Series 45 Electronic Torque Limiting Control User Manual
Contents
1. 3 Ld I E wh Y T ie M9 P108779 Pump torque consumption is a function of pump outlet pressure pump displacement and pump mechanical efficiency When pump mechanical efficiency is considered constant the pump torque can be limited when pump displacement is known and pump pressure is controlled As pump displacement increases the pump outlet pressure can be limited using the PRV to result in a constant torque limit 6 11519202 Rev AA March 2015 User Manual S45 ETL Control General Electronic Torque Control Information Pump outlet pressure is equal to the load sense pressure which is limited with the PRV plus the margin pressure setting of the pump Pump Outlet Pressure bar Pump Displacement T em 62 8 Pump Mechanical Ef ficiency 96 LS Signal Line Orifice 545 Electronic Torque Limiting Controls require the use of an LS signal line orifice The LS signal line orifice is used to enhance system stability as well as allow the limiting of torque throughout the full range of pump pressure and flow The standard 0 8 mm orifice is best suited for use in a wide variety of applications Please contact your Danfoss representative for further information on the availability of additional LS signal line orifice sizes Electronic Torque Limiting Control Characteristic The Electronic Torque Limiting control all2. 35 11519202 Rev AA March 2015 User Manual S45 ETL Control Overview Purpose of this Manual Before You Start This manual is intended to be a reference for customers using Danfoss S45 Open Circuit Axial Piston Electronic Torque Limiting ETL pumps in conjunction with the keyed ETL MC012 and PLUS 1 Guide Subsystem Application Block The setup and operation of the PLUS 1 ETL software will be illustrated with 545 ETL pumps by utilizing the ETL PLUS 1 service screens Users setting up an ETL system with both PLUS 1 software and S45 Open Circuit ETL pumps should have a working knowledge of basic hydraulic systems principles and PLUS 1 Service Tools Users should also have access to PLUS 1 and S45 technical literature Literature References Useful technical information on pump displacements controls specifications software and operating condition requirements can be found in the following literature Literature references Literature type Literature title Literature number MC012 112 Technical Information Series 45 Axial Piston Open Circuit 520L0519 Pumps Service Manual Series 45 Frame J Open Circuit 520L0607 Series 45 Frame F Open Circuit 11005158 Series 45 Frame E Open Circuit 520L0606 Parts Manuals Series 45 Frame J 520L0585 Series 45 Frame F 11007197 Series 45 Frame E 520L0584 Repair Instructions Series 45 Frame J Ope
3. 10 5 Ebo HERR escas caras aig aree bua Hace 24 Perform RPM Input Setup 4 Torque Potentiometer Calibration 25 Torgue Potentiometer Calibration Parameters 25 Calibrate Torque 1 1 25 Pressure Sensor SetU iu WYAF 26 Pressure Sensor Setup lt 26 Select 26 Torque Limit Profile Set p tii tese a GW tope eques 27 Torque 28 Establish Torque Limit Profile with Torque 28 29 Adjust Torque Setpoints essent 29 Considerations for Establishing the Torque Limit 30 Additional Setup 31 80051 M 31 11519202 Rev AA gt March 2015 3 User Manual S45 ETL Control Contents Troubleshooting 32 Command Filter Settip a 32 34 Pressure Setpoint Faults tritt rette erecti debeo teet FFCD dd 35 Electrical NYTH
4. File View Design Log Parameter Communication Options Tools Help 14 2901214 4 n e wo a een S 5 8 8 8 8 8 0 Pump Setup Outputs Torque Limit Setpoint 0 53 506 En Speed f Parameter Functions 2413 RPM E f System Overview O F Torque Umit Setpoint 20 008 Pressure Setpoint Torque Potentio b d Torque Limit Profi 100 00 8 P Torque Setpo ba FI CAN Torque Setp Z Command Filter Setup Angle Sensor Calibra P Boost Setup Z RPM Input Setup A Pump Setup Logging Requested 100 Actual 98 Danfoss CG150 CG150 2 0 Channel 0 22 11519202 Rev AA March 2015 User Manual S45 ETL Control ETL Service Tool Setup Pump Setup Parameters Pump Setup Parameters Inputs Max Pump Pressure Defines the maximum desired system pressure created by the pump in bar This must be less than or equal to the Pressure Compensator PC setting This software setting DOES NOT override the pump s factory set mechanical Pressure Compensator setting If the Max Pump Pressure is higher than the PC setting the pump will default to the physical PC pressure of the pump and the ETL system will not function correctly Max Pump Speed Calculates power consumed by the pump Generally the highest engine operation speed of the machine should be used See Series 45 Pumps Technical Information 520
5. 13 Sensor Connector and 12 Microcontroller Pin Assignments Angle Sensor DTM04 4P Connector Pin Assignments Pre compiled 12 Pin ASSiQnMents cssssssecssstscssssecssseseesstecesssecssnseeessseessnseesees 14 Potentiometers Pressure Transducers and the PumpTorqCalc Function Block ss 15 15 Y RIEN NEN FU 15 General PLUS 1 ETL Service Tool Information Systemi 18 Torque Limit Setpoint 18 Torque Limit Setpoint Parameter sccsssssssssessssscssosssssssessnssesssesssrsssessssesssssesssesssenssesssssssssussersssesssesessssssatsneestonseetses 18 ETL Service Tool Setup Angle Sensor Calibration 19 Angle Sensor Calibration Parameters 20 Establish the Minimum Pump Displacement 20 Establish the Maximum Pump Displacement with Engine Off 2 21 Establish the Maximum Pump Displacement with Engine 21 5 SE E 22 Pump Setup Parameters uisu ierrttsatt bein ttt ertet 7 23 Define Pump Displacement seccssscscoassosdversestesceossscsosscasnssccanisconnnsstsnsccansnseectassessbeggsisonegnisassunssendnssseszesceundeeconsgesiosisqnansvenadea 23 RPM 24 RPM
6. C Users vewald 000 Documents 4 Pro Documentation Plus File View Design Log Parameter Commonications Options Tools Help 2 6 618100 x Torque Limit Profile Setup e 9 2 5158119 6 Diagnostic Navigator TETL ServiceTool P1D E8 2 9 Em E Torque Limit Profile Setup Torque Limit Profile Faults Parameter Inputs No Fatt 96 Torque 8 Parameter Functions 3 7 System Overview 3 7 Torque Limit Setpoint P Torque Potentio Torque Unit Profi PH Torque Setpo CAN Torque Setp Command Filter Setup Speed 5 F Angle Sensor Calibra Z Boost Setup Z RPM input Setup 20005 Z Pump Setup F Pressure Sensor Setup Pressure Setpoint Fa P Electrical interface Speed 2 Speed 3 1100 4 RPM Ld Speed 6 5 2300 Speed 7 1400 RPM e 2750 5 Speed 4 1700 5 RPM Logging Requested 100 Actual 99 Danfoss CG150 CG150 2 50 Channel 0 Torque Limit Profile Setup Parameters Torque Limit Profile Setup Parameters Inputs Speed Inputs 1 7 These speed inputs correspond to 7 engine speed points on a torque curve for which torque is to be limited Torque Inputs 1 7 These torque inputs correspond to the 7 engine speed points on a torque curve for which torque is to be limited Faults Parameter inputs Speed N is l
7. m 0 Outputs Torque Limit Setpoint 91 59 Engine Speed 2410 RPM Pressure Setpoint 240 00 bar Control Current 0 7 O logging Danfoss CG150 CG150 2 50 Channel 0 For questions on system stability and tuning with Command Filter time constants consult your Danfoss representative Command Filter Setup Parameters Command Filter Setup Parameters Inputs Low Speed Speed at which Low Speed Decreasing time constant is used for filtering the torque setpoint output High Speed Speed at which High Speed Decreasing time constant is used for filtering the torque setpoint output Low Speed Decreasing Low pass filter time constant to limit decrease in pressure setpoint The actual used filter value is a scaled between High Speed Decreasing and Low Speed Decreasing depending on speed Associated with Low Speed High Speed Decreasing Low pass filter time constant to limit decrease in pressure setpoint The actual used filter value is a scaled between High Speed Decreasing and Low Speed Decreasing depending on speed Associated with High Speed Increasing Low pass filter time constant to limit increase in pressure setpoint Faults Parameter Fault High Speed out of range Low Speed out of range Input Fault Displacement too low high Speed to low high Torque Demand too low high 34 11519202 Rev AA March 2015
