Dana APC121 - Technical Leaflet - V12 - Customer

HARDWARE
APC121 : Advanced Programmable Controller
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SPICER OFF-HIGHWAY PRODUCTS APC121

Ten Briele 3, 8200 Brugge, Belgium Rev 1.2 released 03/05/07 03-05-2007
Tel: +32 (0) 50 402 450 CONTROLS@DANA.COM APC121 – technical leaflet_customer Page : 1 of 28
TABLE OF CONTENTS
1. 1. HARDWARE BLOCK DIAGRAM ........................................................................................3
1.1 LIMITS AND STANDARDS .....................................................................................................4
1.2 ELECTRICAL CHARACTERISTICS .........................................................................................5
1.2.1 Digital inputs (DI0 – DI7) .............................................................................................5
1.2.2 Analog inputs (resistive and voltage inputs) (ANI0-ANI3) ...........................................6
1.2.2.1 Resistive analog inputs .................................................................................................. 6
1.2.2.2 Voltage analog inputs..................................................................................................... 6
1.2.3 Reference voltage (VREF_5V)....................................................................................6
1.2.4 Speed inputs (SPIN0–SPIN1) .....................................................................................6
1.2.5 Outputs with current feedback (AO7–AO8) ...............................................................7
1.2.6 Outputs without current feedback (AO0-AO6) ............................................................7
1.2.7 Speedometer output (SPEED0_OUT) ........................................................................7
1.2.8 Safety Relay ................................................................................................................7
1.2.9 Watchdog ....................................................................................................................7
1.3 PHYSICAL DIMENSIONS.......................................................................................................8
2. INSTALLATION GUIDE ....................................................................................................11
2.1 CONNECTOR ...............................................................................................................11
2.2 MECHANICAL MOUNTING ..................................................................................................13
2.3 MATING CONNECTOR .......................................................................................................18
2.4 REQUIRED WIRE THICKNESS ON THE MATING CONNECTOR .................................................19
2.5 BATTERY PLUS CONNECTIONS (TERMINAL 20,45,60) ........................................................20
2.6 PLOAD SIGNAL (TERMINAL 21) ........................................................................................21
2.7 POWER GROUND TERMINALS (TERMINAL 5,44) ..................................................................21
2.8 SIGNAL GROUND TERMINALS ............................................................................................22
2.8.1 Analog inputs (terminal 13, 24, 26, 28) .....................................................................22
2.8.2 Speed sensor inputs (terminal 9, 11) .......................................................................22
2.8.3 Communication links (terminal 36) ............................................................................22
2.9 VOLTAGE REFERENCE OF 5V (TERMINAL 15).....................................................................22
2.10 DIGITAL INPUTS (TERMINAL 52-59) ...................................................................................22
2.11 ANALOG INPUTS (TERMINAL 14,25,27,29).........................................................................22
2.11.1 Resistive inputs.....................................................................................................23
2.11.2 Voltage inputs. ......................................................................................................23
2.12 SPEED SENSOR INPUTS (TERMINAL 10,12)........................................................................23
2.12.1 Inductive sensors..................................................................................................23
2.12.2 Magneto Resistive sensors...................................................................................24
2.12.3 Hall effect sensor ..................................................................................................24
2.13 OUTPUTS (TERMINALS 01,03,17,18,31,33,35,46,48) .......................................................25
2.14 DISPLAY ..........................................................................................................................25
2.15 COMMUNICATION LINES ....................................................................................................26
3. GENERAL WIRING DIAGRAM .........................................................................................27
4. DISCLAIMER.....................................................................................................................28

1. Hardware block diagram
SRAM
512 Kbyte
Digital inputs
#8 Infineon
XC161CJ Program Flash
512 KByte
µC 16-bit
Analog inputs
#4
Data Flash
64 Kbyte
Speed inputs
#2
RS232
Speedo output
#1
LIN / RS232
Analog output
with current
feedback # 2 CAN
Analog output
without current
feedback # 7
VP_PWR (permanent power)

On/off loads POWER SUPPLY Vref +5V
VS_PWR (switched power)
Power supply input 12/24V DC

User diagnostics by CAN or by Remote Display RD.120
Proportional load control
CAN V2.0B, J1939 compliant
1 RS232 port exclusive for controller programming purposes
1 RS232 multipurpose port : either it can be used for controller programming
purposes or it can be used for remote display / fleet management purposes
Auto power-off.

