MAKING MODERN LIVING POSSIBLE

System Description

PLUS+1® Compliant
Integrated Automotive Control

powersolutions.danfoss.com
System Description PLUS+1® Compliant Integrated Automotive Control

Revision History Table of Revisions

Date Changed Rev

Feb 2014 Converted to Danfoss layout-DITA CMS BA

Mar 2010 First edition AA

2 11066201 • Rev BA • Feb 2014

System Description PLUS+1® Compliant Integrated Automotive Control

Contents

Overview
About this document......................................................................................................................................................................5
Referenced Documentation......................................................................................................................................................... 5
Hydraulic Products..................................................................................................................................................................... 5
Electronic Products.....................................................................................................................................................................5
Software Products.......................................................................................................................................................................6
OEM Responsibility.......................................................................................................................................................................... 6
Concept and Function.................................................................................................................................................................... 6
AC-1 System Option Portfolio......................................................................................................................................................6
AC-2 System Option Portfolio......................................................................................................................................................7
Benefits
Driving Profiles.................................................................................................................................................................................. 8
Advanced Control Functions........................................................................................................................................................8
Integrated Motor Controller.........................................................................................................................................................8
Auxiliary Functions...........................................................................................................................................................................9
Economic Features...........................................................................................................................................................................9
CAN Options.......................................................................................................................................................................................9
Functional Safety.............................................................................................................................................................................. 9
Installation Features........................................................................................................................................................................ 9
System Details
System Overview............................................................................................................................................................................10
Wiring Diagram...............................................................................................................................................................................11
System Controller Details............................................................................................................................................................12
Inputs............................................................................................................................................................................................ 12
Outputs........................................................................................................................................................................................ 13
Configuration Options
Automotive Mode..........................................................................................................................................................................14
Non-automotive Mode................................................................................................................................................................ 14
Creep Automotive Mode.............................................................................................................................................................14
System Modes and Selection.....................................................................................................................................................14
Advanced Functions..................................................................................................................................................................... 14
Inch Function............................................................................................................................................................................. 14
Drive Curve with Independent Pump/Motor Profiling and Ramping................................................................... 14
Constant Speed Drive............................................................................................................................................................. 15
Vehicle Speed Limiter............................................................................................................................................................. 15
Engine Overspeed Protection ............................................................................................................................................. 15
Motor Overspeed Protection................................................................................................................................................15
Engine Anti-Stall........................................................................................................................................................................15
Flow Limitation and Control.................................................................................................................................................15
Load Independent Swashplate Control........................................................................................................................... 16
Temperature Compensation................................................................................................................................................ 16
Overheat and Low Temperature Protection...................................................................................................................16
Hydraulic Products
Pump.................................................................................................................................................................................................. 17
Motors................................................................................................................................................................................................ 17
Electronic Products
Integrated Automotive Controller...........................................................................................................................................18
H1 Speed Sensor............................................................................................................................................................................ 18
KEP Electronic Foot Pedal........................................................................................................................................................... 18
Joystick...............................................................................................................................................................................................18
Graphical Terminals and Displays............................................................................................................................................ 19
Application Software Products
Ordering Process............................................................................................................................................................................ 21
How to Download Service Tool Software from the Danfoss Web Site..................................................................21

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System Description PLUS+1® Compliant Integrated Automotive Control

Contents

SIL 2 Certified H1 AC Systems Service Tool Software ................................................................................................. 21

Application Software Overview................................................................................................................................................ 21
Service Screens.......................................................................................................................................................................... 21
Parameter Functions screens............................................................................................................................................... 22
Log Functions Screens............................................................................................................................................................22
User Interface............................................................................................................................................................................. 22

4 11066201 • Rev BA • Feb 2014

System Description PLUS+1® Compliant Integrated Automotive Control

Overview

About this document

This document provides general information about the Integrated Automotive Control System. In
addition, it is a reference tool for vehicle OEM design, engineering, and service personnel.
For easy access by control system developers, this document along with relevant software files, user
manuals, and other documents is included in the application file posted on line at www.danfoss.com
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

Referenced documents are on line at: www.danfoss.com

(enter provided Danfoss order numbers in search feature on web site).

