Danfoss Transit Mixer Controller (TMC) User guide

Brand: Danfoss

Model: Transit Mixer Controller (TMC)

Type: User guide

powersolutions.danfoss.com

MAKING MODERN LIVING POSSIBLE

Technical Information

Transit Mixer

Controller (TMC)

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 20132

Table of Revisions

Date Page Changed Rev

17 Sep 2013 All New layout CA

02 Jul 2013 Updated photo of TMC BA

02 Dec 2010 Initial release AA

Revisions

Revision History

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 2013 3

Contents

Product Overview Features ........................................................................................................................................................................................ 4

Ordering Information .............................................................................................................................................................. 5

Mechanical

Installation

Unit Dimensions ........................................................................................................................................................................ 6

Panel Cutout Dimensions ...................................................................................................................................................... 6

Electrical

Installation

Pin Assignments ........................................................................................................................................................................ 7

Input/Output .............................................................................................................................................................................. 7

Wiring Recommendations ..................................................................................................................................................... 8

Product

Speciﬁcations

Environmental Testing Criteria ............................................................................................................................................ 9

General PLUS+1 Module Ratings ................................................................................................................................... 9

Testing Criteria ..................................................................................................................................................................... 9

Housing ................................................................................................................................................................................10

TMC Software Overview .................................................................................................................................................................................... 11

Operation Deﬁnitions ............................................................................................................................................................ 11

Cabin Station ...................................................................................................................................................................... 11

Remote Station .................................................................................................................................................................. 11

LED Indicator ...................................................................................................................................................................... 11

Activate Function .............................................................................................................................................................. 11

Overtaking Control Function ....................................................................................................................................... 11

Charge Function ................................................................................................................................................................ 12

Discharge Function .......................................................................................................................................................... 12

Limp Home Function ....................................................................................................................................................... 12

Error Codes .......................................................................................................................................................................... 12

System Installation System Set-up ........................................................................................................................................................................... 13

Software Parameter Set-up Service Tool Interface ............................................................................................................................................................ 14

Limit Drum Speed ............................................................................................................................................................. 14

TMC System Overview .................................................................................................................................................... 14

Rotary Switch Calibration .............................................................................................................................................. 15

Rotary Switch Time Ramp .............................................................................................................................................. 15

System 0, 1, 2, or 3 ............................................................................................................................................................. 16

PID Feed-Forward Parameters ..................................................................................................................................... 17

PID P Parameters ............................................................................................................................................................... 18

PID Algorithm Parameters ............................................................................................................................................. 19

Engine RPM Request Proﬁle ..........................................................................................................................................20

Output Soft Ramp ............................................................................................................................................................. 21

All Parameter Summary ..................................................................................................................................................22

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 20134

Product Overview

The Danfoss Transit Mixer Controller (TMC) is designed to control the drum functions of concrete

transit mixers. The TMC is shipped from the factory with ready-to-use transit mixer control software

installed. TMC software allows OEMS to optimize the performance of their machines by adjusting

tuning parameters using the PLUS+1 Service Tool. CAN bus communication technology allows

multiple TMCs to be installed on a transit mixer providing OEMs with a convenient and cost eﬀective

way to provide cabin and remote control.

Features y TMC controllers are designed to survive the demanding transit mixer environment by providing

Ingress Protection IP 69K for front of panel and IP 67 for back of panel.

y TMC mechanical design provides a compact hardware footprint minimizing machine space

requirements.

y A Deutsch® sealed connector is molded into the TMC housing.

y A non-contacting rotary dial and switch on the front of the TMC allows reliable control of drum

speed and direction for mixer charge and discharge functions.

y Hardware conﬁguration pins allow the TMC to interface with Danfoss and competitor hydraulic

systems.

y TMC software parameters and control features are easily accessed and changed using the PLUS+1

Service Tool.

y CAN bus communication allows up to ﬁve TMC controllers to be installed on a vehicle allowing

both cabin and remote control. J1939 CAN message protocol allows the TMC to read engine

variables and control the engine throttle.

y 9 to 36 Vdc power supply.

y CE compliant.

PLUS+1™ TMC Controller

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 2013 5

Ordering

Information

TMC (Transit Mixer Controller) part number 11056444

Related products Part numbers

CG150 CAN/USB gateway 10104136

Deutsch® mating connector

bag assembly

110126 48

Panel mounting kit 110 83012

PLUS+1 GUIDE P1D ﬁle is required in order to access tuning parameters.