1.1 Limits and standards
All functions operate as intended when the controller is used within specified operating limits.
Use beyond this limits can cause structural damage to the controller.
PARAMETER STANDARD LIMITS, REMARKS
1. Min/Max supply voltage SAE J1445:2006 9…32 V
2. Operating temperature -40°C to +85°C
3. Storage temperature -55°C to +105°C
4. Supply current
Maximum 10 A
Standby Typ. 1,5 to 2,0 mA
5. EMC
Emission ISO 13766:2006
Immunity 1 ISO 13766:2006
Bulk current injection ISO 11452-4:2005 20-400 MHz 80 mA
Radiated EM energy ISO 11452-2:2004 V. polarization 80 -1000 MHz 80 V/m
AM modulation H. polarization 400- 1000 MHz 80 V/m
Immunity 2 2004/104/EC
Radiated EM energy ISO 11452-2:2004 V. polarization 800 - 2000 MHz 80 V/m
Pulse modulation H. polarization 800 - 2000 MHz 80 V/m
Electro-static discharge ISO 13766:2006
Contact Discharge EN 61000-4-2:2001 Testlevel IV 8kV class A behaviour
Air Discharge EN 61000-4-2:2001 Testlevel IV 15kV class A behaviour
Conducted Transients ISO 13766:2006 Testlevel III class A behaviour for 12 and
ISO 7637-2:2004 24 V applications.
6. Short Circuit Protection
To GND SAE J1455:2006 All terminals(1)
To Vbat SAE J1455:2006 All terminals(2)
7. Steady State Behaviour
Min/Max operating voltage SAE J1455:2006
Reverse polarity SAE J1455:2006
Jump start SAE J1455:2006 48V for 5 minutes
Batteryless operation Variant on 12 V system V = 6.0 +  12.6 sin(2πft) 
ASAE EP455 24 V system V = 12 +  23.2 sin(2πft) 
for f = 150 Hz to 1.5 kHz
source impedance : Zo = 2.9 Ω + 1.5
mH
8. Sealing IEC 60529 IP65
9. Temperature cycling
Storage temperature 24h Min t° followed by 24h Max t° cycle
Operating temperature 48h cycle, variant on SAE J1445 t°
profile
Thermal shock 3X 8h cycle, variant on SAE J1445 t°
profile
10. Shock
Handling drop test SAE J1445:2006
Operational shocks IEC 60068-2-29 2000 bumps positive and negative
Amplitude: 30 g, ½ sine
Duration: 11 ms
Rate: 2 bumps/sec
Direction: 3 orthogonal axes
Transit drop test DANA standard
11. Vibration
Endurance test IEC 60068-2-34 Duration: 1 hour at 3 g and 1 hour at 5 g

PARAMETER STANDARD LIMITS, REMARKS
in each direction.
Frequency range: 10 to 150 Hz
sweep rate: 1 oct/min
direction: 3 orthogonal axes
Wide random vibration test IEC 60068-2-35 Frequency range: 5 Hz to 2 kHz
Duration: 1 hour
Amplitude: 6.5 g RMS
Direction: 3 orthogonal axes
Profile:
20 Hz : 0.0116515 g2/Hz
20 to 80 Hz: +3 dB/oct
80 to 350 Hz: 0.04602 g2/Hz
350 to 2 kHz: -3 dB/oct
2 kHz: 0.0080541 g2/Hz
Resonance search test Frequency range from 10 to 150Hz.
Constant acceleration 2g.
Sweep rate : 1oct/min.
Direction: 3 orthogonal axes.
Duration: one sweep for each of the
three orthogonal axes.
12. Humidity 24h cycle, variant on SAE J1445
humidity profile
(1)
Except the supply voltage terminals. An externally placed series fuse (15A) must be used to
prevent damage.
(2)
Except the GND terminals: an externally placed series fuse (15A) must be used to prevent
damage, and for the RS232 communication lines: protection garantueed till 15 volts.
The APC121 complies to following standards and directive:
standard year
ISO 13766 2006 Earth moving machines
ISO 14982 1998 Agricultural and forestry machines
EN 12895 2000 Industrial trucks
EN 13309 2000 Construction Equipment machines with internal Electrical
Power Supply
Commision directive 2004/104/EC 2004 Adapting to technical progress council directive 72/245/EEC
1.2 Electrical Characteristics
1.2.1 Digital inputs (DI0 – DI7)

All inputs are switch to plus
Parameter
Number 8
Low level maximum voltage 2.25V
High level minimum voltage 3.8V
Low level minimum resistance(1) 99KΩ-24V, 22.5KΩ-12V
High level input current > 2 mA
Maximum input voltage 48 V
Reverse polarity -24V
Fault detection capability Yes, short to ground
(1)
HW programmable