Hydraulic Products

H1 Pump with Integrated Automotive Control Document Order Numbers

Description Data Sheet number Technical Information number User Manual number
H1P045/053 11063904 11063344
H1P060/068 TBA TBA
H1P078 11038154 11068353
H1P089/100 11071391 11071849
H1P115/130 11063906 11071850
H1 AC Embedded Controller 70012797

H1B Motor Document Order Numbers

Description Data Sheet number Technical Information number
H1B080 11055986
H1B110 11042714
H1B Motors 11037153

Electronic Products

Document Order Numbers

Description Technical Information number
H1 Automotive Control Product Electrical Installation 11063344
H1 Speed and Temperature Sensor 11046759
KEP Electronic Foot Pedal 11044978
JS1000 Joystick 520L0826
JS6000 Joystick 520L0760
DP200 Graphical Display 11023625
DP600 Graphical Display 520L0699

11066201 • Rev BA • Feb 2014 5

System Description PLUS+1® Compliant Integrated Automotive Control

Overview

Software Products

Document Order Numbers

Description Technical Information number User Manual number
PLUS+1 Service Tool 520L0899
Recommended System Start-up Procedures 11010667

OEM Responsibility
The manufacturer of a machine or vehicle using PLUS+1® electronic controls is responsible for correctly
applying and configuring PLUS+1 products. Danfoss strongly recommends that the OEM perform a
system-level Failure Mode Effects Analysis (FMEA).
You can find additional information about OEM responsibilities in the PLUS+1 Controller Family Technical
Information, 520L0719 and Recommended System Start-up Procedures Technical Information, 11010667.
Concept and Function
The Danfoss H1 Automotive Control (H1 AC) system is designed to provide a “drive like your car”
seamless, shift free, variable automatic transmission for off-highway propel drive systems. An electronic
controller integral to the H1 pump combines enhanced control performance with a flexible, configurable
control scheme for an entire single path propel transmission. The controller converts either direct
operator input or an engine speed signal into an automotive drive signal to control the displacement of
an axial piston pump. It is also designed to control motor displacement via an electric two position or
electric proportional control valve, as well as manage other inputs and outputs related to the vehicle
propel transmission. With easily changeable control parameters, it is possible to tailor the vehicle driving
behavior to the individual requirements of the machine.
The H1 AC is integrated with the NFPE (Non-Feedback Proportional Electric) Control. The flexible system
configuration allows use of a wide range of foot pedal, joystick, and motor combinations out of the
Danfoss product portfolio.
The H1 AC has also been certified by TÜV Nord to SIL 2 level functional safety standard according to IEC
61508 standard. With a pre-certified propel transmission it will reduce OEM time and expense to achieve
vehicle certification according to Machinery Directive 2006/42/EC applicable to all vehicles produced in
or sold into the European Community after 29 December 2009.

The combination of state of the art technology of embedded digital electronic control and Danfoss
proven axial piston pump technology opens a wide range of application possibilities.
AC-1 System Option Portfolio

Any combination of packages A + (B, C, and/or G) is available. For package combinations specific to your
needs consult your Danfoss representative.

Key: Basic functionality: ○ Full functionality: •

Feature type Function description Functional Option Packages (FOPs)

FOP A FOP B FOP C FOP F FOP G FOP H

Basic Motor CAN Full SIL-2 Full

Speed J1939 without Certified with SIL
Sensor SIL System
Functional Forward-Neutral-Reverse directional control (F-N-R) • • • • • •
features
Inching • • • • • •
Motor control • • • • • •
Engine RPM signal • • • • • •

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System Description PLUS+1® Compliant Integrated Automotive Control

Overview

Feature type Function description Functional Option Packages (FOPs)

FOP A FOP B FOP C FOP F FOP G FOP H

Basic Motor CAN Full SIL-2 Full

Speed J1939 without Certified with SIL
Sensor SIL System
Selectable System Modes • • • • • •
Creep mode • • • • • •
Temperature compensation • • • • • •
Engine overspeed protection • • • • • •
Pump hysteresis compensation • • • • • •
Park brake torque test • • • • • •
Forward & Reverse LED output • • • • • •
Anti-stall ○ • ○ • ○ •
Brake Pressure Defeat (BPD) ○ • ○ • ○ •
Closed loop Constant Speed Drive (CSD) • • •
Maximum torque at vehicle start • • •
Hydraulic motor over-speed protection • • •
Engine data via CAN • • •
H1 AC subsystem data via CAN • • •
Engine speed control shared with external controller • • •
Safety features Hydraulic system overheat and low temperature • • • • • •
protection
Operator presence detection • • • • • •
Brake light output • • • • • •
Vehicle speed triggered digital output signal • • • • • •
Safety controlled start • • • • • •
Fault LED output • • • • • •
Parking brake control • • • • • •
Reverse buzzer output • • • • • •
SIL-2 certified hardware • • • • • •
Vehicle speed limitation • • • •
SIL-2 certification for propel system (Hardware and • •
Software) per IEC 61508
Economic Easy to use electronic inching calibration (no extra • • • • • •
and valving or mechanical adjustments)
convenience
Semi-automatic sensor calibration (i.e. foot pedals) • • • • • •
features

AC-2 System Option Portfolio

AC-2 system, available with all AC-1 functional option packages, provides enhanced pump control and
system functionality with the addition of a pump swash angle sensor and related software.

