L Battery Positive Battery positive is supplied to the PDM via the single pin connector to suit wire sizes 16 mm 6 or 25 mm 4 The PDM16 and PDM32 use an Autosport connector PDM15 and PDM30 use a 6 mm eyelet to suit the wire size The wire gauge should be chosen according to the wire temperature limit and acceptable voltage drop Tefzel wire must not exceed 150 C The temperature of the wire is affected by the ambient temperature air circulation current wire gauge the temperature of a
19. essages on any of four sequential CAN IDs The IDs must be within the standard address range The base CAN address is selected in Global Setup in the Configuration Tree The CAN communication rate of the PDM is 1 Mbit sec The communication rate in other devices must be set to the same speed Channels are extracted from the CAN messages by specifying a CAN address and an offset The offset determines which byte in the message is used as the channel value Each CAN generated channel will be set to zero on start up and stay zero until a matching CAN message is received If any of the CAN messages is not received for 1 second the corresponding timeout channel will be set to TRUE During the CAN timeout period the channel value remains at the last received value Tip The timeout channel can be used in a condition 8 Bit Values The PDM can receive 8 bit values which can be used directly or masked with a bit mask 16 Bit Values The PDM may receive 16 bit signed values A divide factor must be specified to reduce the value to fit into the 8 bit result channel which has a range of 0 to 255 unsigned 16 Configuration For example a 16 bit RPM value with resolution of 1 RPM could be divided by 100 to give a value with a resolution of 100 RPM The maximum channel value of 255 will be equivalent to 25500 RPM If the value after division is greater than 255 then the result value will be clamped to 255 The PDM treats the received value a
20. f relay must handle the wiper motor current typically 4 ampere The control switches can be low current types since they only connect to PDM inputs 4 Direct Method i Output 9 ontrol gt S Switches PDM e Input lt F Home L Pe Park Switch The wiper unit can be wired directly to the PDM as long as it is only connected to one output In this method the park switch is wired directly to a PDM input so the park logic must be configured in the PDM This method requires the use of Output 9 which performs motor braking The PDM performs motor braking by momentarily shorting the output to ground when the output turns off The PDM must be configured with the appropriate logic to perform on off and intermittent operation based on the state of the control switches Slow operation can be achieved using a switch between the fast and slow windings as used in the other methods or intermittent operation can be used to wipe less frequently The control switches can be low current types since they only connect to PDM inputs Solenoids The current drawn by a normal single coil solenoid ramps up from zero to its steady state value over a period of time The time taken to do this depends on the inductance and resistance of the solenoid but is normally very short less than 0 1 second This has no affect on the PDM A solenoid will generate a voltage spike when turned
21. gine management systems data acquisition systems radios etc Many electronic devices will have a short inrush current The PDM will largely ignore this due to the Output Load filtering See the Over Current Shutdown section for details The PDM provides reverse battery protection and load dump clamping to protect itself and the connected devices Ignition Systems Inductive Ignition Systems Most inductive ignition systems draw a peak current of about 8 ampere some draw as much as 20 ampere however the average current is much lower In most cases inductive ignition systems can be connected to an 8 Amp output however the Output Load current must be checked to ensure it stays well clear of 100 10 Installation The average current will increase with increasing RPM so the Output Load should be checked at maximum RPM CDI Ignition Systems CDI ignition systems can draw peak currents of as much as 50 ampere It is recommended that all CDI ignition systems are connected to a 20 Amp output The average current will increase with increasing RPM so the Output Load should be checked at maximum RPM Engine Management Systems The current drawn by an engine management system will depend on the type of loads it is connected to and the operating conditions Fuel injectors draw current in pulses The maximum average current drawn by the fuel injectors is when they are at maximum duty cycle For servo devices such as Drive by Wire motor