1.2.2 Analog inputs (resistive and voltage inputs) (ANI0-ANI3)
There are 4 analog inputs. These inputs can be configured as following :
2 voltage and 2 resistive inputs.
4 voltage inputs.
4 resistive inputs.
1.2.2.1 Resistive analog inputs

Parameter
Range 0 – 5KΩ
Internal pull-up to Vsens 9 KΩ
Vsens 14 V
Accuracy 1% full scale
Maximum reverse polarity voltage -24 V
Fault detection capability Yes, related to input
range
1.2.2.2 Voltage analog inputs

Parameter
Range 0–5V
Accuracy 1% full scale
Max. reverse polarity voltage -24 V
Fault detection capability Yes, related to input
range
1.2.3 Reference voltage (VREF_5V)

Parameter
Number 1
Output voltage 5V
Output current 100 mA
Accuracy 1%
Load protected Yes
Max. reverse polarity voltage -24 V
Fault detection capability Yes
1.2.4 Speed inputs (SPIN0–SPIN1)

Parameter
Number 2
Range 0 – 40 KHz
Type Programmable (magnetoresistive, inductive or hall-effect
with/without external resistor)
Fault detection capability Yes (open load and short circuit)
Bidirectional capability Yes

1.2.5 Outputs with current feedback (AO7–AO8)
Parameter
Number 2
Current range 0 – 1200 mA
Minimum Load resistance 4Ω
PWM Modulation frequency 40 - 1200 Hz
1.2.6 Outputs without current feedback (AO0-AO6)

Parameter
Number 7
Current range 0 – 4A
Minimum Load resistance 4Ω
PWM Modulation frequency 40 - 1200 Hz
1.2.7 Speedometer output (SPEED0_OUT)
Parameter
Number 1
Max. output current 10 mA
Nominal output level OFF -10 V
Nominal output level ON +10 V
Frequency range 0 – 10 kHz
PWM Capability Yes
Fault detection capability No
1.2.8 Safety Relay
Based on IEC61508, in order to increase safety, a relay is used to switch-off all outputs when a
functional disorder is recognized.
1.2.9 Watchdog
Based on IEC61508, in order to increase safety, an external watchdog is used to check the
correct behaviour of the microprocessor.

1.3 Physical dimensions
Dimensions: 234 x 181 x 48 mm³
Weight : approx. 0,8 kg
TOP VIEW :

APC121 – TOP VIEW with and without connector
SIDE VIEW :

BOTTOM VIEW :
APC121 – BOTTOM VIEW with and without connector

2. INSTALLATION GUIDE
2.1 CONNECTOR
For the connection to the vehicle the 60-pole connector is used, Tyco brand,
partnumber 284742-1. The 94-pole connector is not used and all pins of this connector
are internally connected to GND .
At the left
side there is
the 60 pole
connector, while at the right side there is the 94 pole connector.
The contacts for the 60 pole connector are:
• 24 x 2,5mm x 0,63mm
• 36 x 0,63mm x 0,63 mm
1 CPA
5 Lever
12 Secondary lock
13 Cover


2.2 Mechanical mounting
General advices
• It has to be assured that water cannot infiltrate through the wiring harness into the control unit.
• The pressure compensation element (DAE) as well as the sealing may not be submersed in
water.
• Dana’s consent is required if the mounting instructions are not followed or the provided
clamps are not used.
Mounting
• Permitted installing area: passenger car, off highway vehicles. • The pressure compensation
element (DAE) as well as the sealing may not be submersed in water.
• Permitted mounting location: chassis and engine compartment.

• Bouncing of ECU in mounting position is not allowed.
• Upper limit of surface pressure at specified clamp areas: 10 N/mm².
• Upper limit of total clamping force: 400 N.
• The ECU should be mounted in such a way, that the pressure compensation element and
the connector for the wiring harness are not exposed to direct splashing water.
• The ECU has to be mounted in such a way that its connector is freestanding in order to
allow its female counterpart to be connected without obstructions.
• The ECU has to be mounted on a totally plane surface.
Wiring Harness
• Harness needs to be fixed mechanically in the area of the ECU (Distance < 150 mm)
• Harness needs to be fixed in such a way that in case of an excitation, the wiring
harness is in-phase with the ECU (e.g. at the fixing point of ECU).
Fitting Position
• Permissible fitting axis (g-vector) must be outside cone A and B (see picture below).