8. 0 36 11519202 Rev AA March 2015 User Manual S45 ETL Control 11519202 Rev AA gt March 2015 37 User Manual S45 ETL Control 38 11519202 Rev AA March 2015 User Manual S45 ETL Control 11519202 Rev AA gt March 2015 39 Products we offer Bent Axis Motors Closed Circuit Axial Piston Pumps and Motors e Displays Electrohydraulic Power Steering Electrohydraulics Hydraulic Power Steering Integrated Systems e Joysticks and Control Handles e Microcontrollers and Software e Open Circuit Axial Piston Pumps Orbital Motors e PLUS 1 GUIDE e Proportional Valves Sensors Steering e Transit Mixer Drives Comatrol www comatrol com Schwarzmilller Inverter www schwarzmueller inverter com Turolla www turollaocg com Valmova www valmova com Hydro Gear www hydro gear com Daikin Sauer Danfoss www daikin sauer danfoss com Danfoss Power Solutions US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 D 24539 Neum nster Germany Phone 49 4321 8710 Danfoss Power Solutions is a global manufacturer and supplier of high quality hydraulic and electronic components We specialize in providing state of the art technology and solutions that excel in the harsh operating conditions of the mobile off highway market Building on our extensive applications expertise we work closely with our customers to ensur
9. LS signal line orifice in the S45 pump When this margin shifts too much the valve cannot flow share correctly Danfoss PVG valve groups reduce this problem with compensator valves which remain open at a very low margin pressure This allows more aggressive torque limiting particularly at low engine idle speeds where torque limiting is most critical In addition to using valves with superior low pressure flow sharing characteristics it is possible to use calculations to identify problem areas where margin erosion can become a concern Please contact your Danfoss representative for more information on calculating and planning for margin erosion L1519202 Rev AA March 2015 9 User Manual S45 ETL Control General Angle Sensor Information PLUS 1 Compliance Angle Sensor Principle Angle Sensor Characteristics The Electric Angle Sensor has met and passed the Danfoss PLUS 1 compliance standard testing and as such this Angle Sensor is PLUS 1 compliant PLUS 1 compliance blocks are available on the Danfoss website within the PLUS 1 Guide section The Series 45 Angle Sensor option allows users to measure the angle of pump displacement The angle sensor is an electronic sensor mounted to the housing of the pump which reads the pump stroke angle based on the swashplate position Interfacing with the angle sensor is achieved through a 4 pin Deutsch 4 4 receptacle attached to a flexible connection cable for a ma
10. User Manual S45 ETL Control Troubleshooting Pressure Setpoint Faults The Pressure Setpoint Faults screen is used for troubleshooting Pressure Setpoint Faults Screen PLUS 1 GUIDE Service Too 7 07 C Uzers vewald 000 Document 4 Projects ETL Documentation P View Design Log Parameter Communication Options Tools Help 1 16 5 8 2 6 8 8 enl 5 3 2168628880 1 Pressure Setpoint Faults Faults Navigate Outputs Inputs Torque Limit Setpoint Torque Consumed 0 69 1 81 96 Engine Speed Power Consumed 2410 RPM 1 45 Pressure Setpoint Displacement Torque Umit Setpoint P Torque Potentio Torque Limit Profi 100 00 Torque Seto 240 00 bar CAN Torque Setp Command Filter Setup P Angle Sensor Calibra P Boost Setup Z RPM Input Setup Z Pump Setup P Pressure Sensor Setup A Pressure Setpoint Fa P Electrical Interface Requested 100 Actual 98 Danfoss CG150 CG150 2 0 Channel 0 Electrical Interface The Electrical Interface screen allows you to troubleshoot the electrical interface including the status of the input pins output pins and supply sensor power L1519202 Rev AA March 2015 35 User Manual S45 ETL Control Troubleshooting ETL Electrical Interface Screen Requested 100 Actual 98 Danfoss CG150 CG150 2 0 Channel
11. torque profile will reference a graph of engine torque available vs engine speed from the engine manufacturer However this basic profile may not always be the best profile and such detailed engine information might be difficult to obtain It is important to realize that the user can tune the reactivity of the ETL system by how closely the 7 input points match the actual torque available from the engine Torque values which exactly match the available torque from the engine may yield a system which allows for noticeable engine speed reactions engine bog or droop as torque limiting takes over This generally occurs because the pump s input torque requirements may increase much more rapidly than the engine s torque output However torque values which are set slightly lower than the actual available engine torque provide some margin between the limited torque and the actual torque This combats any reactivity from the engine at all and gives the operator the setup with the lowest potential for noticeable engine speed changes The desired amount of engine reaction is subjective and can vary for different applications You can create a Torque Limit Profile with or without a torque curve A torque curve is highly recommended for best optimization but it is not necessary L1519202 Rev AA March 2015 27 User Manual S45 ETL Control ETL Service Tool Setup Torque Limit Profile Setup Screen 14 PLUS 1 GUIDE Service Tool 7 0 7
12. Di sabled The control current should approximate 0 mA 3 Operate the pump at one or both of the following conditions Condition When to use Low Pressure Standby Use when the machine s main valve block completely shuts off flow to any Condition LPSB downstream components zero flow needed by machine functions valves from pump High Pressure Standby Use when the machine s main valve block does not completely shut off flow to all Condition HPSB downstream components some small flow needed by machine functions valves from pump at all times even with no operator command a If using LPSB let the machine stand at full engine speed without operating any functions This allows the pump to de stroke naturally because no flow is commanded from the pump and system pressures will be only slightly higher than the pump s LS setting b If using HPSB operate a machine function over a hard stop and reach full pressure compensator PC setting with system pressure This allows the pump to de stroke by porting high pressure oil to servo From the Angle Sensor Calibration screen while maintaining either LPSB or HPSB 4 Click Minimum Pump Displacement Capture Voltage Establish the Maximum Pump Displacement with Engine Off 1 Turn off the machine 2 Momentarily jog the starter to turn the pump shaft a few revolutions without actually running the engine This allows the pump s swashplate to return to its naturally spring biased full s
