APC200 Basic Training

Basic training APC200

16 bit controllers – CAN2.B

APC200 TCon.Fxxx

APC200

Overview Naming convention Link with the transmission APC200 System calibration

APC200

Overview Naming convention Link with the transmission APC200 System calibration Hydrostatic simulation BBC

Naming CAN2B controllers APC200  … CON . … … … …

Naming … CON . … … … … E, T, P, I or A Technology A, B, C, … etc. Functionality 120, 210, 211, 212, 213, 214, 215 or 216 Hardware reference

Technology … CON . … … … … E : (Essential) all synchro shuttle and on/off powershift technology transmissions without single pedal drive.

T : (Transmission) all powershift transmissions of which at least the direction has electronic modulation without single pedal drive and without brake by clutch technology.

P : (Powertrain) all synchro shuttle and on/off powershift technology transmissions with single pedal drive technology (P = E + single pedal drive).

I : (Intelligent) all powershift transmissions of which the direction has electronic modulation with single pedal drive technology (I = T + single pedal drive).

A : (Advanced) all powershift transmissions of which all clutches have electronic modulation with brake by clutch technology (A = T + brake by clutch).

Functionality … CON . … … … … An alphabetic letter is used to reflect the functionality of the firmware, made for a specific hardware in combination of the valve and the transmission. For the TCON :  A : all T16000 without ECI      

B : all PS08 without ECI C : all PS09 with ECI -PC D : all T16000 with ECI-PC E : all PS09 without ECI F : all TE with VFS/booster valve (overlap & ECI-SC) . . . Etc.

Note : the functionality level is a level within the technology group.

Hardware reference

… CON . … … … … 210 : (APC201-12) 12 Volt / 4 PWM’s closed loop / No H-bridge / Analog inputs 2  & 4 V 211 : (APC201-24) 24 Volt / 4 PWM’s closed loop / No H-bridge / Analog inputs 2  & 4 V 212 : (APC202-12) 12 Volt / 4 PWM’s closed loop / H-bridge / Analog inputs 2  & 4 V 213 : (APC202-24) 24 Volt / 4 PWM’s closed loop / H-bridge / Analog inputs 2  & 4 V 214 : (APC200A) 12 Volt / 5 PWM’s closed loop / No H-bridge / Analog inputs 1  & 5 V 215 : (New -12) 12 Volt / 4 PWM’s closed loop / No H-bridge / Analog inputs 1  & 5 V 216 : (New -24) 24 Volt / 4 PWM’s closed loop / No H-bridge / Analog inputs 1  & 5 V Note : the 215 & 216 R8 is needed for the TE15, TE13, TE17 andTE32 full flow valve.

Example T CON . F 211 a powershift transmissions of which at least the direction has electronic modulation without single pedal drive and without brake by clutch technology.

all TE transmissions with VFS/booster valve (overlap & ECI-SC)

24 Volt hardware, with 4 PWM’s closed loop, no H-bridge and 6 analog inputs of which 2 resistive () and 4 voltage (V).

Conclusion ACON . A 214

The 1st and 2nd part reflects the firmware of the controller The 3rd part reflects the hardware of the controller

APC200


APC200

Additional signals Speed sensors    

Engine speed Turbine speed Drum speed Output speed

Pressure feedback sensor Sump temperature sensor Converter out temperature switch

TE 10

APC200

Control valve  Proportional solenoids  VFS0 for forward  VFS1 for 2nd  VFS2 for reverse  VFS3 for 1st / 3rd  Pressure reducer  Pressure intensifiers for each VFS  Selector solenoid 1st/3rd  Total neutral solenoid

TE 10

APC200


APC200

Controller

APC200

Controller

 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 speed controlled or torque controlled

 Overlap control  Self diagnostics  Throttle by Wire – engine control  CAN Network Integration

APC200

PSU = Power Supply Unit  Version : 12V or 24V  Two power lines  PPWR : permanent power Connected directly to the battery  SPWR : switched power Connected via key contact to the battery

Controller

Controller

APC200 Bootstrap and reset circuit  Bootstrap:  Special mode, controller wants to receive serial data, to program the firmware into the program memory  While in bootstrap all output functions are hold off  Start : during power up both buttons pressed

 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 trigger²

Controller

APC200 Functions  Manual / automatic shifting  Electronic modulation  Overlap control  Electronic inching  Start 1st / 2nd  Limit vehicle speed  Reduce vehicle speed (by use of an input)  Limit engine speed

