DBW-4 Drive By Wire Controller User Manual Copyright – MoTeC Pty Ltd – 2001-2006 The information in this document is subject to change without notice. While every effort is taken to ensure correctness, no responsibility will be taken for the consequences of any inaccuracies or omissions in this manual.
MoTeC DBW-4 2 Contents Introduction .........................................................................3 Abbreviations & Definitions ...............................................4 Inputs & Outputs.................................................................5 PID Fault Conditions...........................................................6 Communications.................................................................7 CAN..........................................................................
MoTeC DBW-4 3 Introduction Introduction This manual describes the functions and specifications of the MoTeC DBW4, and configuration for use with the MoTeC “hundred” series ECUs (M400, M600 & M800). The DBW-4 works with ECU Firmware V3.30T and later. The DBW4 provides 4 PID Controllers for drive by wire control or generic PID control. PID Set points are received from the ECU over the CAN bus and are separate for each PID Controller.
MoTeC DBW-4 4 Introduction Abbreviations & Definitions DBW - Drive By Wire ECU - Engine Control Unit O/P - Output PID - Proportional, Integral, Derivative Controller PWM - Pulse Width Modulation TP - Throttle Position One TP2 - Throttle Position Two TPD1 - TP One Driver TPD2 - TP Two Driver UTC - USB to CAN converter Measured Value 1 & Measured Value 2 For drive by wire PID applications Measured Value 1 refers to TP & Measured Value 2 refers to TP2.
MoTeC DBW-4 5 Introduction Inputs & Outputs Inputs (AV1 – AV8) The DBW-4 has eight 0-5V analog voltage inputs (AV1 to AV8). These are suitable for Potentiometers, voltage output sensors and variable resistance (temperature) sensors (these require an external pull-up resistor to 5V). These inputs are directly connected to the TP & TP2 position potentiometers on drive by wire throttle bodies. Outputs All outputs are disabled until the first CAN message is received.
MoTeC DBW-4 6 Introduction PID Fault Conditions This section describes the fault conditions for each type of PID Controller. These fault conditions will be monitored by the ECU for safe operation. During installation and fault finding, these conditions can be examined with the Motec DBW-4 Manager software. Commanded Shutdown This is not strictly an error condition, but is included with the fault flags and hence handled here.
MoTeC DBW-4 7 Introduction Communications CAN The CAN bus is used for PC communications during testing, calibration and firmware upgrades, and for communicating to the ECU. The following data is transmitted by the DBW-4 at 200Hz: • Measured Values 1 & 2 for each PID (AV1-AV8) • Measured Value 1 with PID diagnostic information. The following data is transmitted by the DBW-4 at 50Hz: • Output driver faults • Internal temperature • Internal voltages (-5v, 8vAux, 5vAux, Vbat, 4.
MoTeC DBW-4 8 Introduction Configuration The DBW-4 unit is configured using the MoTec DBW-4 Manager Software. This software can load/save configurations and display diagnostic information. DBW-4 Manager communicates with the DBW-4 using the MoTeC CAN cable. The software is used to configure all PID Parameters as well as calibrate the maximum, minimum and measured value ranges.
MoTeC DBW-4 9 Introduction Drive By Wire Calibration WARNING! Drive by wire throttle body motors are very powerful and can cause serious injury to users or damage to the throttle body. Never attempt to move the butterfly by hand with the motor connected to the DBW-4 Unit. To calibrate a DBW throttle body, the high and low limit positions must be measured and included in the calibration.
MoTeC DBW-4 10 Introduction Step 5: This step is only applicable for DBW throttle bodies with a linear characteristic for the Meas2 (TP2) sensor (ie. Meas2 Max % Target = 100%), where the high limits for both measured values are set at the same time. Set the high limits for the measured values by following the instructions displayed (see below). For indication purposes, the raw position values for the two measured values will be displayed as the butterfly valve position is changed.
MoTeC DBW-4 11 Introduction This step is only applicable for DBW throttle bodies with a “knee” characteristic for the Meas2 (TP2) sensor (eg. Meas2 Max % Target = 62.5%), where the high limit is measured separately for measure value 1 (TP) and measured value 2 (TP2). Set the high limit for the measured value 2 (TP2) by following the instructions displayed (see below). It is important to position the butterfly as close to the target (eg. 62.5%) as possible when setting measured value 2.