Functional Load independent pump displacement control • • • • • •

features
Breakaway motor torque override • • • • • •

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System Description PLUS+1® Compliant Integrated Automotive Control

Benefits

The new Automotive Control (AC) option for H1 pumps puts 40 years of mobile machinery propel system
experience at your fingertips: through software configuration it enables faster time-to-market and
improved performance and functionality for both new machine designs and model variants.
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 certified to

SIL 2 per IEC 61508 standard
• Enhanced, flexible functionality through embedded intelligent electronics

Driving Profiles

• Four selectable system modes, selectable via switches

• 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-like behavior
• Creep speed mode (for example: slow shunting, digging operation, etc)
• Constant speed mode (for example: 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
• Configurable engine antistall protection
• Engine overspeed protection while inching

Integrated Motor Controller

• Integrated hydraulic motor control for:

‒ Proportional, variable PCOR or two position motor controls

‒ Brake pressure defeat, depending on the FNR position or the actual vehicle
driving direction
‒ Initial breakaway motor torque override
• Separate overspeed protection for the hydrostatic motor

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System Description PLUS+1® Compliant Integrated Automotive Control

Benefits

Auxiliary Functions

• Four auxiliary digital 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 enabler for economic driving and fuel savings

• Easy combination options to other components of the PLUS+1 Family

CAN Options

• Engine remote control via CAN J1939

• Integrated signal converter (analog driving pedal into CAN signal, etc)
• Compatible to all CAN J1939 components on market (displays, etc)

Functional Safety

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

• External Safety Certification for SIL-2 per IEC 61508 standard

(see also appropriate H1 AC pump Technical Information brochure specified in section 1.2.1 for
minimum system hardware, vehicle wiring, and software parameter setting requirements to meet SIL
2 certification standard)
• 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 road roller (compactor) vehicle applications to fulfill EN500-4

Installation Features

• Factory calibration for hysteresis compensation

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System Description PLUS+1® Compliant Integrated Automotive Control

System Details

System Overview

FNR switch

Inch pedal

Drive/Creep/
Rocker pedal

Mode switch A
+ −

Batt.
12/24 VDC
Mode switch B

NFPE Valve

Pressure reducing Pressure reducing

valve forward valve reverse

PPU motor

Engine

PPU pump/engine

Motor displacement Vgmax

Brake pressure defeat

Brake light

Parking brake

Reverse buzzer
S02086C

Swashplate sensor included (option). Temperature sensor on board.

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System Description PLUS+1® Compliant Integrated Automotive Control

System Details

Wiring Diagram
Generic Wiring and Component Interconnections
1 Contact capability min. 10A
2 Melting fuse 16A
3 Functional options

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
PSC
DEUTSCH connector CC3
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
Sensor (-) 3 PPUp03
CC2p03 Electronic Displacement
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 12/24V DC
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
P108 109E

Swashplate sensor included (option). Temperature sensor on board.

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 System Description PLUS+1® Compliant Integrated Automotive Control

