H1-Automotive Control

Application Guideline
Electrical Installation

DEUTSCH connector
CC1 DTM/12 pin

Battery (-) 1 CC1p01

Battery (+) 2 CC1p02
Sensor (+) 3 CC1p03 CC1p03
Motor RPM/Direction
Sensor (-) 4 CC1p04 CC1p04
Motor RPM Input (Frequency) 5 CC1p05
Forward Input (Digital) 6
CC1p06
A e.g.
Reverse Input (Digital) 7 B FNR Hand Brake
CC1p07
Sensor (+) 8 CC1p08
CC1p12
CNT Switch Seat-Switch
Sensor (-) 9 CC1p09
Drive Pedal Input (Analog-Nom) 10 Rv
CC1p08
Drive Pedal Input (Analog-Red) 11
CC1p10
Drive/Creep/Rocker
Neutral Input (Digital) 12 Pedal
CC1p11
Rv
Terminals CC1p09
Sensor (+)
DEUTSCH connector
CAN DTM/3 pin
Terminals
Sensor (-)
CAN High 1 CANp01
CAN Low 2 CANp02 CAN Bus
CAN Shield 3 CANp03
Terminals
Batt. (+)
DEUTSCH connector
PPC DTM/6 pin 3
CC3p01
Brake Reverse FNR in
Sensor A (+) 1
Light Motion Reverse
Analog Input A 2
Sensor A (-) 3
Sensor B (-) 4 CC3p02
Fault Reverse
Analog Input B 5 LED LED
Sensor B (+) 6
Vehicle-Speed-Dependent
Output-Signal
DEUTSCH connector CC3
PSC DTM/6 pin
DEUTSCH connector
DT04/2 pin
PWM C1 (+) 1 PSCp01
PWM C2 (+) 2 PSCp06 C1
Digital Output A1 (+) 3 PSCp03 1
PSCp02 Electronic Displacement
Digital Output A2 (-) 4 PSCp04 2
Control Pump
PWM C2 (-) 5 PSCp05 C2
PWM C1 (-) 6
PPUp03
Terminals
PPUp02 Pump RPM
DEUTSCH connector Batt. (-)
PPU DTM/3 pin
PPUp01

CC2p03
Sensor (+) 1 PPUp01
2-P
Pump RPM Input (Frequency) 2
CC2p03 Electronic Displacement
Sensor (-) 3 PPUp03
PROP
Control Motor
CC2p08
DEUTSCH connector
CC2 DTM/12 pin
BPD

CC2p04
Inch Input (Analog-Red) 1 CC2p01 Nominal
Mode Switch B
Mode Switch B Input (Digital-Nom) 2 CC2p02 1
Motor PROP/PCOR Driver 3 CC2p12
S1 2
Motor Direction Input (Analog) 4 Redundant
F1
Sensor (+) 5 CC2p05 Rv
CC2p05
Sensor (-) 6 CC2p06
CC2p07 Inch Pedal + Batt. -
Inch Input (Analog-Nom) 7
Motor BPD Driver 8
CC2p06
Rv 12/24VDC
Digital Output B2 (-) 9 Alternative Brake
Digital Output B1 (+) 10 Pressure Inch Sensor
Mode Switch A Input (Digital) 11
CC2p10
Mode Switch B Input (Digital-Red) 12
Reverse FNR in
Motion Reverse
CC2p09

Parking Brake FNR in Fault Forward

Brake Light Reverse LED LED 3

Brake
Light

Mode Switch A
CC2p11

70012798

Document designed by Sales Propel Europe

 Contents

Overview 3
About this Document ....................................................................................................................... 3
Referenced Documentation ........................................................................................................... 3
Hydraulic Products ....................................................................................................................... 3
Electronic Products ...................................................................................................................... 3
Software Products ........................................................................................................................ 3
Concept and Function...................................................................................................................... 4
Benefits .................................................................................................................................................. 4
Driving Profiles.................................................................................................................................... 4
Advanced Control Functions ......................................................................................................... 4
Integrated Motor Controller ........................................................................................................... 5
Auxiliary Functions ............................................................................................................................ 5
Economic Features ............................................................................................................................ 5
CAN Options ........................................................................................................................................ 5
Functional Safety ............................................................................................................................... 5
Installation Features .......................................................................................................................... 5
System Diagram 6
Generic System Diagram ................................................................................................................. 6
Hydraulic System Diagram ............................................................................................................. 7
Service and Diagnostic Screens 8
General .................................................................................................................................................. 8
Sensor Connections 9
Generic Connection Diagram ........................................................................................................ 9
SIL2 System Requirements 10
Introduction ....................................................................................................................................... 10
General Sensor Requirements ..................................................................................................... 10
General Actuator Requirements ................................................................................................. 10
Digital Inputs 11
General ................................................................................................................................................ 11
Electronic switch/Controller output .......................................................................................... 11
FNR Switch ......................................................................................................................................... 12
Mode Switch A .................................................................................................................................. 12
Mode Switch B .................................................................................................................................. 12
Solutions for different Mode Switches ..................................................................................... 13
Analog Inputs 14
General Sensor Requirements ..................................................................................................... 14
Drive/Creep/Rocker & Inch Pedal ............................................................................................... 15
Pressure Inch Sensor ....................................................................................................................... 15
Analog Joysticks ............................................................................................................................... 16
Hydromotor-Direction-Sensor .................................................................................................... 16
Frequency Inputs 17
Hydromotor Speed Sensor ........................................................................................................... 17
Honeywell GTN 1Axxx Hydromotor Speed Sensor ............................................................. 18
Speed, Direction and Temperature Sensor ............................................................................. 19
Electrical Characteristics 20
Pin Configuration ............................................................................................................................. 20
Supply Characteristics .................................................................................................................... 22
I/O Characteristics ............................................................................................................................ 23
Digital Inputs ................................................................................................................................ 23
Analog Inputs ............................................................................................................................... 23
Frequency Input (Motor RPM) ................................................................................................ 23
Analog Input (Motor Direction) ............................................................................................. 23
PWM Output for Motor Displacement Control ................................................................. 23
Digital Outputs ............................................................................................................................ 23
Operating Characteristics 24
Temperature Ratings ...................................................................................................................... 24
Protection Characteristics ............................................................................................................. 24
General Wiring Guidelines 25
CAN bus wiring ................................................................................................................................. 25
CAN Adapter Cable ......................................................................................................................... 26
Machine Wiring Guidelines .......................................................................................................... 27
Safety Precautions 28
Safety Precautions ........................................................................................................................... 28
Revision History ........................................................................................................................... 29