PLUS+1 GUIDE application (including Service

Tool)

.exe File *

TMC parameter ﬁle (P1D) 70048136.P1D *

* Download on line at: www.Danfoss.com

Deutsch Mating Connector

Description Deutsch Part Number Quantity Required

Connector DT16-18SB-K004 1

Terminals 0462-201-1631 18

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 20136

4 x R4

72.80 ± 0.50

[2.87 ± 0.20]

93.80 ± 0.50

[3.69 ± 0.20]

P108 255

Panel Plate

Panel

Panel Cutout

Panel Seal

TMC Unit

Screw (4): Delta PT® WN 5451 35 X 30 - s

Torque: 1 Nm [0.737 lb-ft]

84.00 [3.30]]

85.00

[3.35]

93.00

[3.66]

64.00 [2.52]

72.00 [2.83]

112.00

[4.40]

P108 256

29.00 [1.14]

40.0 [01.57]

Dimensions for

Deutsch connector

(not included)

Minimum 1.00 [0.04]

Maximum 5.00 [0.20]

Dual Color (amber/red) LED

Mechanical Installation

Unit Dimensions

mm [in]

Panel Cutout Dimensions

Use fastener screws: Delta PT® WN 5451 35 X 30 - s

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 2013 7

Electrical Installation

Pin Assignments

TMC Conﬁguration Options*

Function Conﬁg 0 Conﬁg 1

TMC remote station O O

TMC cabin station with Danfoss hydraulics I O

TMC cabin station with Bosch-Rexroth® hydraulics

O I

TMC cabin station with Eaton® hydraulics

I I

* Each Conﬁg pair (Conﬁg 0/Conﬁg1) deﬁnes a pre-determined set of TMC software parameters

Input/Output

C1P7, C1P8 Speciﬁcations

Parameter Units Minimum Maximum Description

Allowed voltage at pin Vdc 0 36 —

Frequency range —

C1P9, C1P10 Digital Input Speciﬁcations

Parameter Units Minimum Maximum Description

Allowed voltage at pin Vdc 0 36 —

C1P13, C1P14 PWM Output Speciﬁcations

Parameter Units Minimum Maximum Description

PWM current A 0 3.0 If the output current exceeds the trip point,

the output will be latched oﬀ

PWM frequency range Hz 33 4000 —

Over-current trip point A 8 8.5 —

18 Pin Connector

Pin Controller function

C1-P1 Power ground -

C1-P2 Power supply +

C1-P3 CAN +

C1-P4 CAN -

C1-P5 CAN shield

C1-P6 5 Vdc sensor power +

C1-P7 Motor Speed PPU

C1-P8 Pump Speed PPU

C1-P9 Conﬁg 0*

C1-P10 Conﬁg 1*

C1- P11 Not used

C1-P12 Not used

C1-P13 PWMOUT (Charge)

C1-P14 PWMOUT (Discharge)

C1-P15 Not used

C1-P16 Not used

C1-P17 Not used

C1-P18 Not used

* See TMC Conﬁguration Options, below.

P108 257

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 20138

Wiring Recommendations y All wires must be protected from mechanical abuse. Wires should be run in ﬂexible metal or plastic

conduits.

y Use 85˚ C [185˚ F] wire with abrasion resistant insulation. 105˚ C [221˚ F] wire should be considered

near hot surfaces.

y Use a wire size that is appropriate for the module connector.

y Separate high current wires such as solenoids, lights, alternators or fuel pumps from sensor and

other noise-sensitive input wires.

y Run wires along the inside of, or close to, metal machine surfaces where possible. This simulates a

shield which will minimize the eﬀects of EMI/RFI radiation.

y Do not run wires near sharp metal corners. Consider running wires through a grommet when

rounding a corner.

y Do not run wires near hot machine members.

y Provide strain relief for all wires.

y Avoid running wires near moving or vibrating components.

y Avoid long, unsupported wire spans.

y All analog sensors should be powered by the sensor power source from the PLUS+1 Controller.

Sensor rounds should be returned to the machine control system

common ground.

y Sensor lines should be twisted about one turn every 10 cm (4 in).

y It is better to use wire harness anchors that will allow wires to ﬂoat with respect to the machine

rather than rigid anchors.

y All machine electronic modules should be grounded to a dedicated control system ground that

consists of a conductor of suﬃcient size that is connected to the

battery (-).

y If a CAN shield is used, the shield must be grounded to the machine control system ground and the

CAN shield pin on the TMC controller.

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 2013 9

Product Speciﬁcations

Environmental

Testing Criteria

General PLUS+1 Module Ratings

Description Units Minimum Maximum Comment

Operating temperature ˚C [˚F] -40 [-40] 70 [158]

Storage temperature ˚C [˚F] -40 [-40] 85 [185]

Allowable module supply voltage Vdc 9 36

Module sensor supply voltage Vdc 4.88 5.12 All current returns must be directly wired

to the machine ground to reduce any

voltage losses to the sensor power line.

Failure to comply may result in a sensor

power voltage lower than the speciﬁed

minimum.