System Details

Detalles del
System Controller Details
controlador del
sistema
Entradas
Inputs

• FNR switchFNR
• Interruptor and driver presence de
y detección detection
presencia del conductor. - El interruptor FNR,
utilizado para comunicar la dirección de conducción, requiere dos o tres entradas
‒ The
digitales losFNR
Laswitch,
lógicausedde to communicate
detección es driving direction, La
configurable. requires two orneutra
entrada three digital inputs. usar
se puede The
detection logic is configurable. The neutral input can be used also
también como una señal de habilitación (interruptor de asiento, detección de as well as an enable signal
presencia(seat-switch, driver presence
del conductor, etc). detection, etc).
• Mode switch A and B
• Interruptor de modo A y B - Los interruptores de modo A y B se utilizan para
‒ Modeuno
seleccionar
switch A and B are used to select one of four different system modes. Mode switch B
de los cuatro modos de sistema diferentes. Interruptor de modo B
features a redundant input for safety purposes.
Cuenta con una entrada redundante por motivos de seguridad.
• Inch pedal/sensor
• Pedal
‒ deThepulgadas / sensor
inch pedal/sensor is an-analog
El pedal
input/ which
sensor en pulgadas
ultimately reduces thees current
una entrada analógica
to the pump and
motor control
que, en última valves. reduce
instancia, This inputlaallows the operator
corriente to keep vehicle
a la bomba propelde
y Válvulas speed low while
control motor.
raisingpermite
Esta entrada the enginealspeed to meetmantener
operador the flow demands
baja laforvelocidad
the auxiliaryde
functions.
propulsión del
• Drive/creep
vehículo mientras elevar
or rocker la sensor
pedal velocidad del motor para satisfacer las demandas de flujo
de las funciones auxiliares.
‒ The drive/creep or rocker pedal sensor is an analog input typically consisting of a potentiometer,
• Sensorjoystick, or rocker
de pedal pedal, all /software
de marcha arrastreconfigurable.
o basculanteThe input
- Elissensor
used in creep automotive
del pedal mode as /
de marcha
the source for the creeping setpoint and in the non-automotive
arrastre o basculante es una entrada analógica que generalmente consta de un mode as the speed or flow
setpoint.Joystick, o pedal basculante, todo software configurable. La entrada
potenciómetro
se•utiliza
Pump/engine
en modo speed
de sensor
automoción de arrastre como la fuente para el punto de ajuste
progresivo y en el modo no automotriz como la velocidad o el flujo punto fijo.
‒ The pump/engine speed sensor, pre-assembled and pre-wired at the factory level, measures
pump/engine speed. The sensor uses Hall Effect technology to detect the rotating speed ring.
• Sensor de velocidad de la bomba / motor - El sensor de velocidad de la bomba /
• Integrated
motor, temperature
premontado sensor
y precableado a nivel de fábrica, mide Velocidad de la bomba /
motor. El sensor utiliza la tecnología de efecto
‒ The integrated temperature sensor measures PCBHall para
board detectarproportional
temperature, el anillo de
to oil
velocidad de rotación.
temperature, to enable temperature compensation and temperature derate functions.
• Hydrostatic motor speed sensor (optional)
• Sensor de temperatura integrado - El sensor de temperatura integrado mide la
‒ The hydrostatic
temperatura de la placamotor speed
PCB, sensor, normally
proporcional alinstalled
aceite.directly on the hydrostatic
Temperatura, motor, las
para habilitar
measures
funciones motor RPM. When
de compensación dethe sensor is installed
temperatura in a gear box,
y reducción dethe software parameter can be
temperatura.
used to define the gear ratio. An additional analog input can be used to detect rotational
• Sensordirection.
de velocidad del motor hidrostático (opcional) - El sensor de velocidad del
• Integrated
motor pump swash-plate
hidrostático, normalmentesensorinstalado
(optional) directamente en el motor hidrostático,
mide las revoluciones del motor. Cuando el sensor está instalado en una caja de
‒ The
cambios, el integrated
parámetro pumpde swash plate sensor
software puede(option
ser Se AC2) detects
utiliza actual
para swashla
definir plate positionde
relación and is
embedded in the pump control. The swash plate position can be passively
transmisión. Se puede usar una entrada analógica adicional para detectar rotaciones monitored or actively
controlled to enable an effective flow control and load independent propel behavior.
dirección.

• Sensor de placa basculante de la bomba integrada (opcional) - El sensor integrado

de la placa colectora de la bomba (opción AC2) detecta la posición real de la placa
colectora y es Embebido en el control de la bomba. La posición del plato oscilante se
puede monitorear pasivamente o activamente controlado para permitir un control de
flujo efectivo y un comportamiento de propulsión independiente de la carga.

12 11066201 • Rev BA • Feb 2014

System Description
Descripción PLUS+1®de
del sistema Control Compliant Integrated
automóvil Automotive
integrado Control
que cumple con PLUS + 1®