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 2

 Overview

About this Document

This document provides information about the Electrical installation of Integrated
Automotive Control System. In addition, it is a reference tool for vehicle OEM design,
engineering, and service personnel.
This document is one of several sources of technical information for the control
system. Other sources of technical information include the referenced documentation
listed below.

Referenced Documentation

Hydraulic Products
 H1P045/053 Single, Technical Information, 11063344
 H1P078 Single, Technical Information, 11062169
 H1P089/100 Single, Technical Information, 11069970
 H1P115/130 Single, Technical Information, 11063346
 H1P115/130 Single, Technical Information, 11063347

Electronic Products
 Speed and Temperature Sensor, 11046759
 KPP Pulse Pickup Speed Sensors, 11029257
 Pressure Sensor MBS1250, 11058299
 JS6000 Joystick, 520L0760
 Graphical Terminals and Displays, 11035455

Software Products
 PLUS+1 Service Tool User Manual, 520L0899
 H1 Automotive Control Service Interface User Manual, 70012797
 Recommended System Start-up Procedures Technical Information, 11010667
 Technical Information for PLUS+1 Controller, 520L0719

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 3

 Overview

Concept and Function

The Sauer-Danfoss integrated automotive control system is designed for pumps with
NFPE (Non-Feedback Proportional Electric) Control. The flexible system
configuration allows use of a wide range of hydrostatic pumps and motor
combinations out of the Sauer-Danfoss product portfolio.
The integrated automotive control combines enhanced control performance with a
flexible control scheme. The controller converts engine speed signal to an automotive
drive signal to control the proportional axial piston pump. It is designed to control a
two position controlled motor or an electric proportional control for a bent axis motor.
With easily changeable control parameters, it is possible to tailor the vehicle's driving
behavior to the individual requirements of the machine.
The combination of state of the art technology of embedded digital electronic control
and Sauer-Danfoss proven axial piston pump technology opens a wide range of
application possibilities.

Benefits
Sauer-Danfoss offers years of application expertise in a fully integrated, pre-tested
Automotive Control System solution that’s ready to be tailored to your vehicle
requirements. The integrated automotive control system is a complete vehicle
transmission solution offering benefits including:

 Reduced OEM time-to-market for new vehicles and model variants

 Reduced system development, vehicle qualification, and certification expense
 State-of-the-art system level functional safety design
 Enhanced, flexible functionality through embedded intelligent electronics.

Driving Profiles
 Four selectable system modes, selectable via switch
 Independent curves and settings for forward and reverse (4 x 2 curves)
 Switch selectable between automotive and engine speed independent driving
modes
 Engine speed independent drive modes for sweepers, snow blowers (non-
automotive mode)
 Load independent drive modes for off road applications (non-automotive for
rollers and forestry machines)
 Load independent swash-plate control via pump swash-plate angle sensor to
achieve EDC behavior
 Creep speed mode (slow shunting, digging operation, etc)
 Constant speed mode (sweepers, snow-blowers, etc)
 Integrated vehicle speed limiter function

Advanced Control Functions

 Inch function without separate control valve
 Integrated temperature sensor for:
− Hydraulic system overheat protection
− Low temperature pump flow limitation
− Compensation of oil viscosity changes if using (radial piston motors, etc)
 Configurable engine antistall protection
 Engine overspeed protection while inching

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 4

 Overview

Integrated Motor Controller

 Integrated electric motor control for:
− Proportional, variable PCOR or two position motor controls
− Brake pressure defeat, depending on the FNR position or the real vehicle
driving direction
− Initial breakaway motor torque override
 Separate overspeed protection for the hydrostatic motor.

Auxiliary Functions
 Four auxiliary outputs for:
− Intelligent brake light control
− Automatic park brake function
− Vehicle speed dependent output to activate (load stabilizer, warning lights, etc)
− Reverse buzzer controlled by FNR or reverse driving
− System status lamp (fault detection for pump solenoids).

Economic Features
 Technology and enabler for economic driving and fuel savings
 Easy combination options to other components of the PLUS+1 Family.

CAN Options
 J1939 protocol compliant CAN messages from/to an engine controller
 J1939-CAN Shared Engine Speed Control with Safety Monitoring. The H1-AC
generates based on e.g. a drive pedal a desired engine speed.
 J1939-CAN Subsystem-Data Interface. The software application can receive CAN
information from the vehicle system (e.g. Drive Pedal, Joystick, FNR).