13. E Service Tool 7 07 CAUsers vewald 000 Documents 4 Projects ETL Documentation Plus 1XETL_ServiceTool P10 File View Design Log Parameter Communication Options Tools Help 6 69 2168 0 9 5 9 CO 9 0 RPM Input Setup Diagnostic Navigator L RPM Input Setup New System RPM Faults Outputs E Torque Limit Setpoint 90 93 Angle Sensor Calibration Pulse Pickup Parameter Inputs 6006 En Sue pedd Pulse Pickup Sensor Inputs Parameter Functions system Overview P Torque Umit Setpoint Pressure Setpont Torque Potentio 5 f Torque Limit Profi 200 00 9 E Torque Setpo 240 00 CAN Torque Setp Command Filter Setup P Angle Sensor Calibra Control Current P Boost Setup RPM Im p Z Pump Setup f Pressure Sensor Setup Pressure Setpoint Fa P Electrical interface Logging Requested 100 Actual 99 Danfoss CG150 CG150 2 0 Channel 0 RPM Input Parameters RPM Input Parameters Inputs Speed Input Toggle switches between two different inputs CAN bus and Speed ring pulse pickup Pulse Per Revolution Sets the number of pulses per revolution of the Hall Effect Sensor when Speed Ring is selected C1p09 MFIn Freq Displays the freguency at which the speed ring sensor is sensing pulses Faults Parameter input f
14. F units with the Right angle sensor position Sensor Output Voltage vs Swashplate Angle CW amp CCW J amp F Frames 45 90cc Primary Output Voltage Secondary Output Voltage Sensor Output Volts 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Swashplate Angle Degrees P108817 L1519202 Rev AA gt March 2015 22 User Manual S45 ETL Control General Angle Sensor Information E Frame 100 147cc Angle Sensor Identification Convention The location convention for the E Frame angle sensor is different from that of the J amp F Frame due to a difference in design of the endcap and servo systems When looking at the input shaft the angle sensor will be positioned on the same side as the outlet port of the endcap The outlet port of the endcap is always the smaller of the inlet and outlet ports indicated below This is the right side order code location even though it appears on the left hand side from a frontal view Cly 36 8 9 1 42 36 1 42 Outlet Port 120 4 72 Approximate 594 Wire Length FLL 2 34 131 5 5 18 126 9 5 0 E Frame Angle Sensor Position P108821 Clockwise rotation E frames appear with the control on the top side in this view Co
15. L0519 for allowed pump operating speeds in order to ensure conformance to recommended continuous operation speeds This input does not limit physical pump speed in any way Max Pump Displacement Defines the true maximum displacement of the pump in terms of cm rev and correlates it to the Maximum Captured Voltage Also known as nominal pump displacement it can be determined by the pump s model code LS pressure setting Defines the margin setting of the pump in bar This must be equal to the LS pressure setting as defined from the factory This may be found on the pump s identification tag Threshold current Defines the minimum current required for active torque limiting in the control It is based on the Max Pump PC Pressure LS Pressure Setting and 12 vs 24 volt coil characteristics This is an interpolated value that references control pressure vs current curves Faults Parameter input faults Max Pump Pressure out of range Max Pump Speed out of range Max Pump Displacement out of range Input faults Displacement value too high or low Speed value too high or low Pressure value too high or low Define Pump Displacement From the Pump Setup screen 1 Set Pump Max Pressure to the desired maximum operating pressure The Pump Max Pressure setting must not exceed the Pressure Compensator PC setting of the pump It should be equal to or less than the PC setting or e
16. MAKING MODERN LIVING POSSIBLE User Manual Electronic Torque Limiting Control Series 45 powersolutions danfoss com User Manual S45 ETL Control Revision history Table of revisions Date Changed Rev March 2015 First edition AA 11519202 Rev AA March 2015 User Manual S45 ETL Control Contents Overview this Mantal inire ter the petiit vr RUE Ue IR e Y RN FERNER 5 Before You Start 5 Literature 5 General Electronic Torque Control Information RU Ip 6 e ai 6 5 6 LS Signal Line Orifi Cesas 7 Electronic Torque Limiting Control Characteristic csssssssssssssssssseccsscsssseesssnsccsssecssssssesssecsssussecsneceesueesssneecsseessnneessaseees 7 System Considerations when Implementing ETL Electronic Torque Limiting and Load 9 9 General Angle Sensor Information PLUS TC Onn pia Ces ee 10 Angle Sensor e sass WC FF DU UF FN FF UU 10 10 J F Frame 45 90cc Angle Sensor Identification 11 E Frame 100 147cc Angle Sensor Identification Convention 12 Angle Sensor Electrical
17. Minimum Maximum displacement not calibrated Invalid setup calibration Parameter out of range Sensor Input Faults Signal 1 input too low high Signal 1 input at Sensor Power Ground Redundant signal indicates error Establish the Minimum Pump Displacement To establish the minimum displacement of the pump you must operate the pump at either the Low Pressure Standby Condition LPSB or the High Pressure Standby Condition HPSB For the best results calibrate and compare using both LPSB and HPSB to achieve the lowest or highest for CW E frame units captured voltages 20 11519202 Rev AA March 2015 Dont User Manual S45 ETL Control ETL Service Tool Setup It is important to compare the minimum displacement voltage readings at both LPSB and HPSB Generally the swashplate angle is lower at LPSB because there are lower leakages at lower pressures so lower displacements are required to make up the leakages This is not true when some flow is allowed past the main valve block at LPSB Then HPSB conditions become preferred Although the leakages are higher at higher pressures the increase in flow due to leakages is lower than the flow allowed by the main valve 1 Set the engine at full operating speed The engine must be operated at full speed to prevent an inaccurate displacement reading 2 If the ETL is not disabled in the System Overview screen toggle ETL Control to
18. Projects File View Design Log Parameter Communication Options Tools Help 6 2 6 6 40 e 9 5 5 2 3 13 GS O 8 88 0 Boost Setup Status Outputs Navigate Torque Limit Setpoint Torque Consumed xxm aan Toad 90 99 1 74 96 Torque Limit Setpoint Engne Speed Power Consumed 2410 RPM 1 40 Vv e e Torque Umit Setpoint Pressure Setpoint Displacement Torque Potentio 3 Torque Limit Profi 100 00 786 Torque Setpo IET 40 00 CAN Torque Setp lt 2 Command Filter Setup P Angle Sensor Calibra ff Boost Setup RPM Input Setup Z Pump Setup F Pressure Sensor Setup Pressure Setpoint Fa rA Electrical Interface Logging Requested 100 Actual 99 Danfoss CG150 CG150 2 0 Channel 0 Boost Mode Parameters Boost Mode Parameters Boost Enable Allows or prevents the use of Boost Mode When Di sabled Boost Mode cannot be used even if an operator interface is present If Enabled Boost Mode can be used when not using the Torque Potentiometer functionality Input Boost mode can be configured with a switch that is either Pull UporPull Down the electrical schematic This toggle switches the logic between the two options Status Indicates whether Boost Mode is Of 5 ETL enabled or Boost Enabled ETL disabled L1519202 Rev AA March 2015 31 User Manual S45 ETL Co