Detalles del
System Details
sistema
Salidas Outputs
• Control proporcional de la bomba. - El control de bomba proporcional conduce
• Proportional
directamente la corrientepump a control
las válvulas de control proporcional de la bomba.
Las válvulas proporcionales están premontadas y cableadas al control automotriz
integrado en‒ ElThe proportional
nivel pumpLa
de fábrica. control directlyde
corriente drives current to
arranque the pump
y final, asíproportional
como las control valves.
configuraciones de histéresis basadas en RPM de inicio precalibradas, se automotive
The proportional valves are pre-assembled and pre-wired to the integrated configurancontrol at
the factory level. Start and end stroke current as well as hysteresis settings
durante las pruebas de final de línea. Fallo del cable y sobrecorriente Las detecciones son based on pre-
calibrated
funciones de control start RPM are configured during end of line testing. Wire fault and over current
integradas.
detection are integrated control functions.
• Control• deTwo position
motor de /dos
proportional motor/control
posiciones proporcional - El control de dos posiciones / motor
proporcional proporciona una salida para controlar dos eléctricos.
an output toPosición o válvula
‒ The two position/proportional motor control provides control an electric two
proporcional de control del motor para controlar el desplazamiento del motor. Falla
position or proportional motor control valve in order to control motor displacement. Wiredefault
cable y sobre la detección
and over currentde corriente
detection están lascontrol
are integrated funciones de control integradas.
functions.
• Brake pressure defeat
• Derrota de presión de freno - La anulación de la presión de frenado es una salida digital
‒ Thede
para una válvula brake pressure defeat
anulación de la ispresión
a digital output for an electrical
de frenado eléctrica brake
depressure defeatdel
un control valve of a
motor.
motor
La salida conecta control. The output
directamente directly de
el control linkspresión
the brakedel
pressure
freno control to the vehicle
a la dirección depropel direction
propulsión
andtiempo
del vehículo y el timing to prevent
para abrupt
evitar deceleration. Duringbrusca.
la desaceleración deceleration events los
Durante the brake pressure
eventos de signal
desaceleración,is prevented
la señal defrompresión
activatingdel
thefreno.
pressure nocompensator
puede activarinside el
thecompensador
motor control (PCOR). The
de presión
motor
dentro del control maintains
del motorminimum
(PCOR).displacement
los El motor (minimum
mantienebraking torque) and is prevented
el desplazamiento from (par
mínimo
shiftingytose
de frenado mínimo) maximum displacement. al máximo desplazamiento.
evita Desplazando
• Park brake control
• Control de freno de estacionamiento - El control automotriz integrado proporciona
‒ The
cuatro salidas integrated
digitales queautomotive
se pueden control
usarprovides four digital outputs
para controlar that can be used to control park
el estacionamiento.
brake activation under conditions such as:
Activación del freno en condiciones tales como: Estado de la máquina del software en
modo STOP Corriente real
Software de la state
machine válvula de mode
in STOP la bomba por debajo del valor definido por el
usuario El comando del pedal de pulgada real excede el valor definido por el usuario
Actual pump
Los tiempos de demora paravalve current below
la aplicación user defined value
y liberación del freno de estacionamiento son
Actual inch pedal command exceeds user defined value
configurables individualmente
Delay times for park brake application and release are individually configurable
• Control de luz de freno - La salida de luz de freno activa digitalmente una lámpara
• (dentro
indicadora Brake light control
de la salida de hardware especificada límites) cuando el comando del
pedal de pulgadas excede
‒ The brake light un valor
output definido
digitally drivespor el usuario.
an indicator lamp (within the specified hardware output
limits) when the inch pedal command exceeds a user defined value.
• Control• del zumbador
Buzzer control - La salida del zumbador de la dirección de marcha atrás controla
un zumbador que indica la marcha atrás. dirección. La lógica de salida puede ser
‒ The reverse driving
controlada directamente por eldirection
estadobuzzer
FNR output
o por controls
propel areal
buzzer that indicates reverse driving
movimiento.
direction. The output logic can be directly controlled by FNR status or by actual propel
• Salida LED demovement.
dirección adelante y atrás. - La función de salida de LED de dirección
directa e•inversa
Forward and reverse
controla direction LED los
digitalmente output
LED como dirección de conducción
Los indicadores se utilizan en el panel de control / pantalla y están directamente
The forward and reverse direction LED output function digitally drives LEDs as driving direction
‒ estado
vinculados al FNR.
indicators for use in dashboard/display and is directly linked to the FNR status.
• Salida •de Status
estado output
(LED (red LED)- La salida de estado de falla proporciona una señal de
rojo)
salida del estado
Thede
faultfalla interna
status / códigoande
output provides error
output capaz
signal deinternal
of the Conducir digitalmente
fault status/error codeun LED.of
capable
‒
digitally driving an LED.
• Salida •dependiente de la velocidad del vehículo. - La señal de salida dependiente de la
Vehicle speed dependent output
velocidad del vehículo alterna una salida digital cuando el vehículo real la velocidad
The vehicle
excede una ‒velocidad speed dependent
definida output signal toggles a digital output when the actual vehicle
por el usuario.
speed exceeds a user defined speed.

11066201 • Rev BA • Feb 2014 13

System Description PLUS+1® Compliant Integrated Automotive Control

Configuration Options

Automotive Mode
In automotive mode the drive curve is defined according to the available torque characteristics of the
combustion engine with consideration for auxiliary power requirements. The current to the pump
proportional valves is directly controlled by the measured engine RPM and configurable via parameters
settings.
Non-automotive Mode
In non-automotive mode the pump proportional valve current is independent of measured engine
speed, allowing fixed engine speed to supply auxiliary functions. The Drive Pedal potentiometer is used
as an analog input to command vehicle speed (pump flow).
Creep Automotive Mode
Creep automotive mode is a combination of the automotive and non-automotive modes. The drive pedal
potentiometer is used as an analog input to command the pump proportional valve current. The
available pump valve current is limited by the automotive drive curve dedicated to this mode type. The
actual current to the pump valve is the product of the actual engine RPM, the defined automotive curve,
and the actual percentage of drive pedal potentiometer input. Creep automotive is active above a user
defined creep start RPM, below this RPM the propel system behaves like automotive mode. The motor
valve current follows the automotive curve.
System Modes and Selection
The application supports up to four system modes. Each of the four selectable system modes can be
configured as one of the three propel methods (automotive, creep automotive, non-automotive).
All advanced functions (CSD, antistall, overspeed protection, etc) are available for use with every Propel
Method.
System modes define the basic characteristic of the transmission and they are selected via two digital
inputs: mode switch A and B. Four different and independent drive curves with individual ramping for
pump and motor can be selected by the system mode switches, allowing individually optimization of the
driving behavior in each mode.

