DANA APC200 CONTROL SYSTEM

FOR DCE 90-180

Henry Tidstrand, Development Engineer

Kalmar Industries
Table of contents

•Introduction APC200
•Programs and machine card
•Flashing binary files into program memory
•Loading APT parameters into data memory
•Loading GDE parameters into data memory
•Uploading GDE parameters from APC200 to PC
•Examples of using PC tools
•Installation on PC:s
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APC 200

 Device for shifting Spicer Off Highway Products ECM powershift

transmissions
 ECM -> Electronic Controlled Modulation
– a transmission control technology, available on a range of transmission models
 ECI -> Electronic Controlled Inching
– to run at very low controlled speed at virtually any engine speed

Throttle by Wire, brake by wire

Engine Control
CAN Network Integration
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Block diagram APC 200

S
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PSU = Power Supply Unit

 Two versions: 12V, APC202-12 or 24V, APC202-24

 Two power lines
– PPWR : permanent power
• Connected directly to the battery
– SPWR : switched power
• Connected via key contact to the battery
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Digital input

 2 inputs can capture fast transcient

 8 inputs can only capture DC-signals
 Low pass filter and over voltage protection logic
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Analog input

 4 voltage inputs, 10 bit resolution 0-5 V

 2 resistive inputs, 0-5 kOhm (pressure FB, temp cooler in)
 Fixed hardware inputs -> operating voltages of APC 200
 Measure resistance between input pin and ground
 Dependent of hardware assembly : resistance, voltage
 Low pass filter and over voltage protection
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Digital output

 Status of the outputs is not derived from the status pin of the switch, but
directly monitored on the output pin itself
 Multiple redundant shutdown paths for all its outputs
 Total neutral: high and low side switch: must be switched off in all cases
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Analog output
 Flexible design
– Closed loop current control (PWM)
– Open loop current control (PWM) and analog input
– Digital output and analog input
– Full bridge DC motor driver
 Ground switch: software opens it when high current are
measured or short circuit between pins
 Output feedback to detect output faults
 Multiple redundant shutdown paths for all its outputs
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Speed circuit
 4 speed signal inputs, type programmable
– Inductive, 0-10kHz (not used on TE13/17)
• Current to voltage, overvoltage protection, band-pass filtering and squaring
• Detecting broken wire or shorted wires
• Measuring frequency and period
– Philips KMI 15/1 magnetoresistive (current loop), 0-10kHz
• Current to voltage, overvoltage protection, band-pass filtering and squaring
• Detecting broken wire or shorted wires
• Reverse polarity of sensor
• Measuring frequency and period
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Control logic
 CPU
– 16 bit device: C167CR with 20 MHz clockspeed
• CPU-function
• 16 DA channels 10 bit
• 2x16 channels capture compare units
• 5 timers
• 2 serial channels
• CAN
• 144 pin MQFP package
 128 kRAM – 16 bit wide (working RAM)
 Program memory: Program is downloaded in 128 kFLASH ROM 16 bit wide
(main program)
 Data memory: volatile data stored in 64 kFLASH in 8 bit wide (parameter
settings APT + GDE & statistics)
 Rev 4 ser.nr.EBEA139203 and earlier
 Rev 6 with larger data flash memory from EBEA139204 and later
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Control logic
APC200 rev6 memory structure
(APC200 rev4 has 32kB data memory)

Program memory Data memory

128 kB Flash 64 kB Flash

APT loading parameters

Binary file Parameters

GDE edit OEM parameters

Statistics
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Communication

 CAN 2.0 B
 RS 232, use cable Kalmar art.no. 923994.0001
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Bootstrap and reset circuit
 Bootstrap:
– Special mode, controller wants to receive serial data, normally the program
that will be written into the program memory
– While in bootstrap all output functions are hold off
– Start: power up both buttons pressed or 8V CANL
 Reset circuit: watchdog & supply supervisor will reset CPU if
either the power supply is outside 10% tolerance window or CPU
has “forgotten” to re-trigger the watchdog trigger
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Display

– 4 red 7-segment LED digits

– 3 status LED lamps
• D -> yellow, diagnostic mode
• E -> yellow, error codes
• F -> red, bootstrap or reset mode
– 2 push buttons
• M -> select information group
• S -> select item within group
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Display modes
M

M M
S S S
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Display modes

 “Err” display
– Shows all existing error codes (none blinking error code) and error codes
detected in the past (blinking error code).