19. Tool 7 07 CNUserswewald DOD Documents Projects ETL Documentation Plus ServiceToolP1D Ele View Log Parametern Gommontarion Options 1005 Help 6 28 mw 93 9 2 G iw E39 E8 EO 3 Gu ED ED Ange Sensor Calibration Angle Sensor Calibration Diagnostic Navigator Angle Sensor Faults Calibration Parameter Inputs Parameter Functions 3 FA System Overview Z Torque Limit Setpoint P Torque Potentio Torque Limit Profi EA Torque Setpo CAN Torque Setp 1 Command Filter Setup 7 Boost Setup P RPM Input Setup Z Pump Setup F Pressure Sensor Setup P Pressure Setpoint P Electrical interface Logging Requested 100 Actual 99 Danfoss CG150 CG150 2 0 Channel 0 Angle Sensor Calibration Parameters Angle Sensor Calibration Parameters Calibration Minimum Pump Displacement Records the angle sensor signal voltage that corresponds to the pump s lowest displacement condition Maximum Pump Displacement Records the angle sensor signal voltage that corresponds to the pump s highest displacement condition Inputs C1p08 Primary Signal Displays the real time voltage signal from the primary sensor pickup C1p09 Secondary Signal Displays the real time voltage signal from the secondary sensor pickup if enabled optional Faults Calibration Parameter Faults
20. Tool screen You can navigate the Service Tool screens in two ways Diagnostic Navigator Panel 1 which allows you to view the hierarchy of all screens Navigation buttons 2 which give you quick access to related screens ETL functionality is listed under Diagnostic Navigator gt Parameter Functions 3 System Overview TorqueLimit Setpoint Torque Potentiometer Calibration Torque Limit Profile Setup Torque Setpoint CAN Torque Setpoint Setup Command Filter Setup Angle Sensor Calibration Boost Setup RPM Input Setup Pump Setup Pressure Sensor Setup Pressure Setpoint Faults Electrical Interface User defined toggle inputs 4 appear with a blue background Parameter faults 5 are shown as green if no fault is present and red if a fault is present Each screen includes navigation links back to the System Overview 6 bounded by red Outputs 7 appear on all ETL Service Tool screens 16 11519202 Rev AA March 2015 User Manual S45 ETL Control General PLUS 1 ETL Service Tool Information Typical ETL Service Tool Screen Eile View Design Log Parameter Communication Options Tools Help 6 9021608 0 C wn D gt o a 1 G8 EO GB Cm EE 9 Torque Limit Setpoint x Torque Limit Sepoint Torque Potentiometer Faults Calibration Parameter Inputs Maximum Torque Allowed Download 100 008 ae SS Torque Limi
21. ate to each ETL functionality to tune changes or conduct diagnostics after the general setup Enable or disable ETL Control using the Toggle button ETL System Overview Screen PLUS 1 GUIDE Service Tool 7 0 7 C Users vewald 000 Documents 4 Projects ETL Documentation Plus 1 ETLServiceToolPi0 nN ra FEST Eile View Design Log Parameter Communication Options Tools Help 0 6 ral A 6 A miim rn I rn ran TAI 2 6 2664 0 60151 1581 i E8 O 9 0 x System Overview ETL Overide off Diagnostic Navigator Ee 545 1 92 96 Engine W Angle Sensor Calibration S Angle Sensor Calibration ECU Ust 06 En Parameter Functions System Overview Z Torque Limit Setpoint Torque Potentio Torque Limit Profi P Torque Setpo Electronic Torque Limitation Valves amp oc Functions F CAN Torque Setp un Z Command Fiter Setup Angle Sensor Calibra SetpYauts GP Boost Setup Displacement RPM Input Setup a 7 Pump Setup Z Pressure Sensor Setup Electrical Interface Pressure Setpoint Fa Electrical Interface Pressure Setpoint Cmd Filter mn o Logging M Requested 100 Actual 99 Danfoss CG150 CG150 2 0 Channel 0 29k Logging data Torque Limit Setpoi
22. aults PPR parameter is out of range gt 10 000 Frequency is too high 250 000 Frequency is too low 20 Perform RPM Input Setup From the RPM Input Setup screen 1 Toggle your desired input to use for the engine speed pickup e Speed ring CAN bus 2 If a hall effect speed ring type is used indicate the number of pulses per revolution in Pulse Pickup Calibration gt Pulse Per Revolution The engine speed output will read the real time speed when set up 24 L1519202 Rev AA March 2015 User Manual S45 ETL Control ETL Service Tool Setup Torque Potentiometer Calibration This section applies only if a potentiometer is used for ETL setup A potentiometer greatly reduces the Torque Limit Profile setup time by allowing quick adjustments to the actual torque limit at any engine speed condition In order for a potentiometer to be used for this functionality it must first be calibrated Torque Potentiometer Calibration Screen lt lt PLUS 1 GUIDE Service Tool 707 CAUsers vewald 000 Documents 4 Projects ETL Documentation Plus is NETL ServiceTooLP1D File View Design Log Parameter Communication Qptions Jools Help S amp 2ee lcal 6 4 0 a e 2 2 2 a 2 Torque Potentometer Calibration Diagnostic Navigator Name New System Torque Potentiometer Faults Calibration Parameter Inputs gt LLL Angle Sensor Ca
23. e exceptional performance for a broad range of off highway vehicles We help OEMs around the world speed up system development reduce costs and bring vehicles to market faster Danfoss Your Strongest Partner in Mobile Hydraulics Go to www powersolutions danfoss com for further product information Wherever off highway vehicles are at work so is Danfoss We offer expert worldwide support for our customers ensuring the best possible solutions for outstanding performance And with an extensive network of Global Service Partners we also provide comprehensive global service for all of our components Please contact the Danfoss Power Solution representative nearest you Local address Danfoss Power Solutions Danfoss Danfoss Shanghai Co Ltd Power Solutions GmbH amp Co OHG Power Solutions ApS Building 22 No 1000 Jin Hai Rd Krokamp 35 Nordborgvej 81 Jin Qiao Pudong New District DK 6430 Nordborg Denmark Phone 45 7488 2222 Shanghai China 201206 Phone 86 21 3418 5200 Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Dan
24. e 20 b Establish the Maximum Pump Displacement with Engine Off on page 21 or Establish the Maximum Pump Displacement with Engine Running on page 21 2 Define Pump Displacement on page 23 3 Perform RPM Input Setup on page 24 4 Calibrate Torque Potentiometer on page 25 5 Select Pressure Sensor Setup on page 26 6 Establish Torque Limit Profile Establish Torque Limit Profile with Torque Curve on page 28 or Establish Torque Limit Profile without Torque Curve on page 29 A fundamental step in setting up ETL is to calibrate your angle sensor The calibration will ensure accurate angle sensor voltage readings based on maximum and minimum pump displacements swashplate angles Calibration does not inform the software what the physical maximum displacement of the pump is in terms of engineering units This is done in the Pump Setup Parameters screen and the correct calibration of the angle sensor is independent of the Max Pump Displacement input It is possible when calibrating the angle sensor that the Minimum Displacement Voltage is greater than the Maximum Displacement Voltage This is due to the different relationships between swashplate angle and voltage for J and F frames versus E frame pumps For more information see the Angle Sensor Characteristics on page 10 11519202 Rev AA gt March 2015 19 User Manual S45 ETL Control ETL Service Tool Setup Angle Sensor Calibration Screen PLUS 1 GUIDE Service