http://www.software995.com/



The 60-pole connector pin assignment is as follows:
Pin Name Function Pin Name Function

01 AO7 (1) Analog output 7 with 31 AO1 (1) Analog ouput 1 without
current feedback current feedback
02 GND_AO7 GND for AO7 32 GND_AO1 Analog output 1 ground
03 AO8 (1) Analog output 8 with 33 AO0 (1) Analog output 0 without
04 GND_AO8 GND for AO8 34 GND_AO0 Analog output 0 ground
05 GND Battery ground 35 AO6 (1) Analog output 6 without
current feedback
06 RS232_RX0 RS232 RX channel 0 36 GND_BUS LIN/RS232/CAN bus ground
07 RS232_RX1 RS232 RX channel 1 37 RESET_REQUEST Reset request pin
08 LIN_BUS LIN BUS 38 RS232_TX1 RS232 TX channel 1
09 GND_SPIN0 Speed sensor 0 ground 39 RS232_TX0 RS232 TX channel 0
10 SPIN0 Speed sensor 0 input 40 GND Digital ground
11 GND_SPIN1 Speed sensor 1 ground 41 BSL_REQUEST Boot load strobe pin
12 SPIN1 Speed sensor 1 input 42 SPEEDO_OUT Speed output signal
13 GND_ANI3 Analog input 3 ground 43 GND_SPEEDO Signal GND
14 ANI3 Analog input 3 44 GND Battery ground
15 VREF_5V Reference voltage 5V 45 VP_PWR Permanent power supply
16 GND_AO5 Analog output 5 ground 46 AO4 (1) Analog output 4 without
current feedback
17 AO5 (1) Analog output 5 without 47 GND_AO4 Analog output 4 ground
current feedback
18 AO3 (1) Analog output 3 without 48 AO2 (1) Analog output 2 without
19 GND_AO3 analog output 3 ground 49 GND_AO2 Analog output 2 ground
20 VS_PWR Switched power supply 50 GND_AO6 Analog output 6 ground
21 PLOADS On/off loads 51 LIN_BUS_PWR LIN bus power supply
22 CAN LO CAN V2.0B BUS 52 DI7 (2) Digital input 7
23 CAN HI CAN V2.0B BUS 53 DI6 (2) Digital input 6
24 GND_ANI0 ANI0 ground 54 DI5 (2) Digital input 5
25 ANI0 Analog input 0 55 DI4 (2) Digital input 4
30 GND_VREF Vref ground 60 VS_PWR Switched power supply
(1) Switch to plus : output internally switches to plus, second side of load must be connected to ground
(2) Pull to plus : input internally pulled low, must be connected to plus to activate

2.3 Mating connector
The Mating connector can be ordered from Tyco :
Tyco Part number

Receptacle 60 pins 284742-1
Pins for 0.50 – 0.75 mm² 968221-1
Pins for 0.75 – 1.50 mm² 1241608-1
There are two different types of pins needed on the mating connector :
• The first group is composed for the following pins: 1-5, 15-20, 30-35, 45-
50, 60 and to connect these pins only the contacts 1.5mm Clean body are
allowed.
The cable thickness range for this contact is: 0.75-1.50 mm².
• The second group is composed by the following pins: 6-14, 21-29, 36-44,
51-59 and to connect these pins only the contact MQS Clean Body contact
(P/N 968221-1) is allowed.
To reduce the noise picked up by the inputs of the controller, it is necessary to separate output
wires and input wires. Therefore two cable trees are made named A and B. The wires of cable
tree A are fed through an expandable braided sleeve even so for the wires of cable tree B. (See
table) If necessary, both cable trees can be fed through an third expandable braided sleeve.