(none blinking)
S
(blinking)
S
Note : when an error is active, (end of faults)
the error led will be blinking
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Diagnostics
M

M M M M M

S S S S S S

S S S S S

S S S S
S
S
Power up
+ S S S S S
... ... ... ...
S S S S S

S S S S
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Control system calibration

•Power up + “S” button in 15 seconds

•Transmission (clutch control) parameter calibration

•Heat mode, for heating up gearbox to above 60degC

•Accelerator pedal (throttle pedal) sensor calibration

•Brake pedal sensor calibration (used with Inching)

•Hydro lever sensor calibration (used with Optidrive)

•Servo motor sensor calibration

•Converter out sensor calibration (not used)
Wiring diagram Controller
Link between APC 200 and “outside” world Controller

POWER T r a n s m i s s io n

S h if t L e v e r C o n t ro l
V al v e

T h r o t t le P e d a l
A PC 200
E ngine S pe ed
T u r b in e S p e e d
D rum S p ee d
O u tp u t S p e e d
B r ake Pe d al
T e m p e ra t u r e

M o d e S e l e c t io n
E n g in e

T h r o t t le
S e r vo
C o n tro l
CAN GND
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Installation guides
Installation dimensions Controller
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Error codes list
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Error codes list
Programs & Machinecard

•P00280.0100 = Volvo TAD620 + 342FTE13310-10

•P00281.0100 = Volvo TAD720 + 340FTE17310-10
•P00282.0100 = Cummins QSB5.9-30 + 300FTE13310-10, 750rpm
•P00282.0200 = Cummins QSB5.9-30 + 300FTE13310-10, 950rpm
•P00357.0100 = Volvo TAD722 + 340FTE17310-10, 750rpm

•Example 1: P00280.0100 (Configuration 3)

•Example 2: P00280.0103
•Last two digits (03) is “Config Set ID” number
 Overview APC200 programs

TE13/17 version A (painted black)

APC200 rev4 <=EBEA139203
Binary program = P00361.0100 V1.9_r4
APT file = Serial number dependent, use unique apt files
GDE edit = OEM engineering tool, edit parameters
APC200 rev6 >=EBEA139204
Binary program = P00362.0100 V1.9_r6
APT file = Serial number dependent, use unique apt files
GDE edit = OEM engineering tool, edit parameters
 Overview APC200 programs

FTE13/17 version B, -10, -12 (painted dark grey)

APC200 rev4 <=EBEA139203
Binary program = P00363.0100 V2.A_r4
APT file = Driveline dependent standard files
GDE edit = OEM engineering tool, edit parameters
APC200 rev6 >=EBEA139204 Kal.art.nr 923315.0031
Binary program = P00364.0100 V3.0_r6
APT file = Driveline dependent standard files
GDE edit = GDE production tool, select ConfigSet ID
or use OEM Engineering tool to edit parameters
 Overview APC200 binary programs

TE13/17 version A (black)

V1.7 = First available program to Kalmar
V1.8 = Second upgraded program
V1.9 = Auto calibration clutches, not mA -> Pressure
V1.9_r6 = Auto cal with APC200_rev_ 6
FTE13/17 version B (grey)
V2.0 = Complete autocalibration and heat mode
V2.A = Fixes for speedlimit problem, used in production today!
V3.0 = New Optidrive version, supporting new servicetool from
DANA, improved FWD/REV and Inching. Release in March 2004!
Flash programming binary file

•Hold “M” and “S” button while power up (Bootstrap mode)

•“F” led is flashing
•Start DanaFlash program and open binary file under c:\temp
•Load file and restart controller
FlashAPC program
APT file download

•Start APT tool

•Open correct *.apt file depending on driveline

•Make full download

APT file download
GDE tool

•Start GDE tool

•Open correct *.gde file depending on driveline

•Type the “Transm S/N” of gearbox

•Type “Vehicle ID” , Z machinenumber

•Select “ConfigSetID” according to machinecard
(contact Kalmar service if not available)
•Make full download
GDE file download
GDE file upload
THANKS!