Functional Safety
 The H1-AC Hard and Software fulfils the requirements of the guidelines accordant
to IEC 61508, SIL2 (Functional safety). Proved by the certification body TÜV NORD,
Hamburg.
 Safety controlled Vehicle Start-Protection (engine speed check, battery check and
FNR must be in neutral, etc)
 Operator presence detection
 Vehicle speed dependent direction change lock
 Brake test mode for roller applications to fulfill EN500-4.

Sauer-Danfoss strongly recommends that the OEM perform a system level Failure
Mode Effects Analysis (FMEA)

Installation Features
 Factory calibration for hysteresis compensation.

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 5

 System Diagram

Generic System Diagram

Note: Swashplate sensor included (Option)

Temperature sensor on board

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 6

 System Diagram

Hydraulic System Diagram

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 7

 Service and Diagnostic Screens

General
Optional the PLUS+1 GUIDE Service Tool can be used to modify and tune the
individual machine settings.
The PLUS+1 GUIDE Service Tool has 2 basic screen areas:

1. Log Functions:
These screens are showing important run data of the transmission system.
They are very useful for understanding the system behavior, for tuning the
system and for trouble-shooting. These data can also be logged and stored
on the hard disk of a laptop for documentation or discussion purposes.

2. Parameter Functions:
These screens are showing the possible system parameter for configuring
and tuning a transmission system according to customer requirements.

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 8

 Sensor Connections

Generic Connection Diagram

Note: Swashplate sensor included (Option)
Temperature sensor on board
DEUTSCH connector
CC1 DTM/12 pin

Battery (-) 1 CC1p01

Battery (+) 2 CC1p02
Sensor (+) 3 CC1p03 CC1p03
Motor RPM/Direction
Sensor (-) 4 CC1p04 CC1p04
Motor RPM Input (Frequency) 5 CC1p05
Forward Input (Digital) 6
CC1p06
A e.g.
Reverse Input (Digital) 7
CC1p07
B FNR Hand Brake
Sensor (+) 8 CC1p08
CC1p12
CNT Switch Seat-Switch
Sensor (-) 9 CC1p09
Drive Pedal Input (Analog-Nom) 10 Rv
CC1p08
Drive Pedal Input (Analog-Red) 11
CC1p10
Drive/Creep/Rocker
Neutral Input (Digital) 12
CC1p11
Pedal
Rv
Terminals CC1p09
Sensor (+)
DEUTSCH connector
CAN DTM/3 pin
Terminals
Sensor (-)
CAN High 1 CANp01
CAN Low 2 CANp02 CAN Bus
CAN Shield 3 CANp03
Terminals
Batt. (+)
DEUTSCH connector
PPC DTM/6 pin 3
CC3p01
Brake Reverse FNR in
Sensor A (+) 1
Light Motion Reverse
Analog Input A 2
Sensor A (-) 3
Sensor B (-) 4 CC3p02
Fault Reverse
Analog Input B 5 LED LED
Sensor B (+) 6
Vehicle-Speed-Dependent
Output-Signal
DEUTSCH connector CC3
PSC DTM/6 pin
DEUTSCH connector
DT04/2 pin
PWM C1 (+) 1 PSCp01
PWM C2 (+) 2 PSCp06 C1
Digital Output A1 (+) 3 PSCp03 1
PSCp02 Electronic Displacement
Digital Output A2 (-) 4 PSCp04 2
Control Pump
PWM C2 (-) 5 PSCp05 C2
PWM C1 (-) 6
PPUp03
Terminals
PPUp02 Pump RPM
DEUTSCH connector Batt. (-)
PPU DTM/3 pin
PPUp01

CC2p03
Sensor (+) 1 PPUp01
2-P
Pump RPM Input (Frequency) 2
CC2p03 Electronic Displacement
Sensor (-) 3 PPUp03
PROP
Control Motor
CC2p08
DEUTSCH connector
CC2 DTM/12 pin
BPD

CC2p04
Inch Input (Analog-Red) 1 CC2p01 Nominal
Mode Switch B
Mode Switch B Input (Digital-Nom) 2 CC2p02 1
Motor PROP/PCOR Driver 3 CC2p12
S1 2
Motor Direction Input (Analog) 4 Redundant
F1
Sensor (+) 5 CC2p05 Rv
CC2p05
Sensor (-) 6 CC2p06
CC2p07 Inch Pedal + Batt. -
Inch Input (Analog-Nom) 7
Motor BPD Driver 8
CC2p06
Rv
12/24VDC
Digital Output B2 (-) 9 Alternative Brake
Digital Output B1 (+) 10 Pressure Inch Sensor
Mode Switch A Input (Digital) 11
CC2p10
Mode Switch B Input (Digital-Red) 12
Reverse FNR in
Motion Reverse
CC2p09

Parking Brake FNR in Fault Forward

Brake Light Reverse LED LED 3

Brake
Light

CC2p11
Mode Switch A

70012798

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 9

 SIL2 System Requirements

Introduction
During several System- and Sub-System-FMEA analysis (Failure Modes and Effects
Analysis), Sauer-Danfoss has identified the following requirements for Customer-
Sensors and Customer-Actuators to satisfy the requirements of a SIL2 certification on
vehicle system level.
The pump valves, the pump rpm sensor, the wiring-harness and the integrated swash
plate angle sensor are part of the SIL2 certification of the H1-AC.