2.4 Required wire thickness on the mating connector
Pin number Contact type Wire thickness Cable tree

1 P/N 1241608-1 AWG16 - 1,50mm2 A
2 P/N 1241608-1 AWG16 - 1,50mm2 A
3 P/N 1241608-1 AWG16 - 1,50mm2 A
4 P/N 1241608-1 AWG16 - 1,50mm2 A
5 P/N 1241608-1 AWG16 - 1,50mm2 A
6 P/N 968221-1 AWG20 - 0,519mm2 B
7 P/N 968221-1 AWG20 - 0,519mm2 B
8 P/N 968221-1 AWG20 - 0,519mm2 B
9 P/N 968221-1 AWG20 - 0,519mm2 B
10 P/N 968221-1 AWG20 - 0,519mm2 B
11 P/N 968221-1 AWG20 - 0,519mm2 B
12 P/N 968221-1 AWG20 - 0,519mm2 B
13 P/N 968221-1 AWG20 - 0,519mm2 B
14 P/N 968221-1 AWG20 - 0,519mm2 B
15 P/N 1241608-1 AWG16 - 1,50mm2 B
16 P/N 1241608-1 AWG16 - 1,50mm2 A
17 P/N 1241608-1 AWG16 - 1,50mm2 A
18 P/N 1241608-1 AWG16 - 1,50mm2 A
19 P/N 1241608-1 AWG16 - 1,50mm2 A
20 P/N 1241608-1 AWG16 - 1,50mm2 A
21 P/N 968221-1 AWG20 - 0,519mm2 B
22 P/N 968221-1 AWG20 - 0,519mm2 B
23 P/N 968221-1 AWG20 - 0,519mm2 B
24 P/N 968221-1 AWG20 - 0,519mm2 B
25 P/N 968221-1 AWG20 - 0,519mm2 B
26 P/N 968221-1 AWG20 - 0,519mm2 B
27 P/N 968221-1 AWG20 - 0,519mm2 B
28 P/N 968221-1 AWG20 - 0,519mm2 B
29 P/N 968221-1 AWG20 - 0,519mm2 B
30 P/N 1241608-1 AWG16 - 1,50mm2 B
31 P/N 1241608-1 AWG16 - 1,50mm2 A
32 P/N 1241608-1 AWG16 - 1,50mm2 A
33 P/N 1241608-1 AWG16 - 1,50mm2 A
34 P/N 1241608-1 AWG16 - 1,50mm2 A
35 P/N 1241608-1 AWG16 - 1,50mm2 A
36 P/N 968221-1 AWG20 - 0,519mm2 B
37 P/N 968221-1 AWG20 - 0,519mm2 B
38 P/N 968221-1 AWG20 - 0,519mm2 B
39 P/N 968221-1 AWG20 - 0,519mm2 B
40 P/N 968221-1 AWG20 - 0,519mm2 B
41 P/N 968221-1 AWG20 - 0,519mm2 B
42 P/N 968221-1 AWG20 - 0,519mm2 B
43 P/N 968221-1 AWG20 - 0,519mm2 B
44 P/N 968221-1 AWG20 - 0,519mm2 A
45 P/N 1241608-1 AWG16 - 1,50mm2 A
46 P/N 1241608-1 AWG16 - 1,50mm2 A
47 P/N 1241608-1 AWG16 - 1,50mm2 A

Pin number Contact type Wire thickness Cable tree
48 P/N 1241608-1 AWG16 - 1,50mm2 A
49 P/N 1241608-1 AWG16 - 1,50mm2 A
50 P/N 1241608-1 AWG16 - 1,50mm2 A
51 P/N 968221-1 AWG20 - 0,519mm2 B
52 P/N 968221-1 AWG20 - 0,519mm2 B
53 P/N 968221-1 AWG20 - 0,519mm2 B
54 P/N 968221-1 AWG20 - 0,519mm2 B
55 P/N 968221-1 AWG20 - 0,519mm2 B
56 P/N 968221-1 AWG20 - 0,519mm2 B
57 P/N 968221-1 AWG20 - 0,519mm2 B
58 P/N 968221-1 AWG20 - 0,519mm2 B
59 P/N 968221-1 AWG20 - 0,519mm2 B
60 P/N 1241608-1 AWG16 - 1,50mm2 A
2.5 Battery Plus Connections (terminal 20,45,60)

The APC121 can be connected to the battery in two ways. In the first solution the
terminals 20 and 60 (switched power supply) are connected straight to the 12V /
24V battery plus via the ignition switch and a fuse of 15 A. The maximum allowable
resistance between the connector of the APC121 and the battery plus is 100 mΩ.
These terminals provide power for the shift logic and the outputs that typically control
the transmission solenoids.
The disadvantage of this connection diagram is that during a short to battery failure on
a power output the VSPWR is forced to battery voltage level even when the ignition
key is off. The internal safety relay has to be switched off by the firmware and
none of the outputs are available for limited operation.
FUSE
VPPWR - µProcessor
45 - logic
FUSE
VSPWR
20,60 - power outputs
PLOAD
21
Ignition key
APC121
- +