25. e Setpoint P Torque Potento amp Torque Limit Profi 100 00 Pin cease aay EXE NE IZI CAN Torque Setp Command Fiter Setup SS Z Sensor Cabra Control Current P Boost Setup XI RPM Input Setup 9 0 MBA Z Pump Setup Presane sew Set Z Pressure Setpoint Fa Bectrical interface Requested 100 Actual 98 Danfoss CG150 CG150 2 50 Channel 0 Pressure Sensor Setup Parameters Pressure Sensor Setup Parameters Inputs Pressure Sensor Enable Enables or disables in line pressure transducer functionality Faults Parameter input faults Pin value too high at sensor power Pin value too low at sensor ground Select Pressure Sensor Setup 26 11519202 Rev AA March 2015 2 User Manual S45 ETL Control ETL Service Tool Setup 1 After system pressure functionality is desired hook up the recommended pressure transducer to the recommended pins For pinout see Pre compiled MC012 Pin Assignments on page 14 From the Pressure Sensor Setup screen Torque Limit Profile Setup 2 Toggle Pressure Sensor Enable to Enabled The Torque Limit Profile is the heart of an ETL system It is what defines how a machine reacts to torque loads and it has an infinite number of tuning possibilities It allows you to define how the system limits torque consumed by the open circuit hydraulic system The most basic
26. ering of control current signals if there are pressure oscillations The ETL system by default sets the command control filter to zero which means it is disabled If the command control filter is used the filter values can be increased until the unwanted oscillations reach an acceptable level Command filter setup is only necessary if unwanted instability or oscillations occur when ETL is active The time constant sets the cutoff frequency for a first order low pass exponential filter Determining the frequency of oscillations can help give you a starting point for the time constant fc 1 2 pi t 32 11519202 Rev AA March 2015 User Manual S45 ETL Control Additional Setup Reduce Oscillation Slower Response y i Filter Time Constant Parameter Increase Oscillation X Faster Response If the ETL control produces unwanted oscillations and all time constant values are set to zero use the following table and the Command Filter Setup screen to reduce oscillations is increasing Are oscillations occurring when the load Yes Increase the Increasing input No Leave the Increasing input at zero Are oscillations only occurring when the Yes load is decreasing at high engine speed Setthe High Speed input to the affected engine speed Increase the High Speed Decreasing input No there is no oscillation when the load is decreasing at high engine s
27. ess than or equal to Speed N 1 Speed N out of range Torque N out of range Inputs Actual engine input speed value too low or high Establish Torque Limit Profile with Torque Curve The following steps establish a torque limit profile if a known engine torque curve is available From the Torque Limit Profile Setup screen 1 Set the engine Speed Inputs Speed 1 7 at which you wish to limit torque For example set the lowest engine idle speed highest engine idle speed and five equally spaced points between the two 2 Set the Torque Inputs Torque 1 7 To do this normalize the engine s torque values to reflect the pump s maximum consumable torque That is divide the available engine torque by the pump s maximum consumable torque to get a Pump Torque Setpoint percentage Pump Torque Setpoint 96 Pump Torque Consumed Engine Available Torque n speed Max Pump Pressure Displacement 28 11519202 Rev AA March 2015 Dee User Manual S45 ETL Control ETL Service Tool Setup For example if your engine s available torgue at 950 rpm is 196 N m and a 75cc J frame pump operating at a pressure limit of 240 bar will consume 302 N m of torgue then 196 302 6590 This is the Pump Torgue Setpoint reguired at 950 rpm Continue using this method for all 7 torgue setpoints After establishing a torgue limit profile the torgue setpoints may still reguire adjustme
28. foss A S All rights reserved 11519202 Rev March 2015 www danfoss com Danfoss A S 2015
29. libration Sensor Inputs SSS ae Engine Speed en Parameter Functions 2409 RPM System Overview f Torque Umit Setpoint Pressure Setpoint FZ Toraue Potent 3 FP Torque Limit Profi 100 00 S P Torque Setpo 7 CAN Torque Setp Command Fiter Setup P Angle Sensor Calibra Control Current P Boost Setup RPM Input Setup Z Pump Setup f Pressure Sensor Setup Pressure Setpoint Fa P Electrical interface Torque Potentiometer Calibration 240 00 bar Logging Requested 100 Actual 99 Danfoss CG150 CG150 2 0 Channel 0 Torque Potentiometer Calibration Parameters Torque Potentiometer Calibration Parameters Calibration C1p10 Voltage Indicates the real time signal voltage being input from the Torque Potentiometer Minimum Captured Voltage Displays the minimum captured voltage created by the potentiometer Maximum Captured Voltage Displays the maximum captured voltage created by the potentiometer Auto Calibration Toggle Enables or disables the auto calibration feature Clear Calibration Clears the minimum and maximum captured voltages from the previous calibration to establish a new calibration Calibrate Torque Potentiometer 1 Connect a potentiometer to the indicated pins in the 12 pin out From the Torque Potentiometer Calibration screen 2 Toggle the auto calibration to A
30. lse the system will lose power because the pump will need to relieve pressure in a constant manner 2 Set LS Pressure Setting to the pump s factory LS margin pressure 3 Set Max Pump Speed to the maximum operating speed at which the pump will operate In general you should use the highest engine operation speed of the machine See Series 45 Pumps Technical Information 520L0519 for allowed pump operating speeds to conform to the recommended continuous operation speeds 4 Set Max Pump Displacement to the physical maximum displacement of the pump in units of cm rev 5 Set Threshold Current a Toggle Coil Setup to the correct coil voltage b Set Max Pump PC Pressure and LS Pressure Setting The Recommended Threshold field will display the recommended threshold C Select Use Recommended The recommended current threshold will transfer to the Threshold Current field Advanced users may reference a control pressure vs current curve and enter their own threshold to create a custom offset for the threshold setting 11519202 Rev AA gt March 2015 23 ones User Manual S45 ETL Control ETL Service Tool Setup RPM Input Setup The RPM input limits the torque throughout an engine s usable speed range To set up this limit you must select the proper speed input either CAN bus speed pickup or speed ring pulse pickup RPM Input Setup Screen n PLUS 1 GUID
31. n Circuit 520L0610 Series 45 Frame F Open Circuit 520L0821 Series 45 Frame E Open Circuit 520L0609 User Guide PLUS 1 Service Tool User Manual L1307770 Also found under Help on toolbar Data Sheet PLUS 1 Controllers MC012 110 and L1301095 Product Electrical Installation MBS1250 Heavy Duty Pressure Transmitter 11062087 L1519202 Rev AA gt March 2015 User Manual S45 ETL Control General Electronic Torque Control Information PLUS 1 Compliance All Series 45 Electric controls have met and passed the Danfoss PLUS 1 compliance standard testing and as such this Series 45 control is PLUS 1 compliant PLUS 1 compliance blocks are available on the Danfoss website within the PLUS 1 Guide section Electric Torque Limiting Control Principle The Electronic Torque Limiting control consists of a normally closed proportional relief valve PRV integrated into a Pressure Compensated Load Sensing control This control operates as a PC LS control with the additional ability to limit load sense pressure using the integrated PRV by varying the current to the solenoid When combined with an angle sensor this control allows for a PC LS control with electronic torque limiting J frame pump with integrated ETL control 2 gt gt y 5 ija o LA SS mi 1