System Mode Selection (Hardware)

System Modes

Mode 1 Mode 2 Mode 3 Mode 4

Mode switch A Low Low High High
Mode switch B Nominal Low High Low High
Redundant High Low High Low

Advanced Functions

Inch Function
The inch command destrokes the pump in order to decelerate the vehicle while maintaining/increasing
engine speed to meet auxiliary function requirements. Inch function profile and interaction with propel
motor are configurable. Engine overspeed protection monitors engine speed during the inch function to
prevent the engine from over speeding when the load is reduced.

Drive Curve with Independent Pump/Motor Profiling and Ramping

The pump and motor can both be independently configured for the forward and reverse driving
direction. The software application facilitates individual command profiles (8pts) based on pump RPM or
drive pedal inputs. Additionally vehicle acceleration timing (1 ramp) and deceleration timing (3 ramps
plus 1 error ramp) are independently configurable.

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System Description PLUS+1® Compliant Integrated Automotive Control

Configuration Options

Constant Speed Drive

This CSD function (CSD by pump flow) calculates pump flow via pump speed and predicted pump swash
plate angle. Swash plate angle is predicted based on factory calibrated pump valve current relationship.
The software will calculate the desired motor speed based on the predicted swash plate angle, actual
pump rpm, and the maximum motor displacement. If the actual vehicle speed differs from the
commanded speed, the software proportional-integral (PI) control will adjust the pump valve current to
compensate for the speed difference.
This function requires motor or vehicle speed sensor but can be used without a drive pedal input.

Vehicle Speed Limiter

The vehicle speed limit is a general vehicle speed limitation that compensates for volumetric pump and
motor losses. This function can be independently activated in each system mode and driving direction. If
the actual vehicle speed exceeds the defined vehicle speed limit the software PI controller function will
reduce pump valve current until the speed limit is met.
This function requires a motor or vehicle speed sensor.

Engine Overspeed Protection

• The engine overspeed protection prevents the engine from over speeding while inching and when
actual engine speed exceeds the user defined RPM. This protection function is only activated while
inching.
• In case of engine over speed due to downhill driving (exceeding the braking performance of the
engine) mechanical brakes are needed to protect the engine.

Motor Overspeed Protection

The motor over speed protection (MOP) prevents the hydrostatic motor from over speeding by either
decreasing pump displacement or increasing motor displacement (only applies to electrical proportional
motor control). The motor RPM speed limit, based on a software PI algorithm, is user defined but is
universally constant for all four system modes when activated.
The engine overspeed protection (EOP) during inching (see above, Engine Over Speed Protection) has
priority and will override the motor over speed protection (MOP).

Engine Anti-Stall
• The engine anti-stall prevents the engine from being stalled due to overload through the
transmission system. There are two independent engine anti-stall modes: fixed engine RPM and all
range engine RPM.
• Fixed engine RPM: fix engine RPM anti-stall is used in applications operating at fixed engine speeds. If
the actual pump speed droops below the target fixed engine speed the software PI controller will
reduce the pump valve current to achieve/maintain the target fixed engine speed.
• All range engine RPM: the engine speed command and the actual pump speed will be compared to
calculate the engine speed droop. If the actual pump speed is below the user defined engine speed
droop the software PI controller will reduce the pump valve current to reduce engine load and
prevent further engine speed droop.
• The engine anti-stall function can be individually enabled for each system mode.

Flow Limitation and Control

The system flow limitation uses the pump swash plate angle sensor information (option AC2) to limit the
vehicle speed for a fixed displacement motor. The software calculates vehicle speed based on measured

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System Description PLUS+1® Compliant Integrated Automotive Control

Configuration Options

swash plate angle, actual pump speed, fixed motor displacement, gear ratio, and the wheel diameter. If
the calculated vehicle speed is above the defined vehicle speed limit the software PI controller function
will reduce pump valve current until the speed limit is met. This function can be independently activated
in each system mode and driving direction.

Load Independent Swashplate Control

The load independent swash plate control maintains commanded swash plate position independent of
load (EDC behavior) using electronic feedback from the pump swash plate angle sensor. The function can
be individually configured in each system mode. The pump swash plate angle sensor calibration is
performed at the factory.

Temperature Compensation
The temperature sensor integral to the controller’s printed circuit board (PCB) measures the PCB board
temperature. The pump case oil temperature and oil viscosity are assumed to be proportional to the
measure PCB board temperature. The function compensates for oil viscosity impact by decreasing the
pump valve current command at cold start and increasing the pump valve current command at high
operational temperatures.

Overheat and Low Temperature Protection

The hydraulic system overheat protection and low temperature pump flow limitation functions are based
on the electronic board integrated temperature sensor which measures PCB temperature. The function
protects the complete hydrostatic system by reducing the pump flow (pump valve current reduction) at
extreme high or low temperatures according to a user defined temperature dependent limitation curve.