In the second solution the internal relay is used to switch all loads on or off by the
PLOAD signal. The terminals 20 and 60 (switched power supply) are connected
straight to the 12V / 24V battery plus via a fuse of 15 A.The maximum allowable
resistance between the connector of the APC121 and the battery plus is 100 mΩ. Even
with a short to plus on one of the outputs, a limited operation of the vehicle is possible.
This wiring is therefore recommended.
FUSE
VPPWR - µProcessor
45 - logic
FUSE
VSPWR
- power outputs
20,60
PLOAD
21
Ignition key APC121
- +
For the both solutions the terminal 45 (permanent supply terminal) must be
connected directly to the 12V/24V battery via a fast 500 mA fuse. Only this way, the
APC121 can save valuable information during power down periods (auto power-off
functionality).
2.6 PLOAD signal (terminal 21)

For the second solution it is of course necessary to switch-off the power to the loads
via a separate control signal. A low level on this input switches off the power to the
outputs with and without current feedback.
2.7 Power ground terminals (terminal 5,44)

These terminals are the APC121's power ground terminals and must be connected to a
well-defined ground potential. This means that each wire must be connected
straight to the battery minus.
Improper grounding may degrade the control system’s operation. The fact that
most outputs conduct pulsed signals tends to generate switching noise on the
ground lines. If the ground lines have insufficient quality or are shared with
other loads, serious degradation of the analog input signal quality may result.

2.8 Signal ground terminals
Remark:
Using these pins for returning solenoid load current or carrying high currents (>20 mA)
from other non-APC121 loads can seriously degrade the function of the control system.
As quite some pins use these ground lines, and considering the fact that the
common resistance in this line can cause significant measurement errors, it is
recommended to use a short lead from the APC121 connector pin to the split
point and go from there with (smaller) dedicated wires to the individual sensor
return paths.
2.8.1 Analog inputs (terminal 13, 24, 26, 28)

Potentiometers, electronic potentiometer devices (based on hall sensor technology)
should be connected to the signal ground. It is not necessary to use all these wires.
2.8.2 Speed sensor inputs (terminal 9, 11)

For the speed sensors inputs the terminal 9 and 11 are preserved. The minus of these
sensors are connected to these pins.
2.8.3 Communication links (terminal 36)

For CAN, RS232 and LIN signals, the terminal 36 is used as ground signal.
2.9 Voltage reference of 5V (terminal 15)

Terminal 15 is a 5V reference intended to provide power to potentiometric sensors
such as throttle pedal position, brake pedal position sensors and for example pressure
sensors.
These sensors have typically impedances in the range of 500 – 5000 Ω. As such the
total current requirement is generally quite low (< 30mA). Keep in mind that the total
power consumption on this terminal pin may not be higher then 100 mA. To reduce the
voltage drop on this line, the recommended wire thickness is 1,50 mm².
It’s not acceptable to use this output to power auxiliary 5V appliances.
2.10 Digital inputs (terminal 52-59)

The connection of discrete inputs is typically not critical in this respect that the input
should be connected to terminal 20 or 60 (switched battery supply) or left open.
If however the input is connected to a voltage source switching between two levels, it’s
important to realize that the switching threshold of these inputs lies somewhere
between 2 and 4 V.
So for a well defined low level, the input must be pulled below 2V. For a guaranteed
high level, the input must be pulled above 4V.
2.11 Analog inputs (terminal 14,25,27,29)

Four analog inputs are available on the APC121. The following two kinds of
measurement are possible: resistive or voltage measurements. In the following table
an overview is made of the different configurations.

Configuration 1 Configuration 2 Configuration 3 Configuration 4
Resistive Voltage Resistive Voltage Resistive Voltage Resistive Voltage
ANI0 X - X - - X - X
ANI1 X - X - - X - X
ANI2 X - - X X - - X
ANI3 X - - X X - - X
2.11.1 Resistive inputs

In order to be able to correctly measure the sensor’s resistance, it’s important that
each sensor has a dedicated ground wire going as direct to the signal ground of the
controller as possible. To increase the signal to noise ratio, it is recommended to twist
the signal and ground wire. Sixty turns per meter is recommended.
2.11.2 Voltage inputs.