32. nnector Pin Assignments For a mating connector use Deutsch plug 6 45 4 1 EH WL 3 2 P108760 Pin Assignment 1 Ground GND 2 Output signal 2 SIG2 Secondary signal 3 Output signal 1 SIG1 Primary signal 4 Supply V Pre compiled MC012 Pin Assignments 12 pin connector i 12 11 10 50 000 NO oO 220008 14 11519202 Rev AA March 2015 User Manual S45 ETL Control General Angle Sensor Information Pre compiled MC012 Pin Assignments Pin callout Pin assignment type ETL function assigned 1 1 Power ground Generic sensor ground C1 P2 Power supply Machine power C1 P3 C1 P4 CAN CAN CAN J1939 High CAN J1939 Low C1 P5 AIN CAN shield Pressure transducer signal optional C1 P6 5Vdc sensor power Angle sensor power mandatory Pressure transducer power optional Torque potentiometer power optional C1 P7 Sensor power ground Generic sensor ground C1 P8 DIN AIN FreglN Angle sensor signal 1 mandatory C1 P9 DIN AIN FreglN Angle sensor signal 2 optional RPM speed ring pickup Boost mode switch functionality C1 P10 DIN AIN FreglN Potentiometer wiper optional C1 P11 C1 P12 PWMOUT DOUT PVGOUT PWMOUT DOUT PVGOUT User function Control coil current supply Potentiometer
33. nputs Torque 1 7 2 Download and check Torque Setpoint Curve 1 Click and drag the points in Torque Setpoint Curve 2 Download and check Torque Potentiometer 1 Use a torque potentiometer to adjust the torque setpoints while operating the machine 2 Enter the setpoints into the Torque Limit Profile 3 Download and check The torque potentiometer has been shown to greatly reduce the process time to adjust torque setpoints and fine tune the torque profile L1519202 Rev AA gt March 2015 29 User Manual S45 ETL Control ETL Service Tool Setup Considerations for Establishing the Torque Limit Profile Theamount of torque limiting required may be objective or subjective Objective examples Killing the machine vs not killing the machine Not allowing the engine to droop more than XXXX rpm below desired idle speed Not allowing the engine to droop to a certain sound criteria Allowing the engine to droop to a certain sound criteria Not allowing the pump to drop below a certain flow requirement based on a pressure criteria necessary function speed under no load Subjective examples Operator must be able to experience some engine reactivity to perceive machine work Operator skill allows for smaller margin between available engine torque and pump torque consumed Operator does not want machine to slow down too much Theamount of torque consumed by the open circuit pump system does not account for
34. nt The Torque Limit Setpoint screen is important because it allows the user to select between two torque limit input options Torque Limit Profile or Torque Potentiometer This screen also provides quick navigation to the most frequently used setup screens Torque Limit Setpoint Parameters Torque Limit Setpoint Parameters Inputs Torque Limit Input Allows the user to select between two different forms of torque limitation controls Torque Profile and Potentiometer The Torque Profile is used when the seven limiting setpoints are finalized and the Potentiometer is used when first setting up ETL or conducting diagnostics These are discussed in detail in Torque Limit Profile Setup on page 27 Maximum Torque Allowed Allows the user to de rate the whole Torque Limit Profile by a common factor The software sets the default value to 10096 18 11519202 Rev AA March 2015 User Manual S45 ETL Control ETL Service Tool Setup Angle Sensor Calibration This section describes the ETL functions that are required for the ETL system to operate including how to set up each ETL function To set up each ETL function you will make changes to each function s respective ETL Service Tool screen similar to the screen shown in Typical ETL Service Tool Screen The following steps are required in order for the ETL system to operate 1 Calibrate Angle Sensor a Establish the Minimum Pump Displacement on pag
35. nt to achieve the desired engine machine reactivity See Adjust Torgue Setpoints on page 29 Establish Torgue Limit Profile without Torgue Curve The following steps establish a torgue limit profile if an engine torgue curve is not available It uses a guess and check method From the Torgue Limit Profile Setup screen 1 Set the engine Speed Inputs Speed 1 7 at speeds which you wish to limit torgue For example set the lowest engine idle speed highest engine idle speed and five egually spaced points between the two 2 Set the Torque Inputs Torque 1 7 The following steps are one suggestion a Pick the lowest engine speed and set the machine at this condition b Operate the machine through various high torque consumption cycles c Adjust the torque limit setpoint to achieve the desired level of torque limiting some or virtually none engine reaction bog The reactiveness is affected by how close the pump s allowed torque is relative to the engine s available torque After establishing a torque limit profile the torque setpoints may still require adjustment to achieve the desired engine machine reactivity See Adjust Torque Setpoints on page 29 Adjust Torque Setpoints After establishing a torque limit profile the torque setpoints may still require adjustment to achieve the desired engine machine reactivity Adjust the torque setpoints using one of the following options Option Steps Torque Inputs 1 Set the Torque I
36. ntrol Additional Setup CAN Torque Setpoint Setup In CAN setpoint enable mode the 45 pump responds to auxiliary command messages When the CAN setpoint is enabled you can remotely send a torque setpoint to the pump by identifying an address on the CAN Please consult with your Danfoss representative for more information on setting up torque setpoints with CAN messaging CAN Torque Setpoint Setup Screen PLUS 1 GUIDE Service Tool 7 07 CAUsersWewald 000 Docu Projects ETL DocumentationlPlus ServiceTool P10 File View Design Log Parameter Communication Options Tools Help 1 amp 1 6 3 Sul 6 6 6 m 0l e 5 8 25 CAN Torque Setpoint Setup Diagnostic Navigator _ Outputs Torque Limit Setpoint li Angle Sensor Calibration 91 26 D Angle Sensor Calibration Engine oos m Parameter Functions 2410 FA System Overview S Torque Limit Setpoint Pressure Setpoint Torque Potento xm amp H Torque Limit Profi 100 00 96 2 Torque Setpo zz ZF Command Fiter Setup Z Angle Sensor Calibra Control Current Zeon seno Z RPM Input Setup Z Pump Setup Z Pressure Sensor Setup Z Pressure Setpoint Fa PP Bectrical Interface m Qi Logging Requested 100 Actual 99 Danfoss CG150 CG150 2 50 Channel 0 Command Filter Setup The Command Filter Setup screen allows for possible filt
37. ntrol Current Displays real time current in milliamps mA being sent to the pump s control solenoid from the PLUS 1 microcontroller A current of zero or near zero mA indicates that the solenoid is not being activated to limit torque Torque Consumed Displays the real time torque consumed by the pump as a calculated percentage of pump maximum torque based on the Max Pump Displacement and Max Pump Pressure inputs Power Consumed Displays the real time power consumed by the pump as a calculated percentage of pump maximum power based on the Max Pump Displacement Max Pump Pressure and Max Pump Speed Displacement Displays the real time pump displacement in both percent of maximum displacement and cm rev This displacement depends directly on the minimum and maximum displacement calibration points Pressure Indicates real time system pressure based on a pressure transducer Note that a pressure transducer must be added to the system by the user for this optional functionality L1519202 Rev AA gt March 2015 17 2 User Manual S45 ETL Control General PLUS 1 ETL Service Tool Information System Overview The System Overview screen is the home screen for the ETL Service Tool This screen shows a high level overview of how the 545 ETL software ties into the machine s engine and hydraulic systems by reporting real time parameters You can also use the System Overview to do the following actions Navig