General Sensor Requirements

CAN Input Signals are not certifiable according SIL2 of IEC 61508.
The J1939 CAN Protocol did not provide the safety relevant features.
Sauer-Danfoss is not responsible for the function and safety of third-party sensors and
actors which are connected to the AC!

The AC Control is designed to connect different kinds of sensors:

 the pump & motor rpm and direction signals are based on the 5V Sensor supply
 the digital inputs (switches) are based on the supply voltage (12/24V)

The high and low input signals are expected in a “band” which can be individually
adjusted to the demands.
For more information please refer below or to the Service Interface User Manual

General Actuator Requirements

 Parking Brake, Brake Light Closed-Loop, FNR in Reverse & Reverse Motion have to
be connected in closed-loop current control
 Motor Displacement and Break-Pressure-Defeat Valve are supplied in open loop
 It is not allowed to overload the hardware outputs

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 10

 Digital Inputs

General
The digital inputs must supplied by battery voltage, independent if using a held or
momentary switch.

Electronic switch/Controller output

If using an electronic switch or output signal of a separate controller, it is required to

supply the right signal level. Electronic outputs can have a leakage current which can
lead into bad signals.
If using a PULS+1 controller output the following configuration is a must:
 DOUT
 Pin Configuration=0 (Push/Pull Output)

All other output configurations like PWM, open collector, open source etc. are NOT
allowed.

For further information please refer to the Technical Information for PLUS+1
Controller 520L0719.

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 11

 Digital Inputs

FNR Switch
F
CC1p06
CC1p12 N + Battery
CC1p07 R Supply

For a SIL2 certification the following settings are required:

 3-Layer switch with held Signal
 Separate output signals for FORWARD, NEUTRAL and REVERSE indication as input
signals of the AC connector pins for CC1p06, CC1p07 and CC1p12.
 Switch has to be supplied by Battery voltage
 Switch needs to be compliant to the input resistance of the digital input
 Gold-Plated contacts are recommended
 Input Selector Configuration:
 FNR-Source: FNR Signal from digital inputs [Parameter 807]
 FNR-Signal Interpretation: F or R or N held (continuous signal) [Parameter 897]

If no SIL2 certification is required, the following settings are possible:

 2-Layer switch for FORWARD and REVERSE minimum
 FNR-Source: FNR Signal from digital inputs on via CAN Bus
 FNR-Signal Interpretation: held or momentary

Mode Switch A

Mode Switch A

For a SIL2 certification the following settings are required:

 Switch has to be supplied by Battery voltage
 Switch needs to be compliant to the input resistance of the digital input
 Gold-Plated contacts are recommended

If no SIL2 certification is required, the following setting is possible:

 Mode Switch Signal via CAN Bus

Mode Switch B
Nominal
Mode Switch B

Redundant
For a SIL2 certification the following settings are required:
 Switching logic has to be diverse redundant (opening and closing in parallel)
 Switch has to be supplied by Battery voltage
 Switch needs to be compliant to the input resistance of the digital input
 Gold-Plated contacts are recommended
 Input Selector Configuration
 If the system mode with this digital input changes between Automotive/Creep-
Automotive or Non-Automotive, it is mandatory, to configure the parameter
“Mode Switch B Redundant”

If no SIL2 certification is required, the following settings are possible:

 Switching logic not redundant (only closing contact) possible.

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 12

 Digital Inputs

Solutions for different Mode Switches

There are different solutions for the wiring of Mode Switches possible. Enclosed you
will find some sample circuits.

Solution with 4 position switch

Battery +

Mode Switch A Input CC2p12

Switch
1 – Automotive (Transport)
2 – Automotive (Work)
3 – Creep-Automotive (Work)
4 – Non-Automotive (Sweeper)
Mode Switch B Input (Nominal) CC2p02

Mode Switch B Input (Redundant) CC2p11

Solution with Joystick (2-position) and 2 separate Switches

Battery +

Mode Switch A Input CC2p12

Joystick Switch
Switch open – Mode 1 or 2
open – Mode 3 closed – Mode 3 or 4
closed – Mode 4

Mode Switch B Input (Nominal) CC2p02

Mode Switch B Input (Redundant) CC2p11

Switch
open – Mode 1
closed – Mode 2

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 13

 Analog Inputs

General Sensor Requirements

 Sensor must be supplied with AC sensor supply voltage and must not exceed the
max output current (overload)
 If an analog sensor (potentiometer) is used, it should have a resistance value of
> 1kΩ and < 10kΩ.
 The voltage range of the output signals must not be lower than 5% and not higher
than 95% of sensor voltage. Upper and lower voltage limits to sensor supply are
requested for wire-fault detection.
 To provide an open lead and short-cut detection it is required to use series
resistors. The resistor value has to be approximately 7% of the poti resistance
value.
 The voltage of the input must increase when the actuator is operated. For SIL2
certification some sensor must have a “Dual redundant Output”.