22. ils The filtering of the load value ensures that the start up current inrush current of motors and lamps does not cause the output to shutdown during this period It also allows for short term overloads to occur without the output shutting down A large over current such as a short circuit will cause the Output Load value to increase rapidly causing the output to shutdown in a short period of time to protect the wire and the PDM output The filtering is set with a time constant of 20 to 50 seconds based on the maximum current setting These values conservatively suit the appropriate wire gauge for the selected current setting and are not adjustable Tips e The Output Load and Output Current values are transmitted via CAN so that they can be logged by another device Check the logged Output 18 Configuration Load value to ensure it is not too close to 100 during normal operation and during start up e The Output Load and Output Current values can also be monitored using PDM Manager See Checking Operation Fault Shutdown A Fault Shutdown occurs when the output voltage is lower than expected This can be caused by a short circuit or thermal overload of the output A short circuit may cause a Fault Shutdown before the Over Current Shutdown occurs Output Settings To configure an Output Pin e Inthe Configuration Tree select Output Pins e Double click the output to setup e Type a channel name and select settings as requ
23. ions to selectively turn off systems during low battery voltage or engine starting reducing drain on the battery 2 Introduction e Providing full diagnostic information including output currents and voltages input voltages and error status e Transmitting diagnostic information via CAN to a display or data logging device or monitoring directly on a PC e Protected against unauthorised access by a password feature Compatibility e All MoTeC Dash Loggers SDL ADL2 ADL3 ACL e Hundred series ECUs M400 M600 M800 M880 Accessories e MoTeC UTC USB to CAN adaptor 61059 Note PDMs are not compatible with MoTeC CAN cable System Overview Battery Battery Input oo CAN bus oo H gt 3 Inputs x pus PDM CAN gt Switches Outputs M M ES LA vv ECU Other Motors Lights Devices MoTeC Installation 3 Installation Mounting When mounting the PDM take into account that the PDM may get very hot during operation Ensure the PDM is mounted in a well ventilated area and not against a hot surface For case dimensions see Mounting Dimensions The internal temperature is highly dependent on ambient temperature and also on the total load current a higher current will cause a higher temperature Tip The internal temperature can be checked in PDM Manag
24. ired Maximum Current This sets the current at which the output will shutdown The output current may exceed this value for a period of time which allows for the start up inrush current of devices such as motors and lamps The maximum current can be set to 10 ampere on the 8 Amp outputs and 25 ampere on the 20 Amp outputs to be clear of the normal running current even for devices that draw the maximum specified current of 8 or 20 ampere Number of Retries and Retry Delay When an Over Current Shutdown or a Fault Shutdown occurs the PDM will attempt to turn the output on again if the Number of Retries is configured The Number of Retries determines how many times an output will attempt to turn on again The Retry Delay determines how long an output remains shutdown before it is turned on again The retry count for an output is reset whenever the condition driving the output changes to FALSE and then to TRUE i e when the condition driving the output turns off then on again Tips e There is a Master Retry feature available in Global Setup MoTeC Configuration 19 e Ensure that the maximum current has been set appropriately by checking that the Output Load value is less than 100 under all operating conditions e The wire used must be capable of carrying the current specified in the maximum current setting See Wire Specification e Set the maximum current well clear of the normal operating current of the device but withi
25. ll outputs that are in error back on If there is still a fault on a particular output this output will go into error again and will go through the normal retry sequence To initiate a Master Retry by pressing a button e Wire a button to a switch input e Use the channel generated by this input as the trigger channel for the Master Retry Input Pins Configuration of an input will create a Status and a Voltage channel Both channels can be used in a condition or to directly control an output They are transmitted via CAN To configure an Input Pin e Inthe Configuration Tree select Input Pins e Double click the input to setup e Type a channel name and select settings as required MoTeC Configuration 15 The trigger voltages are fully programmable The recommended trigger voltages are approximately 3 5 V for the low threshold and 4 2 V for the high threshold The high threshold should be set below 6 V to ensure detection of a high level signal when the battery voltage is low To avoid switch bounce and or to delay recognition when the switch changes state the inputs also have programmable trigger times A trigger time of 0 1 second will normally reject switch bounce Channel Name CAN Output InputName Input Status Yes 0 Off 1 On InputName Voltage Voltage on the input Yes Resolution 0 2 V CAN Inputs The PDM can receive CAN messages allowing the outputs to be controlled by other devices The PDM receives CAN m