The inputs are selected analog inputs designed to measure voltages from 0 – 5 Volts.
Typically however the used range is restricted somewhat to allow the detection of open
connections and shorts to ground. The signal wire can be twisted with ground terminal
to increase the signal to noise ratio. Sixty turns per meter is recommended.
2.12 Speed sensor inputs (terminal 10,12)

The APC121 supports 3 types of speed sensors. For the three types, open circuit and
short circuit detection is implemented.
The sensor type is software programmable and depends on the application.
2.12.1 Inductive sensors

For inductive sensors, the wiring and sensor to gear gap setting is quite critical. The
next picture shows the connection diagram to the controller.
As the output signal for these sensors is an AC voltage, it’s quite susceptible to
electromagnetic influences.
The use of shielded or twisted cables is recommended. The next picture shows the
connection diagram to the controller.
If shielded cable is used, the shield must at the sensor side be connected to one
terminal and on the other side to the correct ground terminal (terminal 9 or 11).
APC121
Shielded cable
SPINx +
Speedsensor
GND
-
Twisted pair cable

SPINx +
Speedsensor
GND -
60 turns/m

The central conductor connects the other pin to the sensor input (either terminal 10 or
terminal 12). In case of twisted cables, use at least 20 turns per meter but more
preferably use 60 turns per meter.
See the transmission user manual for more details about the ‘sensor to gear gap’
distances.
2.12.2 Magneto Resistive sensors

The magneto resistive sensors used with the APC121 are of a Spicer Off Highway
proprietary design and offer some advantages over inductive sensors. They sense
speeds down to standstill even with a sensor to gear gap of 1.7 mm. Furthermore, they
exhibit far better EMC behaviour and therefore need no special cabling, although the
use of twisted pair cables further increases EMC immunity and is recommended.
They have some disadvantages too however : the sensors have an electrical polarity
and must be correctly oriented relative to the gear’s turning direction in order to
operate properly. For this purpose, each sensor has to be mounted according to the
indication mark. See the transmission user manual for more details.
Make sure to observe the polarity indicated on the application specific wiring diagram.
Failure to do so causes loss of the speed signal. The APC121 will report the fault as a
short circuit.
Incorrect mounting also results in loss of speed, but is not detected by the APC121
hardware, and thus can cause improper transmission control.
2.12.3 Hall effect sensor

The APC121 can also be connected to a Hall effect gear tooth speed sensor. The
preferred sensor for new applications is the 1GT101DC from Honeywell. Because this
sensor has three wires, a special connection diagram must be provided to connect it to
the 2-wires speed input from the APC121. The detection is based on the current the
sensor draws from the power supply.
The next picture shows the correct diagram :

Remark: If the APC121 replaces an APC50 or APC70 controller, the connection of the
sensor to the controller was made in the past with 2 resistors :
See the picture below for this connection :
SPIN+
270Ω 1/4W
N
270Ω 1/4W
SIGGND
D
The above configuration is still possible, but it is strongly recommended to use here
also the connection diagram with 1 resistor as shown in the first picture. This for
reason that the latter configuration has a better signal/noise ratio than the 2 resistor
connection.
2.13 Outputs (terminals 01,03,17,18,31,33,35,46,48)

PWM outputs with inductive loads typically only draw current from the battery a part of
the time. The other time, the current flows through the ground wire back into the
APC121. Having the ground anywhere else than directly on the terminal , requires the
current to flow all the way to the battery and from there through the connection to the
terminal 2,4,16,19,32,34,47,49 and 50 into the APC121. This causes ground noise
which can significantly degrade the measurements of the analog inputs.
On the APC121, 2 PWM outputs with current feedback, and 7 without current feedback
are available.
The terminals 1 and 3 are current feedback outputs and are connected to the
proportional valves. The returning terminals are 2 or 4.
The terminals 17,18,31,33,35,46 and 48 are outputs without current feedback. The
returning terminals are 16,19,32,34,47,49 and 50.
2.14 Display
It is possible to connect a display to the APC121. The display gets its info via a serial
link from the controller, which is called LIN bus. The display is connected to the
controller as follows:
• The supply voltage of the display is connected to terminal 51.
• The ground terminal is connected to terminal 36.
• The serial bit info is connected to terminal 8.
Remark: It is not necessary to connect the power supply terminal of the display to the
controller. A power supply voltage controlled by the ignition switch will also serve.

2.15 Communication lines
It is recommended to twist the RX and TX line with the signal ground of the RS232
interface or to use a shielded cable. For theCAN interface is recommended to twist the
CAN LO and CAN HI wire. The signal to noise ratio will be much better and this can
result in less retransmissions on the bus. An overview is shown in the following table:
Protocol RX PIN / CAN LO TX PIN / CAN HI Twisting

RS232_1 6 39 6 and 39 with 36
RS232_2 7 38 7 and 38 with 36
CAN 22 23 22 with 23
Between 20 and 60 turns per meter is the recommended value. The higher the value,
the better it will be for the signal to noise ratio.
Attention : the CAN bus must be terminated with a 120 ohm resistor.