Poti resistance Rv
1 kΩ 68 Ω
5 kΩ 330 Ω
10 kΩ 680 Ω

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 14

 Analog Inputs

Drive/Creep/Rocker & Inch Pedal

Rv
Sensor supply
Nominal

Rv
Rv
Redundant

Ground
Rv

For a SIL2 certification the following settings are required:

 Analog sensor must have a dual output (e.g. two independent potentiometers).
 This sensor must produce two electrically independent output signals that are in
direct correlation with each other.
 The first output signal is used as the source of pedal position signal information
and the second output signal is used for diagnostic purposes.
 In case of an internal detected error, the sensor output signal has to be clamped by
the sensor itself to sensor supply voltage. This feature enables the software
application to recognize this failure.
 The voltage range of the output signals have to be in the allowed input range of
the analog inputs

If no SIL2 certification is required, the following settings are possible:

 A single output (not redundant) is possible

Pressure Inch Sensor

CC2p05
CC2p07
CC2p06

Alternative Brake
Pressure Inch Sensor

For a SIL2 certification the following settings are required:

 For the pressure inch sensor a redundant inch signal is not needed. A Single
output signal is sufficient, because the redundancy is here given by the hydraulic
brake system and the direct measurement of the hydraulic braking pressure. The
inch function is only supporting the vehicle brake system to prevent driving
against the brakes.
 The voltage range of the output signals must not be lower than 5% and not higher
than 95% of sensor voltage.
 Upper and lower voltage limits to sensor supply are requested for wire-fault
detection
 In case of an internal detected error, the sensor output signal has to be clamped by
the sensor to sensor supply voltage. This feature enables the software application
to recognize this failure.
 Sensor must be supplied with AC sensor supply voltage and must not exceed the
max output current (overload) (see section 1.11.1).
 Recommended pressure sensor:
Pressure Sensor MBS1250 (0-40/160/250/400/500/600 bar)
Technical Information 11058299

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 15

 Analog Inputs

Analog Joysticks
The demands on an analog Joystick are the same like connecting a potentiometer or
an Electronic Pedal.
For further information about our analog Joystick JS1000 please refer to the Technical
Information 11007854.

Hydromotor-Direction-Sensor
The motor direction is detected by using an analog input signal.

 Sensor must be supplied by the sensor supply voltage of the H1-AC

 Upper and lower voltage limits for the output signals below sensor supply are
requested for wire-fault detection
 The voltage range of the output signals have to be in the allowed input range of
the analog inputs
 PPU needs to be compliant to the input resistance of the rpm and analog input

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 16

 Frequency Inputs

Hydromotor Speed Sensor

 Sensor must be supplied by the sensor supply voltage of the H1-AC
 Upper and lower voltage limits for the output signals below sensor supply are
requested for wire-fault detection
 The voltage range of the output signals have to be in the allowed input range of
the analog inputs
 PPU needs to be compliant to the input resistance of the rpm and analog input

AC Control Connector The listed resistors and diodes are recommandations

Sensor (+5V) CC1p03

15k R1
Motor RPM Input CC1p05 R1 = 1k
R2 R2 = 100R
Motor Speed sensor
R3 = 100k
13k5 R3 Open collector NPN Signal Level 0,5V / 4,6V
Sensor (-) CC1p04

No SIL2 certification
Sensor (+5V) CC1p03
15k R4
Motor Speed sensor R4 = 100k
5V Sensor Supply R5 = 100R
Open collector PNP
R6 = 1k5
R5
Motor RPM Input CC1p05 Signal Level 0,5V / 4,6V
13k5 R6
Sensor (-) CC1p04

R7 = 820R (9V)
No SIL2 certification
1k2 (12V)
Battery supply CC1p01
3k3 (24V)
Motor Speed sensor
Sensor (+5V) 9 to 36V Battery Supply 4k7 (32V)
15k Open collector PNP R8 = 1k8
R7 ZD = 4V7 / 0,25W
Motor RPM Input CC1p05
13k5
ZD 4V7
R8
Signal Level 0,5V / 4,6V
0,25W
Sensor (-) CC1p04

Sensor (+5V) CC1p03

15k R
R9 Sauer-Danfoss
Motor RPM Input CC1p05
Motor Speed sensor
13k5 R Supplied with 5V

Sensor (-) CC1p04

No SIL2 certification
Battery supply CC1p01
Sensor (+5V)
KPPG x6xxx Signal Level
15k
R9 = 1k0 (12V) 0,5V / 4,5V
R9 Sauer-Danfoss
Motor RPM Input CC1p05 1k0 (24V) 0,5V / 4,7V
Motor Speed sensor
ZD 4V7 Supplied with 12 to 32V 1k5 (32V) 0,6V / 4,6V
13k5 0,25W ZD = 4V7 / 0,25W
Sensor (-) CC1p04

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 17

 Frequency Inputs

Honeywell GTN 1Axxx Hydromotor Speed Sensor

The Honeywell Sensor GTN 1A131 (9-16V supply) and 1A211 (21-32V supply) are often
used in the ICVD gear box. The digital output provides an open collector, switching to
ground.
For further technical details, please visit the Honeywell homepage.

AC Control Connector The listed resistors is a recommandation!