 Direction change protection (speed and engine RPM)  Declutch (inching / none inching)  Engine control  Seat orientation  Hydro lever function in neutral

APC200

Communication  CAN 2.0 B  Communicate with different controllers and PC

 RS 232  To flash a new firmware (main program)  To download the parameter settings (APT-file)  To edit specific parameters (GDE-file)

Controller

APC200

Controller

Parameter setting 1 approved drive-line = 1 APT-file Approved drive-line = Specific type of vehicle + specific engine + specific transmission ( + axle + tires )

eg.: APT-file for the Perkins engine

APC200

Parameter editing

Controller

Controller

APC200 Parameter editing

Controller

APC200

GDE user levels  Maintenance

(only for DANA engineering)

 Service

(only for DANA service)

 OEM engineering  OEM service

Controller

APC200

Parameters can have different access levels depending on the GDE user levels Write access Safe write access Read access Not visible

Controller

APC200 Configuration management

Can only be created by OEM engineering.

Controller

APC200

Configuration management Different axles, tire sizes and functions are selected via the configuration management.

The configuration management is the responsability of the OEM engineering.

Controller

APC200

Configuration management

When the APC200 is connected a full upload can be made.

Controller

APC200

Configuration management Defining different configurations

An existing configuration can be adapted or a new can be made.

APC200

Controller

Correct way to reprogram the APC200 Highest level : firmware of the APC200 The firmware is the main program of the APC200

2nd level : APT-file of the APC200 The APT-file is the parameter file with all settings and parameters

3rd level : GDE-file of the APC200 (if needed) The GDE-file is a part of the parameter file depending of user-level

Controller

APC200

Tools to reprogram the APC200 Highest level : firmware of the APC200 A windows based flash program for the TCT19.bin file

2nd level : APT-file of the APC200 A windows based APT (APC Production Tool) program

3rd level : GDE-file of the APC200 A windows based GDE (Generic Data Editor) program  GDE will only download the parameters depending of the user level (GDE OEM Engineering level for configuration managment).

Controller

APC200

APT to download all parameters / data

Configuration selection

Controller

APC200

APT to download all parameters / data

Configuration selection

An existing configuration can be selected

APC200

Controller

Display

4 red 7-segment LED digits 3 status LED lamps • D -> yellow, Diagnostic modes • E -> yellow, Error • F -> red, Failure or APC 200 in reset conditions

2 push buttons • M -> which information group • S -> item within group

Controller

APC200 Display modes M S

M

M S

S

Controller

APC200 Display modes “GPOS” display

Reflects the actually engaged transmission direction and range

Controller

APC200 Display modes “VSPD” display

Shows the vehicle speed in km/h or MPH, with a resolution of 0.1 km/h or 0.1 MPH

Controller

APC200 Display modes “DIST” display

Shows the distance travelled in km or miles, with a resolution of 0.1 km or 0.1 miles

Note : the distance can be reset by pushing the “s” button during 3 seconds when being in this display mode.

Controller

APC200 Display modes “oper” display Shows the operating time (engine running time) in hours

Note : The numbers of “.” gives the number of 10000 hours to add to the displayed value – example : 12.5.1. = 30000 + 1251 = 31251 hrs.

Controller


M

M S

S

Controller

APC200 Display modes “CPOS” display Reflects the actually shiftlever position

Controller

APC200 Display modes “ESPD” display Shows the measured engine speed in RPM

Controller

APC200 Display modes “TSPD” display Shows the measured turbine speed in RPM

Controller

APC200 Display modes “OSPD” display Shows the measured output speed in RPM

Controller

APC200 Display modes “SRAT” display Reflects the current speed ration ( Tspd / Espd ), which is an important factor in automatic shifting

Controller

APC200 Display modes “TQ I” display

Reflects the measured torque (turbine torque) at the transmission input side in Nm

Controller

APC200 Display modes “TTMP” display Shows the transmission sump temperature in °C

Controller

APC200 Display modes “CTMP” display Shows the Converter out temperature in °C

Note : due that the converter out temperature is measured by a temperature switch : 50 on the display means below 120° C 150 on the display means above 120° C

Controller


M

M S

S

Controller

APC200 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, the error led will be blinking

(end of faults)

Controller

APC200

Electronic controlled modulation (E.C.M.) Oil pressure

Time Phase 1

Filling of clutch

Phase 2 Build up of pressure

Controller

APC200 Overlap control Oil pressure

Pressure phase out in clutch 1 “overlap”

Pressure phase in in clutch 2 Time

Controller

APC200 Speed controlled inching

Inch speed (kph)

Inch speed as function of brake pedal position No Inching

10

8

8

Speed control

No braking

6

Low Speed against brake

4

De-clutch

2

1

0

0 0

25

50 Brake position (%)

75

100

Controller

APC200 Torque controlled inching

Controller

APC200 Error list

Controller

APC200 Diagnostics M M

M

M

M

M

S

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

Controller


M

M

M

M

S

S

S

Power up +

S

Note : for the firmware version, the display is using a scrolling text moving to the left (continuously).