38. or Information Electrical specifications continued Description Minimum Typical Maximum Unit Note Supply protection 28 Vdc Sensor will switch off above 5 5 V Supply current drawn 22 25 mA Sensor supply at 5 V Output short circuit current 7 5 mA Additional 7 5 mA for each sensor signal VDD to SIG 1 2 and GND to total sensor 7 5x2 22 37 mA typical for SIG 1 2 FSO Sensitivity in sensing rangeat 70 02 78 85 8 mV calibration temperature for primary and secondary sensor Resolution 0 03 degree 11 bit output channel Hysteresis Design of sensor eliminates any mechanical hysteresis Environment temperature 40 40 80 176 104 220 C F If temperature limits are exceeded the range sensor will function at a reduced level of performance Operating temperature range 20 68 50 122 95 203 C F Temperature of oil Storage temperature 40 40 125 257 C F Accuracy for primary and Primary 0 65 degree Includes linearity temperature drift and secondary signals throughout Secondary 0 85 repeatability Does not include the error operating temperature range due to offsets and different ferrous when calibrated at 50 deg C environment Refresh rate of the sensor 100 us Internal ADC refresh rate Sensor Connector and MC012 Microcontroller Pin Assignments Angle Sensor DTM04 4P Co
39. ows users to limit pump torque consumption electronically by combining a pressure limiting PRV and angle sensor This torque limit can be changed with varying engine speeds as shown in the Electronic Torque Limiting graph below allowing the use of full engine torque at all engine speeds and increasing machine productivity A microcontroller is required to store engine torque vs speed receive the pump angle sensor signal and then calculate and output the pump outlet pressure limit The basic torque limiting control logic for a single engine speed is shown below Danfoss offers a PLUS 1 subsystem application block for the Electronic Torque Limiting control option in combination with keyed MC 12 microcontroller hardware Electronic Torque Limiting N uw o N e o my e 9 o 2 o g 2 2 150 a a E 2 a o o 50 100 150 Pump Displacement cc P108783 L1519202 Rev AA gt March 2015 7 User Manual S45 ETL Control General Electronic Torque Control Information Basic ETL Control Logic 500 z g w E a E 9 x E gt o E x e 5 c om E t 9 gt 20 E x 8 50 x0 0 0 0 5 10 15 20 25 30 35 40 45 50 Pump Displacement cc gt Maximum System Pressure ETL Active bar Current to Valve mA P108785 11519202 Rev AA March 2015 Def User Manual S45 ETL Control System Considerations when Implementing ETL When setting up an ETL sy
40. peed Leave the High Speed Decreasing input at zero Setthe High Speed input to the high engine speed No oscillations occur when the load is decreasing at both high and low speeds Ensure the High Speed and Low Speed inputs match the engine tuning speeds before adjusting filter inputs Setthe High Speed Decreasing and Low Speed Decreasing inputs to the high and low engine setpoints 11519202 Rev AA gt March 2015 33 User Manual S45 ETL Control Additional Setup Command Filter Setup Screen 1416 Diagnostic Navigator E Angle Sensor Calbraton Angle Sensor Calibration amp CU ust oe En B Parameter Functions 3 System Overview Torque Limit Setpoint Torque Potentio Angle Sensor Cabra P Boost Setup RPM Input Setup Z Pump Setup Z Pressure Sensor Setup PP Bectrical Interface HF Torque Limit Profi P Torque Setpo A CAN Torque Setp PETI SERES Pressure Setpoint Fa Command Filter Setup Faults Parameter Inputs File View Design Log Parameter Communication Options Tools Help 3 9 2 6 6 4092 6 0151 2 o 2 Command Fiter Setup _ r 14 PLUS 1 GUIDE Service Too 7 0 7 CAUsers vewald 000 Documents 4 Projects ETL Documentation Plus ServiceTool P1D High Speed Decreasing Download 2000 ms Increasing 5 8 3 a
41. s Pressure Transducers and the PumpTorgCalc Function Block Potentiometer It is possible to use a potentiometer to control the torque limiting signal for ETL setup purposes Use a 1k ohm potentiometer with a 120 ohm resistor on the V and V ends Pressure transducer Using a pressure transducer allows the ETL service tool to report actual torgue and power consumed by the 45 pump via the PumpTorgCalc Funcion Block The PumpTorqCalc function block is an optional part of the ETL system and it allows the user to report real time data on a graphical display terminal to help eguipment operators understand and improve operating efficiencies or share data between subsystems to coordinate power sharing For more detailed information on the PumpTorqCalc Function Block see Work Function Control Blocks Library L1313265 Danfoss recommends using the MBS1250 Heavy Duty Pressure Transducer with a measuring range of 0 to 400 bar 5800 psi For information on this transducer see MBS1250 Heavy Duty Pressure Transmitter Product Electrical Installation 11062087 L1519202 Rev AA gt March 2015 15 Defi User Manual S45 ETL Control General PLUS 1 ETL Service Tool Information The Electronic Torgue Limiting ETL Service Tool is used to set up the torgue limiting functionality on a machine See ETL Service Tool Setup on page 19 for the steps reguired to set up an ETL system Typical ETL Service Tool Screen shows a typical ETL Service
42. stem to function properly you must account for LS signal line orificing and margin erosion Electronic Torgue Limiting and Load Sense Signals Danfoss PVG valves as well as many competitor valves are manufactured with LS signal line orifices installed in the pump inlet PVP module These orifices enhance system stability by dampening the highest load pressure signal before it is relayed to the open circuit pump They also help limit the amount of flow over the load sense relief valve inside the PVP It is important to ensure that when using these LS line orifices the highest resolved load sense pressure is communicated to the pump or loss of some flow sharing functionality may occur If you experience symptoms of loss of flow sharing some troubleshooting steps may include removing the LS line orifice in the valve stack or ensuring that the LS pressure rails are connected to each other when using two or more different valve stacks In this way the highest load from the system is communicated to the pump Electronic Torque Limiting and Margin Erosion A potential flow sharing problem may arise when several functions are actuated at the same time and require a high flow demand from the pump This problem may include a loss of movement in the highest pressure function when many functions are actuated at the same time This problem is margin erosion Margin erosion is caused when margin pressure is shifted from the operator controlled valves to the