Battery supply CC1p01

3
Sensor (+5V) CC1p03
15k 3K3 Supply Signal Level
2 Rv
Motor RPM Input CC1p05
Honeywell
GTN 1A131 8-16V 1,3V / 3,7V
13k5 GTN 1Axxx GTN 1A211 21-32V 1,6V / 3,7V
1
Sensor (-) CC1p04

Recommended configuration for the Motor RPM

Additional PPU Functions = 107 [RPM Diagnostics]

RPM Diagnostics (signal levels)

Name % V
Short Power 80 4,0
No Error High 66 3,3
Ground Lead 50 2,5
Open
Signal Lead Open 45 2,25
Power Lead Open 40 2,0
No Error Low 20 1,0

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 18

 Frequency Inputs

Speed, Direction and Temperature Sensor

The Speed, Direction and Temperature-Sensor is specially designed for the H1Product
Family and is used in the H1 Pumps and Motors.
The Sensor provides the following Output Signals:
 Two Speed Signals (only one Signal used for AC Control)
 One Analog direction Signal
 One Analog Temperature Signal (not used at the AC Control)

The electrical design was tailored for the AC Control, so there are no adjustments
required.
For using with H1B Motors a DEUTSCH Connector DTM06-6S is required.

For further information of the Speed, Direction and Temperature Sensor please refer
to the Technical Information 11046759.

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 19

 Electrical Characteristics

Pin Configuration

Connector / Name Note

Pin
CC1:01 Battery (-) Power supply input for battery (-)
CC1:02 Battery (+) Power supply input for battery (+)
Estimated maximum current is 12A
CC1:03 Motor-PPU-Supply (+) Sensor-Supply (+) for the HST-Motor-PPU-Sensor
Supply for sensors within 4.825 to 5.075 V
CC1:04 Motor-PPU-Supply (-) Sensor-Supply (-) for the HST-Motor-PPU-Sensor
CC1:05 Motor-PPU-RPM-Input Frequency-Input for HST-Motor-PPU-Sensor
CC1:06 Forward-Direction-Input Digital Input for driving direction FORWARD
Switched to battery supply (12/ 24 V)
CC1:07 Reverse-Direction-Input Digital Input for driving direction REVERSE
Switched to battery supply (12/ 24 V)
CC1:08 Creep/Drive-Analog- Sensor-Supply (+) for Creeping- or Driving-Pot
Supply (+) Supply for sensors within 4.825 to 5.075 V

CC1:09 Creep/Drive-Analog- Sensor-Supply (-) for Creeping- or Driving-Pot

Supply (-) Direct GROUND-Connection
CC1:10 Creep/Drive-Analog-Input Analog-Input for nominal Creeping- or Driving-Pot
CC1:11 Red-Creep/Drive-Analog- Analog-Input for redundant Creeping- or Driving-Pot
Input
CC1:12 Neutral-Direction-Input Digital Input for driving direction NEUTRAL
Switched to battery supply (12/24 V)

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 Electrical Characteristics

Pin Configuration

Connector / Pin Name Note

CC2:01 Red-Inch-Analog-Input Analog-Input for redundant Inching-Pot
CC2:02 Mode Selection Input B Digital-Input for driving mode selection
CC2:03 Motor PROP/PCOR Valve- Proportional-Output (+) for the Pressure-Control-
Output Override or Prop-Motor Valve
CC2:04 Motor-PPU-Direction-Input Analog-Input for HST-Motor-Direction
CC2:05 Inch-Analog-Supply (+) Sensor-Supply (+) for Inching-Pot
Supply for sensors within 4.825 to 5.075 V
CC2:06 Inch-Analog-Supply (-) Sensor-Supply (-) for Inching-Pot
Direct GROUND-Connection
CC2:07 Inch-Analog-Input Analog-Input for nominal Inching-Pot
CC2:08 Motor BPD Valve-Output Digital-Output for the Brake-Pressure-Defeat
(BPD) Valve
Switched to battery (+)-supply
CC2:09 Digital Output B2 (-) Digital-Output for Brake Light
Switched to battery (-)-supply
CC2:10 Digital Output B1 (+) Digital-Output for the FNR Forward LED, Fault LED
Switched to battery (+)-supply
CC2:11 Mode-Selection-Input A Digital-Input for driving mode selection
CC2:12 Mode Selection Input B Digital-Input for driving mode selection
(Redundant) (Redundant)
CC3:01 Digital Output A1 (+) Digital-Output for Brake-Light, Fault- and Reverse-
LED
Switched to battery (+)-supply
CC3:02 Digital Output A2 (-) Digital-Output for Vehicle-Speed-Dependent
Output-Signal
Switched to battery (-)-supply
CAN:01 Communication-Connection
for CAN-High-Line
CAN:02 Communication-Connection
for CAN-Low-Line
CAN:03 Communication-Connection
for CAN-Ground

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 21

 Electrical Characteristics

Pin Configuration
Connector / Name Note
Pin
PPU:01 Pump-PPU-Supply (+) Sensor-Supply (+) for HST-Pump-PPU-Sensor
Supply for sensors within 4.825 to 5.075 V
PPU:02 Pump-PPU-RPM-Input Frequency-Input for HST-Pump-PPU-Sensor
PPU:03 Pump-PPU-Supply (-) Sensor-Supply (-) for the HST-Pump-PPU-Sensor
PSC:01 Forward-Valve (+) Proportional-Output (+) for the FORWARD-Valve.
PSC:02 Reverse-Valve (+) Proportional-Output (+) for the REVERSE Valve
PSC:03 Digital Output A1 (+) Connected via wiring Harness to CC3:01
PSC:04 Digital Output A2 (-) Connected via wiring Harness to CC3:02
PSC:05 Reverse-Valve (-) Feedback for the REVERSE-Valve
PSC:06 Forward-Valve (-) Feedback for the FORWARD-Valve
PPC:01 Sensor-A-Supply (+) Sensor-Supply (+) for Pump-Pressure-Sensor A
Supply for sensors within 4.825 to 5.075 V
PPC:02 Sensor-A-Signals Analog-Input for Pump-Pressure-Sensor A
PPC:03 Sensor-A-Supply (-) Sensor-Supply (-) for Pump-Pressure-Sensor A
Direct GROUND-Connection
PPC:04 Sensor-B-Supply (-) Sensor-Supply (-) for Pump-Pressure-Sensor B
Direct GROUND-Connection
PPC:05 Sensor-B-Signals Analog-Input for Pump-Pressure-Sensor B
PPC:06 Sensor-B-Supply (+) Sensor-Supply (+) for Pump-Pressure-Sensor B
Supply for sensors within 4.825 to 5.075 V