3. General wiring diagram
VALVE
AO 7 1 29
2 28 ANI2
CAN BUS
AO 8 3
4
14
ANI3
ON/OFF 33 13
34
ON/OF 31
F 15 +
32 Pot
24
ON/OFF 17
A 25
-
16 P 15 +
ON/OFF 18
C 26
Pot
19 1 27
-
2
10
0
+
speed in n
9
-
51
+
8 LIN DISPLAY
+ 12
n 36
speed in 11 -
-
CAN BUS
42 CANH
+
n out 22
speedo out 43 CANL
-
23
GND
36
500mA 45
RS232 BUS
15A 20, 21, 60 06 RXD
Drive TXD
5, 44 39
+ - 36 GND
+12V

4. Disclaimer
APPLICATION POLICY
Capability ratings, features and specifications vary depending upon the model type of
service. Application approvals must be obtained from Spicer Off-Highway Systems. We
reserve the right to change or modify our product specifications, configurations, or
dimensions at any time without notice.
SPICER OFF-HIGHWAY SYSTEMS
Ten Briele 3
B-8200 Brugge, Belgium
Tel: +32 (0) 50 40 22 11


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HARDWARE

APC121 : Advanced Programmable Controller

SPICER OFF-HIGHWAY PRODUCTS APC121

SPICER OFF-HIGHWAY PRODUCTS APC121

VP_PWR (permanent power)

Power supply input 12/24V DC

SPICER OFF-HIGHWAY PRODUCTS APC121

SPICER OFF-HIGHWAY PRODUCTS APC121

The APC121 complies to following standards and directive:

1.2 Electrical Characteristics

1.2.1 Digital inputs (DI0 – DI7)

SPICER OFF-HIGHWAY PRODUCTS APC121

1.2.2.1 Resistive analog inputs

1.2.2.2 Voltage analog inputs

1.2.3 Reference voltage (VREF_5V)

1.2.4 Speed inputs (SPIN0–SPIN1)

SPICER OFF-HIGHWAY PRODUCTS APC121

1.2.6 Outputs without current feedback (AO0-AO6)

1.2.7 Speedometer output (SPEED0_OUT)

1.2.8 Safety Relay

SPICER OFF-HIGHWAY PRODUCTS APC121

SPICER OFF-HIGHWAY PRODUCTS APC121

SPICER OFF-HIGHWAY PRODUCTS APC121

APC121 – BOTTOM VIEW with and without connector

SPICER OFF-HIGHWAY PRODUCTS APC121

SPICER OFF-HIGHWAY PRODUCTS APC121

SPICER OFF-HIGHWAY PRODUCTS APC121

• Permitted mounting location: chassis and engine compartment.

SPICER OFF-HIGHWAY PRODUCTS APC121

SPICER OFF-HIGHWAY PRODUCTS APC121

SPICER OFF-HIGHWAY PRODUCTS APC121

SPICER OFF-HIGHWAY PRODUCTS APC121

Pin Name Function Pin Name Function

SPICER OFF-HIGHWAY PRODUCTS APC121

The Mating connector can be ordered from Tyco :

Tyco Part number

SPICER OFF-HIGHWAY PRODUCTS APC121

Pin number Contact type Wire thickness Cable tree

SPICER OFF-HIGHWAY PRODUCTS APC121

2.5 Battery Plus Connections (terminal 20,45,60)

SPICER OFF-HIGHWAY PRODUCTS APC121

Ignition key APC121

2.6 PLOAD signal (terminal 21)

2.7 Power ground terminals (terminal 5,44)

SPICER OFF-HIGHWAY PRODUCTS APC121

2.8.1 Analog inputs (terminal 13, 24, 26, 28)

2.8.2 Speed sensor inputs (terminal 9, 11)

2.8.3 Communication links (terminal 36)

2.9 Voltage reference of 5V (terminal 15)

2.10 Digital inputs (terminal 52-59)

2.11 Analog inputs (terminal 14,25,27,29)

SPICER OFF-HIGHWAY PRODUCTS APC121

2.11.1 Resistive inputs

2.11.2 Voltage inputs.

2.12 Speed sensor inputs (terminal 10,12)

2.12.1 Inductive sensors

Twisted pair cable

SPICER OFF-HIGHWAY PRODUCTS APC121

2.12.2 Magneto Resistive sensors

2.12.3 Hall effect sensor

The next picture shows the correct diagram :

SPICER OFF-HIGHWAY PRODUCTS APC121