26. may be manually turned on and off in PDM Manager to check the current levels To be able to test an output it must first be configured in PDM Manager MoTeC Operation 23 Serial Number e Onthe Online menu click Show Serial Number A configuration file can only be sent to the PDM with the matching serial number This allows multiple PDMs to be used without special device configuration requirements and also ensures that each PDM has the correct configuration file Firmware Versions and Updating e On the Online menu click Update Firmware The software inside the PDM firmware can be updated by the user at any time to take advantage of the latest features Matching Versions The firmware version must match the version of the PDM Manager software on the PC in order to communicate PDM Manager will show a warning if the versions do not match Tip To check the version of PDM Manager software click About MoTeC PDM Manager on the Help menu To check the firmware version in the PDM click Show Serial Number on the Online menu Matching Configuration File Configuration files created with new software including new features can not be used with older version of the software lf required create backup files before updating Password Protection e Onthe Online menu click Set Password The password will prevent unauthorised retrieving and sending of configuration files It is not possible to update firmware if the PDM is pass
27. n the current rating of the wire Use a larger wire to achieve this if necessary For example for a device that draws no more than 5 ampere except at start up use a wire that is rated at 8 ampere and set the maximum current to 8 ampere to give a clear margin e Consider the voltage drop of the wire when selecting the wire size Sometimes this dictates that a larger wire gauge is needed than the current rating would suggest e Setting the current close to the normal current of the device to try and protect the device is unlikely to be effective and could result in an inadvertent shutdown The purpose of the maximum current setting is to protect the wire from overheating not to protect the connected device e Some devices draw more current under circumstances such as high or low battery voltage Also a motor will draw increased current when under more load Set a good margin and where possible check the Output Load value under these varying circumstances Configuration of an output will create a number of channels some of which are transmitted via CAN OutputName Status channel is used for output status information on CAN The output should be on for any non zero value Channel Name Description CAN Output OutputName Output Control Status 0 Off 1 On Note the output may be off due to Over current Shutdown or Fault Shutdown OutputName Voltage Voltage on the output Resolution 0 2 V OutputName Current Output Current in amp
28. nt tab pages of a screen To select the next tab press CTRL TAB To select the previous tab press CTRL SHIFT TAB Text Box Channel Name A text box is used to enter a value or text MoTeC Appendices 47 Press ALT the key for the underlined letter or use the TAB key to navigate to the Text Box type in the new value or text Use the BACKSPACE or DELETE to remove unwanted characters Tree Structure Search FA Indicators D Left DIO Right 0001 CAN Timeout o L Constants Du Global Error H Input Voltages OO Internal SE Ol Temperature DO Total Current Cancel A Tree Structure is used to select items from a hierarchical list The UP ARROW key moves the cursor up selects the item above The DOWN ARROW key moves the cursor down selects the item below The RIGHT ARROW key expands expandable branches indicated by a plus sign The LEFT ARROW key collapses collapsible branches indicated by a minus sign 48 Appendices Glossary MoTeC Devices ACL ADL2 ADL3 BR2 BTX CIM CLS DBW4 E816 E888 i2 12 Pro IEX LTC LTCD M2R M4 M400 M48 M600 M800 M800 Plug In M880 MDC MDD MLS PCI cable PDM15 PDM16 Advanced Central Logger Advanced Dash Logger second generation Advanced Dash Logger third generation Beacon Receiver Beacon Transmitter Computer Interface Module Central Logging System Drive By Wire expander Input Output Expander Input Output E
29. ny surrounding wires and the covering sheath See Wire Specification and Connectors and Pinout for details Battery Isolator Switch Battery positive must generally be connected via an isolator switch or relay The isolator must isolate the battery from all devices in the vehicle including the PDM starter motor and alternator The isolator must be rated to handle the starter motor current When the battery is isolated the engine may continue to run due to power supplied by the alternator To avoid this the isolator switch should have a secondary switch that is connected to a shutdown input on the ECU MoTeC Installation 5 If the ECU does not have a shutdown input the switch can be connected to a PDM input The PDM can then turn off power to the ignition system or the ECU which will cause the engine to stop Battery Negative Both of the Batt pins should be wired to battery negative via 20 wire These pins normally only carry the very low operating current however during a load dump they carry the load dump current which may be 50 ampere or higher CAN Wiring The PDM communicates over CAN with other devices connected to the same CAN bus The CAN bus must be wired according to CAN Bus Wiring Requirements The PC also communicates to the PDM via the CAN bus See Connecting the PDM to a PC Input Wiring The PDM Switch Inputs are intended for use with a switch that is directly wired between a PDM input pin and a PDM 0