Analog input voltage levels Vdc 36

Allowable output load current

(per pin)

A 8

TMC allowable total output current A 11. 5

IP rating

(with mating connector attached)

IP 69K (front)

IP 67* (rear)

CE rating CE compliant

* PLUS+1 module IP 67 rating is only valid when the module mating connector is in place and unused connector pin positions

have sealing plugs installed.

Testing Criteria

Climate Environment

Description Applicable standard Comment

Storage temperature IEC 60068-2-1, test Ab, IEC

60068-2-2 test Bb

Operating temperature IEC 60068-2-1, test Ab, IEC

60068-2-2 test Bd

Thermal cycle IEC 60068-2-2, test Na, IEC

60068-2-38 (partial)

Humidity IEC 60068-2-78, IEC

60068-2-30 test Db

Damp heat steady state and cyclic.

Degree of protection IEC 60529

Chemical Environment

Description Applicable standard Comment

Salt mist IEC 60068-2-58 test Kb

Chemical resistance ISO 16750-5

Mechanical Environment

Description Applicable standard Comment

Vibration IEC 60068-2-6 test Fc,

IEC6008-2-64 test Fh

Bump IEC 60068-2-29 test Eb

Shock IEC 60068-2-27 test Ea

Free fall IEC 60068-2-32 test Ed

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 201310

Environmental

Testing Criteria (continued)

Electrical/Electromagnetic

Description Applicable standard Comment

EMC emission ISO 13766, SAE J1113-13 Electromagnetic compatibility for earth moving

machinery.

EMC immunity ISO 13766 Electromagnetic compatibility for earth moving

machinery.

Electrostatic discharge EN 60-1 000-4-2

Auto electrical transients ISO 7637-2, ISO 7637-3

Short circuit protection Danfoss test Inputs and outputs survive continuous short

circuit. Normal function resumes when short is

removed.

Reversed polarity protection Danfoss test Survives reverse polarity at supply voltage for at

least ﬁve minutes.

Housing

The TMC housing features a snap together assembly that is tamper-proof. Once assembled at the

factory, the housing cannot be opened for service.

Opening the TMC housing will void the factory warranty.

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 2013 11

TMC Software

Overview

Operation

Deﬁnitions

Cabin Station

One TMC controller on the machine is designated as the cabin station. Machine inputs and outputs

(motor speed PPU, conﬁguration, charge and discharge outputs, and

CAN bus) are connected to the cabin station controller’s connector pins.

Remote Station

Up to four remote stations can be installed on a vehicle. Remote stations are only connected to the

vehicle’s CAN bus and power—other connector input and output pins are not used.

LED Indicator

The TMC station status is provided to the operator by a dual color (amber/red) LED located to the

right of the yellow control button, see Unit Dimensions, page 6.

TMC software controls the operation of a transit mixer drum by reading inputs from the TMC

controller’s input pins, CAN bus, operator control dial and operator switch, and by providing control

outputs to the TMC controller’s output pins and CAN bus.

The TMC software uses drum motor and engine speed to provide control inputs to the proportional

integral derivative controller (PID controller) algorithm controlling drum motor speed. Engine speed

is also controlled by the software when the vehicle is in work mode.

The TMC controller has two digital input conﬁguration pins, allowing up to 4 sets of parameters to be

stored in the memory of the controller. This feature allows OEMs the ﬂexibility to use the TMC

controller with hydraulic systems from diﬀerent suppliers.

TMC Station Status

Indication Status

LED not illuminated Another TMC station is active

Blinking amber LED No TMC station is active

Solid amber LED The TMC station is active

Blinking red LED Error condition. See Error Codes, page 12, for error blink code information.

Active Station

The active TMC is the controller receiving operator inputs and sending outputs to the vehicle.

Activate Function

Each time a vehicle’s engine is started, one TMC station must be activated. To activate a speciﬁc TMC,

that TMC’s rotary dial must be in the neutral (center) position and the yellow TMC control button must

be pressed for two seconds.

Overtaking Control Function

This function transfers operator control from one TMC on the machine to another if more than one

TMC is installed on a vehicle. To make a speciﬁc TMC active, that TMC’s rotary dial must be in the

neutral (center) position and the yellow TMC control button must be pressed for two seconds.

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 201312

Charge Function

Transit mixer charge functionality is enabled from an activated TMC by pushing the yellow TMC

control button and turning the rotary dial to the right (clockwise). Drum speed and engine RPM are

functions of the rotary dial position.

Discharge Function

Transit mixer discharge functionality is enabled from an activated TMC by pushing the yellow TMC

control button and turning the rotary dial to the left (counterclockwise). Drum speed and engine RPM

are functions of the rotary dial position.

The vehicle parking brake must be engaged to enable the discharge function.