Supply Characteristics
Parameter Min Max Units Note
Battery Supply-Current - 12 A
Recommended fuse size - 16 A
Permanent Supply-Voltage-Range 9 36 VDC
Rated-12V-Range 9 16 VDC
Rated-24V-Range 18 32 VDC
Permanent Reverse-Voltage-Protection - -36 VDC
Current per Connector-Pin - 3 A

Sensor-Supply-Voltage-Range (internal) 4.825 5.075 VDC

Sensor-Supply-Current - 1 A

It is strongly recommended to switch the power supply of the AC control together

with the power supply of the engine to avoid misleading errors.
This even includes the use of emergency stops, safety switches etc.

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 22

 Electrical Characteristics

I/O Characteristics
Digital Inputs
Parameter Min Max Units Note
Rising voltage threshold - 7.00 VDC A digital input is guaranteed to be read as
high if the voltage is grater than 7.00V.
Falling voltage threshold 1.66 - VDC A digital input is guaranteed to be read as
low if the voltage is less than 1.66V.
Input Impedance 13.4 13.8 k

Analog Inputs
Parameter Min Max Units Note
Input voltage range 0.08 5.26 VDC
Resolution - 12 Bit 4096 steps
Input Impedance 230 236 k

Frequency Input (Motor RPM)

Parameter Min Max Units Note
Rising voltage threshold (middle - 3,5 V The frequency input is guaranteed to
range) be read as high if the voltage is
grater than 3.5V.
Falling voltage threshold 0.74 - V The frequency input is guaranteed to
(middle range) be read as low if the voltage is less
than 0.74V
Input Impedance 7.00 7.21 kOhm 15kOhm to sensor supply / 13.5
kOhm to GND
Frequency Range 0 10000 Hz In steps of 1 Hz.

Analog Input (Motor Direction)

Parameter Min Max Units Note
Input voltage range 0.08 5.26 VDC
Resolution - 12 Bit 4096 steps
Input Impedance - - k 15kOhm to sensor supply / 14.1 kOhm to
GND

PWM Output for Motor Displacement Control

Parameter Min Max Units Note
Proportional Current 0 3.0 A
Output voltage - Supply Output voltage is supply voltage!
PWM frequency 33 200 Hz

Digital Outputs
Parameter Min Max Units Note
Output Current 0,005 3.0 A
Output voltage A1(+)/B1(+) Supply Output voltage is supply voltage!
Output Current A2(-)/B2(-) GND Output voltage is GND!

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 23

 Operating Characteristics

Temperature Ratings
Parameter Min Max Units Note
Operating Temperature- -40 104 °C 115°C (240F) Intermittent = Short term
Range -40 220 F t < 1min per incident and not exceeding
2 % of duty cycle based load-life
Application Software 0 70 °C
download 32 158 F
Parameter download -40 104 °C
-40 220 F

Protection Characteristics
Parameter Min Max Units Note
Short Circuit All inputs and outputs shall withstand
continuous short circuit to all other leads.
When the short circuit is removed the unit
returns to normal function.
EMC-Immunity 100 V/m EN 61000-6-2
EMC generic standard for immunity, industrial
environment
- incl. 1kHz w/ AM 80%
EMC-Emission EN 61000-6-3
EMC generic standard for emission, residential
and industrial environments.
EN 12895 for industrial trucks.
ESD 15 kV EN 61 000-4-2
8 kV - Electrostatic discharge immunity test Level 4.
- Direct contact discharge to connector pins.
Automotive Transients ISO 7637 / 1-3
Temp / Volt / Humidity IEC 60068-2-38
IP67 & IP69K IEC 60529 & DIN 40050 part 9
Sinusoidal vibration
- IEC60068-2-6 Fc, 60 Level 2
Vibration Level Sine-
30 G (Resonance search not practicable)
Acceleration
Vibration test random
- IEC 60068-2-64, test Fh Level 3

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 24

 General Wiring Guidelines

CAN bus wiring

The wiring of the vehicles CAN bus must be according SAE J1939-11 Physical layer
and ISO 11898-2. The following information are an abstract of the ISO11898-2, please
consider as well the official rules.

For the High-Speed (250 kbit/s) CAN bus both ends of the signal wires (CAN_H and
CAN_L) must be terminated with 120 Ω, because the communication flows both ways
on the CAN bus.

ECU ECU ECU

1 ls 2 n

ls
120 120

d d
L

The following points have to be considered:

 Cable twisted pair, shielded
 Cable impedance (Z) 120 Ω nominal
 Length-related resistance 70 mΩ/m (copper wire 0,25mm² min)
 Maximum 30 devices (ECU) on the bus
 Maximum bus length (L) 40m
 Maximum cable stub length (ls) 0,3m
 Node distance (d) 0,1 – 40m
 Termination resistor 120 Ω on both ends, not directly on a ECU
 Bus traffic less than 40% recommended

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 25

 General Wiring Guidelines

CAN Adapter Cable

To connect the AC Controller with the CG150 CAN Gateway a CAN adapter cable is
required.