Display test

Controller


M

M

M

M

S

S

S

Digital input test

0

2 4

6 8

10 12

1

3 5

7 9

11 13

Digital input reference

S ...

Note : input 10 till 13 are the 4 analog inputs, which could be used as digital inputs

S

Digital input 3 on wire 17 S

input not active

Controller


M

M

M

M

S

S

Analog input test

S

No . meaning the value is in 

S ... S

value (k or V) of the 1st 4 analog inputs

1st

Analog input 3 on wire 47 (47 – 30 pins on connector A = B17) S

A . meaning the value is in Volts

Controller


M

M

M

M

S

S

S

Speed sensor test

C informs the sensor is a current sensor, value is expressed in Hz or kHz (ex.: c2.45)

S ... S

1st value (kHz) of the 4 speed sensors

Speed sensor 0 on wire 22 S

Controller


M

M

M

M S

Analog output 3 on wire 8

S

Output test

S

Note : 0 till 6 are analog outputs, and 7 till 10 are digital outputs.

S

Analog output Current of 997 mA

... S

output active

Digital output 1 (7 – 6 = 1 ) on wire 10 S

Controller


M

M

M

M S

S

Voltage switched power

Voltage test S

22.7 volt S

8.1 volt

Voltage sensor power supply

APC200


Calibration

APC200 Control system calibration  Transmission (clutch control) parameter calibration  Heat mode (to warmup the transmission)  Stall test  Accelerator pedal (throttle pedal) sensor calibration  Brake pedal sensor calibration  Hydro lever sensor calibration  Servo motor sensor calibration

Calibration

APC200 Clutch filling calibration

Shift after ‘Pressure to mA’ & ‘Filling’ tuning

Calibration

APC200 Pressure to torque calibration

Calibration

APC200 Calibration done at the OEM The calibration mode can be activated by : -

pushing the “S” button for 15 seconds during powerup

-

the GDE (header Global & select for “DisplayMODE” : “Transcal” & press “F5”)

-

Sending a specific CAN message

-

using the Dashboard Tool

Calibration

APC200 Calibration done at the OEM Select the requested calibration mode by pushing the “M” button. Possible calibration modes : -

“tran” : transmission calibration “heat” : transmission warming up “thro” : throttle pedal calibration (connected to an analog input) “brak” : brake pedal calibration (connected to an analog input) “hydr” : hydro lever calibration (connected to an analog input) “serv” : servo calibration (connected to the H-bridge) “cool” : not used in this application

Calibration

APC200 Calibration done at the OEM After selecting the requested calibration mode by pushing the “S” button the calibration will be started.

Clutch filling  “tran” To start this calibration the driver will be asked to select forward (by selecting reverse the calibration will be stopped) During this calibration : -

the parking brake must be activated

-

the transmission temperature must be above 60° C

-

engine speed must be 800 RPM  200 RPM

Calibration


Warming up  “heat” When stalling the transmission at full stall : maximum 30 seconds in gear followed by minimum 15 seconds in neutral During this mode : -

only the highest gear can be selected

-

the parking brake and brake pedal will not force neutral

-

the display will show the sump temerature

Calibration


Throttle pedal  “thro” (throttle pedal connected to an analog input) During this calibration : -

the idle position is requested

-

the full throttle position is requested

By pushing the “S” the driver confirms the requested positions.

Calibration


Brake pedal  “brak” (brake pedal connected to an analog input) During this calibration : -

the idle position is requested

-

the mid point (when the brakes starts to operate) is requested

-

the full brake position is requested


Calibration


Hydro lever  “hydr” (hydro lever connected to an analog input) During this calibration : -

the 0 % position is requested

-

the 100 % position is requested


Calibration


Servo  “serv” (servo motor connected to the H-bridge) During this calibration : -

the APC200 will calibrate the idle position

-

the APC200 will calibrate the full throttle position

Thank you !

APC200 Basic Training

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