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System Description PLUS+1® Compliant Integrated Automotive Control

Hydraulic Products

Pump

• H1 Axial Piston Pumps with integrated Automotive Control (AC)

• Vehicle propel transmission microcontroller integrated on pump control
• Complete propel drive system functionality embedded in microcontroller
• Optional SIL-2 certification simplifies vehicle certification

Motors
The H1 AC propel transmission programming has been optimized for the H1 bent axis variable
displacement motors, but can work with a wide variety of motors from the Danfoss portfolio, including
those listed below.

• H1 Bent Axis Variable Displacement Motors

• Series 42 Axial Piston Motors
• Series 90 Axial Piston Motors

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System Description PLUS+1® Compliant Integrated Automotive Control

Electronic Products

The H1 Automotive Control is a PLUS+1 Compliant solution, designed to be compatible with the range of
other PLUS+1 compliant components in the Danfoss product portfolio, examples of which are
highlighted below.
Integrated Automotive Controller

• Complete propel drive system functionality

• PLUS+1 Service Tool configurable for custom drive behavior
• PLUS+1 Compliant pump and motor control, pedal, joystick, and sensor options

H1 Speed Sensor
The H1 speed sensor is a required option for the H1 AC pump and an optional feature for the H1 motor.

• Designed for rugged outdoor, mobile or heavy industrial speed sensing applications.
• Ideal for high and low speed measurements and sensing the direction of rotation.
• Capability to detect the H1 pump or motor case oil temperature.

KEP Electronic Foot Pedal

The KEP Electronic Foot Pedal is used to drive vehicles equipped with hydrostatic transmissions and/or
electronically-controlled engines.

• Provides an electrical signal to the engine’s electronics proportional to the degree of pedal actuation.
• Features a sensor specifically designed for heavy vehicle applications.
• Provides hydrostatic braking, inch, drive or creep command signal.

Joystick
JS1000

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System Description PLUS+1® Compliant Integrated Automotive Control

Electronic Products

• High-reliability operator input device for controlling mobile machine work functions.
• Available in single axis spring-centered and dual axis spring-centered configurations.
• Resistant to the extremes of temperature, shock, vibration, and EMI/RFI typically found in mobile
machine operating environments.
• Uses non-contact Hall effect technology.
• Output options:

‒ Analog
‒ CAN 2.0B, J1939 protocol
• Provides the drive command signal.

JS6000

• Metal construction with a large diameter stainless steel operating shaft, an innovative ball and socket
gimbal design manufactured from pressure die cast zinc alloys, a custom high strength material for
the center return cone, and optional contactless Hall effect sensing technology.
• Many options, making it the right choice for applications that require more than a simple dual axis
joystick with spring return to center.
• Output options:

‒ Analog
‒ CAN 2.0B, J1939 protocol
• Provides the drive command signal.

Graphical Terminals and Displays

DP200

• Cost effective alternative to existing analogue gages.

• High-resolution monochrome displays fit every budget without compromising performance.
• Options featuring front USB 2.0 port for easy connection to PC-based service and diagnostic tools,
extended IO for improved input design flexibility, real-time clock, display heater, and Engine
Information Center (EIC), J1939 software.
DP600

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System Description PLUS+1® Compliant Integrated Automotive Control

Electronic Products

• For high-end applications, these sophisticated graphical terminals provide optimal performance and
flexibility.
• Transflective TFT and DSTN, LCD display technologies, high resolution display, antiglare screen, and
sensor controlled backlighting.
• CAN, RS-232 and USB interfaces.
• Additional inputs for an external navigation button, which enables you to maneuver through all
terminal functions.

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System Description PLUS+1® Compliant Integrated Automotive Control

Application Software Products

Ordering Process
The Automotive Control software is specified by the customer for prototypes according to the Functional
Option Packages in section Y (settings) of the H1 pump model code. Once final parameters are selected
by the customer during prototype testing, a customer specific H1 pump material number is created with
the proprietary settings. In the case of both prototype and production H1 AC pump deliveries, the
complete software programming is factory loaded onto the embedded AC controller.

How to Download Service Tool Software from the Danfoss Web Site
To download service tool software and obtain a free service tool license:
1. Go on line to: http://www.danfoss.com/Products/MobileElectronics/PLUS1Guide/
PLUS1GuideDownloads/PLUS1GUIDEServiceToolSoftwareLicense/index.htm.
2. Download .exe file.
3. Click on How to obtain a free license for the PLUS+1 Service Tool.
Specific .P1D and .PLG files relative to customer prototype or production H1 AC pumps will be provided
by Danfoss to designated customer contacts at time of initial pump delivery, or can be accessed in the
application software download page http://www.danfoss.com/Products/MobileElectronics/PLUS1Guide/
PLUS1GuideDownloads/Application Software for Microcontrollers.