DEUTSCH connector Female D-SUB connector

DTM06 3 pin 9 pin

CAN High 1 120 1 nc

CAN Low 2 2 CAN Low
CAN Shield 3 3 Ground
4 nc
5 Shield CAN Bus
6 nc
7 CAN High
8 nc
9 Power Supply (+)
F
1A
- Batt. +
12/24VDC

Bill of material:
 CAN Deutsch Connector DTM06 3-SKT PLUG GY
Material No. 11033864
 9 pin female D-SUB Connector with housing
 120 ohm resistor 1/4W ± 5% or better
 1 m Cable 3 wire, diameter 0,2 to 1,0 mm² (0,5 mm² recommended)

If using a cable longer than 1 m, a shielded cable is required. For further information
see the JR1939 specification.

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 26

 General Wiring Guidelines

Machine Wiring Guidelines

The following Guidelines are recommendations, please consider official rules like SAE,
ISO etc.

1. All wires must be protected from mechanical abuse. Wires can be rum in
flexible metal or plastic conduits.
2. Use 85°C (185F) wire with abrasion resistant insulation. 105°C (221F) wire
should be considered near hot surfaces
3. Use AWG 20 -24 wires (0,2 – 0,5 mm²) for solid crimp Type contacts (standard
in assembly bag) or AWG 16 – 20 (0,5 – 2,0 mm²) for Stamped & formed Type
contacts.
4. The outer diameter for Cables must be in the following range to comply the
environmental protection:
Connector Name Connector Type Outer Diameter
CC1 or CC2 DTM12 1,35 to 3,05 mm
0.053 to 0.120”
CAN DTM06 1,35 to 3,05 mm
0.053 to 0.120”
PSC Adapter DT04 2,23 to 3,68 mm
0.088 to 0.145”

5. Separate high current wires such as solenoids, lights, alternators or fuel

pumps from control wires.
6. Run wires along the inside of, or close to, metal machine frame surfaces
where possible. This simulates a shield which will minimize the effects of
EMI/RFI radiation.
7. Do not run wires near sharp metal corners. Consider running the wire
through a grommet when rounding a corner.
8. Do not run wires near hot machine members.
9. Provide strain relief for all wires.
10. Avoid running wires near moving or vibrating components.
11. Avoid long, unsupported wire spans.
12. All sensors and valve drive circuits have dedicated wired power sources and
ground returns. They should be used.
13. Sensor lines should be twisted about one turns every 10 cm (4 inches).
14. It is better to use wire harness anchors that will allow wires to float with
respect to the machine frame rather than rigid anchors.

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 27

 Safety Precautions

Safety Precautions
Always consider safety precautions before beginning a service procedure. Protect
yourself and others from injury. Take the following general precautions whenever
servicing a hydraulic system.

Unintended machine movement


! Warning
Unintended movement of the machine or mechanism may cause injury to the
technician or bystanders. To protect against unintended movement, secure the
machine or disable/disconnect the mechanism while servicing.

Flammable cleaning solvents


! Warning
Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning
solvents in an area where a source of ignition may be present.

Fluid under pressure


! Warning
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your
skin causing serious injury and/or infection. This fluid May also be hot enough to
cause burns. Use caution when dealing with hydraulic fluid under pressure. Relieve
pressure in the system before removing hoses, fittings, gauges or components. Never
use your hand or any other body part to check for leaks in a pressurized line. Seek
medical attention immediately if you are cut by hydraulic fluid.

Personal safety

! Warning
Protect yourself from injury. User proper safety equipment, including safety glasses, at
all times.

Welding on a machine
! Warning
The following procedures are recommended when welding on a machine:
- The engine should be off
- Disconnect the negative battery cable from the battery
- Do not use electrical components to ground the welder. Clamp the ground cable for
the welder to the component that will be welded as close a possible to the weld.

During on machine tests make sure, that all persons are in safe positions. Be sure, that
unexpected movement of the machine will not injure persons or damage property.
Best practice is, to lift the driven wheels or tracks off the ground during start-up and
test runs.

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 28

 Revision History

Date Page Changed Rev

28 Oct, 2009 - Initial Revision A
29 Jan 2010 12 Sample circuts for Mode switch A and B B
11 June 2010 17, Connector Speed sensor changed, C
21 Digital Output specification changed
08 Nov 2010 3, 11, Reference list updated, new specification for digital D
15 inputs, new pressure sensor defined
09 Dec 2010 24 CAN bus wiring guideline added E
28 June 2011 24 New page 18, Honeywell sensor GTN 1Axxx added F
24 Nov 2011 22, Recommendation Power supply, CAN Adapter G
26 circut

2010 Sauer-Danfoss. All rights reserved.

Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed
material. Sauer-Danfoss reserves the right to alter its products without prior notice. This also applies to
products already ordered provides that such alterations aren’t in conflict with agreed specifications. All
trademarks in this material are properties of the respective owners. Sauer-Danfoss, the Sauer-Danfoss
logotype, PLUS+1 and PLUS+1 logo are trademarks of the Sauer-Danfoss Group.

Revision G H1 AC Application Guideline - Electrical Installation_Rev G.doc 29