43. t Profi SSS f Torque Setpo PI CAN Torque Setp P Command Filter Setup P Ange Sensor Calibra P Boost Setup Torque Potentometer Calibration Z RPM Input Setup Z Pump Setup F Pressure Sensor Setup Pressure Setpoint Fa P Electrical interface CAN Torque Setpoint Setup Torque Limit Profile Setup Logging Requested 100 Actual 98 Danfoss CG150 CG150 2 0 Channel 0 Typical ETL Service Tool Outputs Output Description Torque Limit Setpoint Displays the real time calculated torque limit for the real time engine speed as a percentage of maximum torque consumable by the pump It is calculated based on the curve fitted from the torque limit profile discussed on torque limit profile page or as an input of the voltage from the Torque Potentiometer Engine Speed Shows the real time engine speed fed back from the machine Engine speed feedback must be wired to the microcontroller by the user using either the CAN High and CAN Low pins C1 P3 and C1 P4 or the RPM speed ring pickup pin C1 P9 see RPM Input Setup on page 24 Pressure Setpoint Displays the real time system pressure currently allowed by the ETL control system Displayed both as a percentage of Max Pump Pressure and in bar It is calculated by referencing current pump displacement and engine speed torque available at engine Co
44. the torque consumed by the closed circuit pump system Propel vs work functions A specific machine function may require more or less torque depending on environmental conditions Cold weather vs hot weather oil viscosity For questions on setting up the Torque Limit Profile for your machine consult your Danfoss representative 30 11519202 Rev AA March 2015 User Manual S45 ETL Control Additional Setup The features in this section are not required for an ETL system to function These features enhance or adjust system performance and functionality Boost Mode Boost mode or ETL override allows the user to configure an operator interface to enable or disable ETL One example is a momentary switch incorporated into an interface such as a joystick The pre keyed 12 does not allow both the torque potentiometer and the boost mode functionality to be used at the same time To use boost mode the potentiometer functionality must be disabled and vice versa The engine will not be protected from stalling while boost mode is enabled One benefit of boost mode includes artificially creating a pressure setting that is lower than the pump s physical pressure compensator setting As a result you can achieve extra pressure capability on command by enabling or disabling ETL and creating an extra power level Boost Setup Screen PLUS 1 GUIDE Service Tool 7 0 7 CAUsers vewald 000 Documents 4
45. ting connector use Deutsch plug DTMO6 4S The sensor is mounted to the pump within an aluminum housing to prevent magnetic interference AMR Sensor Swashplate MM lt lt Deutsch Plug P108788 The angle sensor package incorporates two sensor signals primary amp secondary within a single sensor housing This allows for improved accuracy and troubleshooting For the Angle Sensor Right order code in the K module the sensor is positioned according to the following conventions 10 11519202 Rev AA March 2015 User Manual S45 ETL Control General Angle Sensor Information 8 F Frame 45 90cc Angle Sensor Identification Convention When looking at the input shaft with the control on the top side the angle sensor will be viewed on the right hand side This convention is true for both Clockwise and Counter clockwise rotation J amp F Frames 86 8 3 417 94 1 3 704 B 36 1 462 1417 1 71 30 5 12 29 5 1 16 374 36 1 462 1417 87 3 93 6 3 44 3 68 J Frame Angle Sensor Position F Frame Angle Sensor Position P108816 This sensor location yields a unigue voltage versus swashplate angle characteristic curve which is the same for both Clockwise and Counter clockwise rotation J amp F frames Although each pair of curves will be unigue for individual pumps a general example of what to expect is provided below for J amp
46. troke position by overcoming residual pressure and friction in the swashplate and servo system From the Angle Sensor Calibration screen 3 Click Maximum Pump Displacement Capture Voltage Establish the Maximum Pump Displacement with Engine Running The engine must be operated at full speed to prevent an inaccurate displacement reading 1 Operate the pump in a full displacement full flow and low load machine condition a Operate engine at full operating speed b Command a single high flow function or multiple machine functions simultaneously while remaining below the pump s pressure compensator setting low system pressure Do not reach or exceed the pressure compensator setting or the pump will begin to de stroke and reduce its displacement and render a bad maximum displacement reading From the Angle Sensor Calibration screen 2 Click Maximum Pump Displacement Capture Voltage 11519202 Rev AA gt March 2015 21 p User Manual S45 ETL Control ETL Service Tool Setup Pump Setup The pump setup function defines the pump displacement in PLUS 1 software It also sets the maximum system pressure and maximum pump speed to calculate the maximum pump torque and power Coil current thresholds are also set up based on the user s inputs Pump Setup Screen r Aj PLUS 1 GUIDE Service Tool 7 0 7 C Users vewald 000 Documents 4 Projects ETL Documentation Plus 1 ETL_ServiceTool P10
47. unter clockwise rotation E Frames appear with the control on the bottom side in this view This sensor location yields a unique voltage versus swashplate angle characteristic curve which is different for Clockwise and Counter clockwise rotation E frames Although each pair of curves will be unique for individual pumps a general example of what to expect is provided below for both Clockwise and Counter clockwise rotation units with the Right angle sensor position 12 11519202 Rev AA March 2015 User Manual S45 ETL Control General Angle Sensor Information Sensor Output Voltage vs Swashplate Angle CW E Frames 100 147cc Primary Output Voltage Secondary Output Voltage Sensor Output Volts o ou e Ui MN wn A 0 1 2 3 4 5 6 7 8 9 101112 13 14 15 16 17 18 Swashplate Angle Degrees P108823 Sensor Output Voltage vs Swashplate Angle CCW E Frames 100 147cc Primary Output Voltage Secondary Output Voltage 2 3 5 i CL LIS T 8 b 1 E 0 1 2 3 5 6 7 8 9 101112 13 14 15 16 17 18 Swashplate Angle Degrees P108822 Angle sensor electrical specifications Electrical specifications Description Minimum Typical Maximum Unit Note Supply V 4 75 5 5 25 Vdc Sensor is ratiometric in the voltage range 11519202 Rev AA March 2015 13 User Manual S45 ETL Control General Angle Sens
48. uto Cal Enabled This calibrates the potentiometer L1519202 Rev AA March 2015 25 User Manual S45 ETL Control ETL Service Tool Setup 3 Turn the potentiometer from lock to lock in a steady manner The auto calibration feature will automatically capture the minimum and maximum allowable voltages registered while the Auto Cal is enabled The proper voltage range will be attained when using a 1k ohm potentiometer with 120 ohm resistors on both the V and V ends 4 After the minimum and maximum voltages are captured toggle the auto calibration to Auto Cal Disabled 5 If the calibration did not cover the full range of the potentiometer or if you need to use a new potentiometer click Clear Calibration This deletes the previously captured voltages to capture a new calibration The minimum and maximum voltages of the potentiometer will not be OV or 5V This is not allowed for fault monitoring purposes Pressure Sensor Setup The Pressure Sensor Setup screen allows the user to enable the use of a system pressure transducer A pressure transducer is helpful to diagnose the system and calculate power consumed by the pump Pressure Sensor Setup Screen Q 6 3 2 6 86 6 069 9162191 Pressure Sensor Setup Diagnostic Navigator Outputs Torque Limit Setpoint 91 36 Engine Speed B Parameter Functions 2411 System Overview amp FH Torque Limit Setpoint Pressur
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