30. o move backwards The selected control is usually indicated by a dotted line around it or by highlighting the text or item selected within the control Using the Selected Item The method of using the selected item or control depends on the type of control The common controls are detailed below Check Box Enable CAN Outputs A check box is used to tick on or off a particular option Press ALT the key for the underlined letter or use the TAB key to navigate to the Check Box To select press SPACEBAR 46 Appendices Command Button Command buttons are generally used to show another screen or perform a particular function Press ALT the key for the underlined letter or use the TAB key to navigate to the command button To select press ENTER or SPACEBAR Drop down List Box Polarity Active Low el A Drop down list box is used to select from a number of items but only the selected item is shown until a new item needs to be selected Press ALT the key for the underlined letter or use the TAB key to navigate to the Drop down List Box To select the desired item use the arrow keys and press ENTER to close the list Group Box Channel 2 Condition The Group box is used to select an item from a group of options Press ALT the key for the underlined letter or use the TAB key to navigate to the Group box To select use the arrow keys Tabs Setup Channels Tabs are used to select the differe
31. ollow the software installation instructions to update to the new version To update the associated firmware in the device select Update Firmware from the Online menu For more information refer to Operation Connecting the PDM to a PC The PC communicates with the PDM via the CAN bus To connect the PC to the CAN bus a mating connector for MoTeC s UTC USB to CAN adaptor must be wired to the PDM CAN port If there are no other CAN devices connected refer to PC Connection Wiring otherwise refer to CAN Bus Wiring Requirements Note MoTeC s CAN cable cannot be used with the PDM 12 Configuration Configuration The PDM requires various settings to be configured such as the maximum current settings for the outputs and the circumstances in which to turn the outputs on The configuration settings are stored in a configuration file on the PC Changes to the PDM configuration are performed Offline i e without the PC communicating with the PDM The changes are saved in the configuration file on the PC The file must be sent to the PDM before the changes take effect See Operation Configuration File From the File menu the following options are available e New creates a new configuration file e Open selects an existing configuration file Right click the configuration file to Rename Delete Send to a disk etc e Close closes the current configuration file e Save after a new configuration has been defined it sh
32. on protocol Capacitive Discharge Ignition Engine Control Unit Global Positioning System Mass Air Flow Manifold Absolute Pressure Proportional Integral and Derivative gain Pulse Width Modulated Revolutions Per Minute Recommended Standard 232 communication protocol Receive Top Dead Centre Transmit 50 Notes
33. ould be saved with a meaningful name e Save as can be used to create a copy of an existing configuration file by giving it a new name e Check Channels verifies that all channels are correctly generated e Exit exits the program To create a new configuration file e On the File menu click New e Select the PDM type and enter the Serial Number The serial number can be found on the PDM label This will open the Configuration Tree panel and the Channels panel Tips e The most recently used files appear at the bottom of the File menu This is often the easiest way to open an existing file e When changing the PDM type all configured inputs and outputs settings will be transferred to the relevant pin number in the new PDM type e Configuration files can be password protected preventing unauthorised retrieving and sending of configuration files MoTeC Configuration 13 Channels Channels are used to link the various systems within the PDM configuration For example The input pin system generates two channels for each configured input pin Depending on the state of the input pin the input channel value will be zero or one The channel can be selected to directly control a particular output lt can also be used as an input to a Condition This is a complex logic function that combines a number of channels to create a new channel This new channel can then be used to control an output or as an input to another condition Ea