MoTeC DBW-4 12 Introduction Step 5: Set the high limit for the measured position by following the instructions displayed (see below). For indication purposes, the raw position value will be displayed as the actuator position is changed. Note that the Set button can be pressed again if the measured position was set incorrectly. When the high limit position has been set, click Finished to continue.
MoTeC DBW-4 13 Introduction Diagnostic/Fault Condition Monitoring To view the Diagnostic/Fault Information, select the Monitor Faults option under the File menu. All red indicators indicate an error condition, green indicators indicate OK. Note that if any error conditions are present the particular PID Controller will be shutdown. If any drive by wire type PID Controllers are shutdown then all other drive by wire type PID Controllers will also be shutdown.
MoTeC DBW-4 14 Appendices Appendix A: General Specifications Physical and Environmental Case Size 99 x 105mm x 40mm Weight 320g Temperature Range -10 to 70°C Power Supply Operating Voltage 9 – 22V DC Operating Current 150mA (excluding sensor currents and outputs) Protection Battery transient protection Reverse battery protection via external fuse CAN Communications CAN bus speed 1Mbit/s No CAN terminating resistor onboard Introduction
MoTeC DBW-4 15 Appendix B: Input Characteristics Analog Voltage Inputs Range 0 to 5V Resolution 4.
MoTeC DBW-4 16 Appendix C: Output Characteristics Outputs Current per output when using the given number of outputs: • 2 Outputs (1 PID) 2.3A • 4 Outputs (2 PIDs) 1.6A • 8 Outputs (4 PIDs) 1.1A Frequency range for PID PWM outputs 500Hz to approx.
MoTeC DBW-4 17 Introduction Appendix D: CAN Wiring – Multiple Device The CAN bus should consist of a twisted pair trunk with 100R (0.25Watt) terminating resistors at each end of the trunk. The preferred cable for the trunk is 100R Data Cable but twisted 22# Tefzel is usually OK. The maximum length of the bus is 16m (50ft) including the MoTeC CAN Cable (PC to CAN Bus Communications Cable) CAN Devices (such as MoTeC ADL, BR2 etc) may be connected to the trunk with up to 500mm (20in) of twisted wire.
MoTeC DBW-4 18 Introduction Appendix E: DBW-4 to M800 Wiring DBW-4 Ground Power ECU Bat See pin list Bat + See pin list 0V 47 CAN-LO 54 CAN-HI B24 / 47 CAN-LO B23 / 48 CAN-HI 8V 71 72 CAN-HI CAN-LO 1 0V 2 3 8V 4 CAN-LO 5 CAN-HI 100R 100R CAN Cable Connector See the CAN Bus Wiring Specification for more Detail Any Other CAN Device Any Other CAN Device DBW-4 Power and Ground Wiring Bat + Bat - 28, 29, 30, 37, 38, 39 13, 14, 15, 19, 20, 21, 22 Additional Power and Ground pins are provi
MoTeC DBW-4 19 Introduction Appendix F: DBW-4 Pin List by Pin Number The DBW-4 uses a 66 pin autosport connector with the following pin-out: Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Function DBW-4 DBW Use PID4 PWM 1 PID3 PWM 2 DBW 4: PMW 1 DBW 3: PMW 2 PID3 PWM 1 DBW 3: PMW 1 RS232 GND BATTERYBATTERYBATTERYPID2 PWM 2 CJC2 0V BATTERYBATTERYBATTERYBATTERYDIGITAL IN 1 DIGITAL IN 2 0V BATTERY+ BATTERY+ BATTERY+ RS232 RECEIVE DIGITAL IN 3 DIGITAL IN
MoTeC DBW-4 20 Appendix G: DBW-4 Connector Mating Connector Deutsch : AS6-18-35SN Wire Wire to suit connector : 22# Tefzel, Mil Spec : M22759/16-22 Crimp Tool Crimp Tool : M22520/2-01 Positioner for Crimp Tool : M22520/2-07 • Note that the Crimp Contacts are type 22D (this is needed to set the crimp tool correctly) Wire Stripping Tool The following tool is recommended Ideal Industries 45-2133 stripping tool with LB1195 wire stop.
MoTeC DBW-4 Notes 21 Introduction