SIL 2 Certified H1 AC Systems Service Tool Software

For H1 AC systems that are SIL 2 certified, it is necessary to use a SIL 2 certified version of the GUIDE
Service Tool in order to access the H1 AC controller or upload, download, and change system parameters.
Instructions for how to obtain a SIL 2 certified service tool version approved for use with SIL 2 certified H1
AC systems is outlined below:
1. Go on line to: http://www.danfoss.com/Products/MobileElectronics/PLUS1Guide/
PLUS1GuideDownloads/Application Software for Microcontrollers.
2. Download Service Tool .exe file.
The service tool version contained in the H1 AC download area may be different than the general
market service tool as described in the previous section above.
3. Click on Service Tool Read Me.
Application Software Overview
The H1 AC utilizes PLUS+1 Service Tool to customize the transmission configuration and performance, as
well as to display operational data for field service, and troubleshooting.
Cooperative development with pilot customers has contributed to the availability of extensive
functionality programming adaptable to a wide variety of vehicle applications, and the ability to tailor H1
AC performance to meet the unique requirements of each OEM.
Please reference H1-Automotive Control PLUS+1 TM Compliant User Manual, 70012797, as well as the
technical information manual for your H1 pump size, for further information ranging from basic
functionality in a Quick Start Guide to more advanced functions configuration capabilities of the H1 AC.

Service Screens
The PLUS+1 Service Tool can be used to modify and tune the performance of the transmission system
through individual parameter settings. The service tool has two basic screen types:

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System Description PLUS+1® Compliant Integrated Automotive Control

Application Software Products

PLUS+1 GUIDE Service Tool Parameter Functions Screen

Parameter Functions screens

The parameter functions screens show the configurable system parameters for tuning the transmission
system according to customer requirements.
PLUS+1 GUIDE Service Tool Log Functions Screen

Log Functions Screens

The log functions screens show operational data of the transmission system. The operational data is
useful for understanding the system behavior, tuning the system performance, and trouble shooting. The
data can also be logged and stored (via external computer interface) for documentation and off line
analysis.

User Interface
A simple laptop connection directly to the H1 AC controller allows both customization of the system
configuration and performance parameters as well as accessing operational data in log functions for
service and troubleshooting requirements. For the convenience of our customers, Danfoss makes
available the CG150 CAN Gateway laptop computer cable and an adapter cable to connect the CG150 to
the H1 AC controller. Specifications are also provided to enable customers to source their own dedicated
cable if desired.

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System Description PLUS+1® Compliant Integrated Automotive Control

Application Software Products

CG150 CAN Gateway

Adapter Cable
H1 AC Controller CG 150 CAN USB Gateway
DEUTSCH connector female D-SUB connector
DTM/3 pin 9 pin

CAN High 120 ohm 1 7 CAN High

CAN Low 2 2 CAN Low
CAN Shield 3 3 CAN Shield

P003 551E

Cable Material Numbers

CG150 CAN Gateway 10104136

Adapter cable 11069593

11066201 • Rev BA • Feb 2014 23

Products we offer: 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
• Bent Axis Motors 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 ensure exceptional performance for a
• Closed Circuit Axial Piston broad range of off-highway vehicles.
Pumps and Motors
We help OEMs around the world speed up system development, reduce costs and bring vehicles to
• Displays market faster.
• Electrohydraulic Power Danfoss – Your Strongest Partner in Mobile Hydraulics.
Steering
Go to www.powersolutions.danfoss.com for further product information.
• Electrohydraulics
• Hydraulic Power Steering Wherever off-highway vehicles are at work, so is Danfoss.

• Integrated Systems 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
• Joysticks and Control comprehensive global service for all of our components.
Handles
• Microcontrollers and Please contact the Danfoss Power Solution representative nearest you.
Software
• Open Circuit Axial Piston
Pumps
• Orbital Motors
• PLUS+1® GUIDE
• Proportional Valves
• Sensors
• Steering
• Transit Mixer Drives

Comatrol
www.comatrol.com
Local address:
Schwarzmüller-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
Danfoss Danfoss Danfoss (Shanghai) Co. Ltd.
Power Solutions US Company Power Solutions GmbH & Co. OHG Power Solutions ApS Building #22, No. 1000 Jin Hai Rd
2800 East 13th Street Krokamp 35 Nordborgvej 81 Jin Qiao, Pudong New District
Ames, IA 50010, USA D-24539 Neumünster, Germany DK-6430 Nordborg, Denmark Shanghai, China 201206
Phone: +1 515 239 6000 Phone: +49 4321 871 0 Phone: +45 7488 2222 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 subsequential 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 Danfoss A/S. All rights reserved.

11066201 • Rev BA • Feb 2014 www.danfoss.com © Danfoss A/S, 2014