34. p or all 20 Amp outputs Wire Gauges The wire gauge must be chosen to suit the current consumed by the connected device and to ensure that the voltage drop is acceptable On long runs it may be necessary to use a heavier gauge wire to minimise voltage drop The wire gauge must also be compatible with the connector pin using a smaller than recommended wire gauge may result in a poor crimp Suitable wire gauges are 24 to 20 for the 8 Amp outputs and 20 to 16 for the 20 Amp outputs See Wiring for details Output Devices Windscreen Wipers The PDM can drive windscreen wiper motors however the PDM cannot be connected to both the fast and slow motor windings at the same time The voltage generated by the slow winding during fast operation will cause braking of the motor and possible damage to the PDM A wiper unit can be wired in a number of ways The following schematics are shown for common ground wiper units For common positive wiper units the schematics must be adjusted accordingly 1 OEM Controller Method Output PDM eS OEM dl M controller F Home sal ome Control gt gt V o Park Switches gt Switch MoTeC Installation 7 The wiper unit can be wired using an OEM wiper controller with the PDM supplying the power only The OEM controller performs the intermittent and motor braking functions 2 Two Switch Method On
35. s Resolution 0 5 A on Outputs 1 8 Resolution 0 2 A on Outputs 9 32 OutputName Load Output Load Filtered current as a percentage of the maximum current setting 20 Configuration Channel Name Description Resolution 1 OutputName Status 0 Off 1 On Active 2 Over Current Shutdown 4 Fault Shutdown OutputName Status O Output is off Active 1 Output is on OutputName Status 0 OK No OverCurrent 1 Over Current Shutdown OutputName Status 0 OK No Fault 1 Fault Shutdown Fault Indicator When an output fault occurs the PDM sets the value of the Global Error channel to TRUE PDM Global Error A fault indicator light can be connected to any PDM output and configured to turn on when the Global Error channel is TRUE The Global Error channel can also be transmitted via CAN to a display device and used to show an alarm message and activate an alarm light Maximum Current for Typical Output Devices Lamps e Tungsten Lamps Typically used for tail lights indicator lights and general lighting Tungsten lamps draw additional current during turn on Typically this peaks at about 5 times the steady state current and dies out in about 0 1 second The PDM will largely ignore this due to the Output Load filtering e Halogen Lamps Halogen lamps are commonly used in headlights and are more efficient than Tungsten lamps Halogen lamps have similar characteristics to Tungsten lamps e
36. s a signed 16 bit value i e 32768 to 32767 Negative values are clamped to 0 To configure a CAN input e Inthe Configuration Tree select CAN Inputs e On the Edit menu click Add e Type a channel name and select settings as required CAN Output A fixed set of messages can be sent from the PDM via CAN to other devices CAN outputs are enabled via Global Setup Most MoTeC logging devices have CAN communications templates available to receive these messages The CAN communication rate of the PDM is 1 Mbit sec The communication rate in other devices must be set to the same speed as in the PDM The transmitted CAN messages include Output Voltage Output Current Output Load Output Status Input State Internal Temperature Battery Voltage Global Error and Total Current See Fuse Characteristics for details The receiving device can use the messages for diagnostic purposes particularly useful if the values are logged in a logging device to show an alarm on a display or to activate a feature in another device depending on the value of a PDM input switch Conditions A condition is a complex logic function that combines a number of channels to create a new channel The logic operations include AND OR flash and many more The new channel with a value of either TRUE 1 or FALSE 0 can be used to directly control an output or it can be used in another condition Number of Operations There is a total of 200 logic operations
37. s maximum current is drawn when making large transitions Check that the Output Load is clear of 100 under worst case operating conditions i e when the injectors are operating at maximum duty cycle servo devices are making large transitions and any auxiliary loads are drawing maximum current PDM Manager Software Installation The PDM Manager software is used to e Change the PDM configuration e Monitor the PDM operation including the output currents and diagnostics e Test the outputs by manually turning them off and on e Set and unlock security password e Update the firmware PC Requirements PDM Manager runs under Windows XP or Vista operating systems The minimum recommended PC specification is a Pentium 90 with 16 MB RAM and a USB port MoTeC Installation 11 Installing PDM Manager Software e Goto the MoTeC website at www motec com and navigate to downloads software latestreleases PDM Manager software OR Locate PDM Manager software on the MoTeC Resource Disc e Save the selected file in your preferred location for example desktop e When downloading is finished double click on the file and select run e Follow the instructions on the InstallShield Wizard e To start the program after installation click Start gt All Programs gt MoTeC gt PDM Manager Updating PDM Manager Software Software updates are available to give access to the latest features Download the latest software version from the website and f
38. uge 4 AWG Digital Switch Input 5 AW A_X Digital Switch Input 9 E A_a Digital Switch Input 12 Ab Pin Function B1 Batt 8 A Output 10 8 A Output 11 Digital Switch Input 2 8 Pin Autosport Mating Plug Deutsch AS616 08SN Pin Function C_A 20 A Output 1 CB 20 A Output 2 GG 20 A Output 3 C_D 20 A Output 4 CE 20A Outputs C_F 20A Output 6 Ce 20A Output C_H 20 A Output 8 Digital Switch Input 7 28 Appendices PDM32 Connector A 37 pin Autosport Mating connector 68089 Function Digital Switch Input 1 Digital Switch Input 2 Digital Switch Input 3 Connector B 26 pin Autosport Mating connector 65040 Function e 8 A Output 10 8 A Output 11 Digital Switch Input 4 ollow 8 A Output 12 gt P PI Digital Switch Input 5 oV h Ojo ojojojo ojojo lt lt lt lt lt lt lt CAN Low CAN High Digital Switch Input 6 Digital Switch Input 7 Digital Switch Input 8 Digital Switch Input 9 Digital Switch Input 10 Digital Switch Input 11 Digital Switch Input 12 Digital Switch Input 13 Digital Switch Input 14 Digital Switch Input 15 AAA 39 9292 sch sch Leck OO COUN OD OT BR OO DO sch CO N OD Or BR O P oO N al O N rick Po Po Po Po Ppo ES 5 Digital Switch Input 16 Digital Switch Input 17 Digital Switch Input 18 Digital Switch Input 19 Digital Switch Input 20
39. witch Input 10 C 1 Battery MoTeC PDM30 Connector A 34 pin waterproof connector Mating connector 65044 Function 20 A Output 1 with A10 8 A Output 9 20 A Output 2 with A12 8 A Output 13 8 A Output 17 A A A A A A A A A A A A A A A A A A Appendices 31 26 pin waterproof connector Mating connector 65045 3 E g S g w w w w 00 00 09 09 olna A n aa 0 00 U 8 A Output 30 Digital Switch Input 11 Digital Switch Input 4 Digital Switch Input 12 8 A Output 18 oV gt P PD Digital Switch Input 7 8 A Output 19 Digital Switch Input 14 Digital Switch Input 16 8 A Output 20 CAN Low DODO FPO PDO PDO FDO DO Spm Ss fs Ss ft sf tf OO OO NI OD OT BY COP PO SH PA Battery Negative Digital Switch Input 1 OV 9 Digital Switch Input 3 0 Digital Switch Input 5 Digital Switch Input 6 lens se O0O N IN N 00 Digital Switch Input 8 Digital Switch Input 9 Digital Switch Input 10 0 1 2 3 4 5 6 7 9 0 1 2 3 4 5 6 1 SH 3 1 SC 1 7 7 2 2 2 2 e 2 2 0 0 0 0 09 00 UY CAN High M6 stud Mating eyelet and M6 nut Pin Function Appendices 32 Mounting Dimensions PDM16 60 Uld 8 JOJ939UUO7 uld Joyo9uu0y uld 97 Joyo uu0y 5 2 Hole 2x To suit M5 or 3 16 Max Washer or Head 10 6 33 Appendices MoTeC PDM32 28
40. word protected Standby Mode The PDM enters a low current Standby Mode when all outputs are off and there is no CAN activity The PDM exits Standby Mode when the state of any input changes or CAN activity resumes 24 Appendices Appendices Specifications General Battery voltage 30 V max 6 5 V min 5 mA typical standby Total output current EE Reverse battery Protection for PDM and all connected devices protection Load dump transient Protection for PDM protection Also assists in protecting connected devices Operating temperature 110 C max internal 100 C recommended Typical 85 C max ambient for 120 A total load for 110 C internal depending on mounting air circulation and load distribution These specifications apply for a 12 V battery For a 24 V battery reduce specified temperatures by 20 C Weight 330 g 260 g 270g 0 72 lbs 0 89 Ibs 0 57 lbs 0 59 lbs 180 mm 107 mm 107 mm 7 15 4 2 4 2 Width 60 mm 133 mm 133 mm 2 4 5 2 5 2 Height 28 mm 28 mm 39 mm 39 mm Case Machined aluminium Magnesium Environmental Rubber seal on lid and Conformal coating on protection connectors conformal PCB coating on PCB MoTeC Appendices 25 20 Amp Outputs e ieee Maximum output current 20 A continuous 115 A transient typical Over current shutdown Programmable in steps of 1 A Protection Short circuit and thermal overload protection Inductive load clamp voltage
41. xpander MoTeC data analysis software MoTeC data analysis software professional version Ignition Expander Lambda to CAN module Lambda to CAN Dual module ECU dedicated to run 2 rotor engines ECU for engines with up to 4 cylinders or up to 2 rotors ECU for modern engines with up to 4 cylinders or up to 2 rotors ECU for engines with up to 8 cylinders and 2 rotors ECU for modern engines with up to 6 cylinders or up to 3 rotors ECU for modern engines with up to 12 cylinders or up to 4 rotors ECU for direct replacement of a factory ECU ECU for modern engines with up to 12 cylinders or up to 4 rotors Mitsubishi Diff Controller Mini Digital Display ECU dedicated to run Chevrolet LS1 and Lexus Toyota V8s PC Interface cable Power Distribution Module with 15 outputs Power Distribution Module with 16 outputs MoTeC PDM30 PDM32 PLM RTC SDC SDL SGA SLM SUU TCM UTC VIM Other Calibration CAN CDI ECU GPS MAF MAP PID PWM RPM RS232 RX TDC TX Appendices 49 Power Distribution Module with 30 outputs Power Distribution Module with 32 outputs Professional Lambda Meter Real Time Clock Subaru Diff Controller Sport Dash Logger Strain Gauge Amplifier Shift Light Module Software Update Unit Traction Control Module USB to CAN adaptor Versatile Input Module The process of converting an electrical value into a physical value e g Volts into kilometres per hour Controller Area Network communicati
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