Limp Home Function

If the cabin station TMC looses motor speed (PPU) input, the drum speed PID algorithm will be reset

and drum speed will be directly controlled from the rotary dial without any feedback compensation

for changes in engine speed and other disturbances.

Error Codes

If the TMC application software detects an error condition, the output signal to the drum motor will

be set to zero and an error blink code will be indicated by a red color LED (to the right of the TMC’s

rotary dial).

Potential TMC Errors

Error code Description

20 Rotary switch error

21 Discharge set point error

22 Charge set point error

23 Motor speed PPU lost. Limp home

24 PID error

25 Error on output

26 Error on input

27 CAN communication lost

28 Engine RPM request error

29 Error in feed-forward from Rotary Switch

30 Error in feed-forward from Engine RPM

Error Blink Code Examples

Error code Description

20 Two long, followed by zero short.

21 Two long, followed by one short.

Operation

Deﬁnitions

(continued)

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 2013 13

System Installation

System Set-up 1. Connect the Cabin Station TMC input and output pins to the vehicle’s wiring harness.

Be sure to have one of the two conﬁguration pins connected, reference TMC Conﬁguration Options,

page 7. The Cabin Station TMC’s CAN bus address will automatically be assigned by the software

when power is applied to the controller.

2. Sequentially connect Remote Station TMCs to the vehicle CAN bus.

Reboot the system so that the new Remote Station TMC can claim a valid node ID. The vehicle TMC

system must be rebooted any time a new Remote Station is connected. Failure to reboot may

cause TMC CAN bus address conﬂicts.

3. Adjust TMC application tuning parameters.

The PLUS+1 Service Tool is used to access and change TMC application software tuning

parameters, reference PLUS+1 GUIDE Service Tool User Manual, 520L0899.

PLUS+1 GUIDE TMC P1D ﬁle is required in order to access tuning parameters.

The P1D ﬁle allows access to the following:

• Limit drum speed

• TMC system overview

• Rotary switch calibration

• Rotary switch time ramp

• Manufacture code

• System 0 to 3 (Shows up to TMC tuning parameters sets—one for up to four conﬁguration input

pin settings)

• PID feed-forward parameters

• PID P parameters

• PID algorithm parameters

• Engine RPM request proﬁle

• Output soft ramp

• All parameter summary

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 201314

Software Parameter Set-up

Service Tool

Interface

Limit Drum Speed

This screen shows an overview of the system, inputs to the application and output signals to the

drum. It also shows what system (as set by the conﬁguration pins) is connected: 0, 1, 2, or 3. There are

also hyperlinks to parameter settings and the log page. If system 1 is connected it takes you to the

system 1 parameter setting.

TMC System Overview

This screen is a simple ﬂow chart of the system where you can follow a signal from input to

output. Most of the images are hyperlinked to parameter setting pages.

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 2013 15

Rotary Switch Calibration

This screen is used to calibrate the rotary dial.

1. Click the start calibration button and turn the switch to neutral and the end positions.

Service Tool

Interface

(continued)

Rotary Switch Time Ramp

Parameters to set ramping time for incoming (scaled) signal:

y EE_RotSwTimeR_Range

y EE_RotSwTimeR_DecTime

y EE_RotSwTimeR_IncTime

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 201316

System 0, 1, 2, or 3

The system screens have hyperlinks to the diﬀerent parameter setting screens, some basic screens,

and some advanced screens where you can set the parameters in a graph. These diﬀerent pages can

also be reached from the hyperlinks in the log page. All the values in System 0 are set to 0 since this is

not in use. When the system is 0 it means that it is a remote unit: only connected to system by the

machine CAN bus.

Service Tool

Interface

(continued)

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 2013 17

PID Feed-Forward Parameters

The proﬁle for the feed-forward from rotary dial signal:

y EE_SysX_RotSw_PID_X1

y EE_SysX_RotSw_PID_X2

y EE_SysX_RotSw_PID_X3

y EE_SysX_RotSw_PID_X4

y EE_SysX_RotSw_PID_X5

y EE_SysX_RotSw_PID_X6

y EE_SysX_RotSw_PID_Y1

y EE_SysX_RotSw_PID_Y2

y EE_SysX_RotSw_PID_Y3

y EE_SysX_RotSw_PID_Y4

y EE_SysX_RotSw_PID_Y5

y EE_SysX_RotSw_PID_Y6

Service Tool

Interface

(continued)

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 201318

PID P Parameters

The Accel_Decel block increases the P variable value of the PID at the pump speed acceleration or

deceleration.

Filter:

y EE_SysX_AccDec_DerivTm

y EE_SysX_AccDec_FltTml

y EE_SysX_AccDec_FltNmbr

y EE_SysX_AccDec_Mull

Time Ramp:

y EE_SysX_AccDec_TRRange

y EE_SysX_AccDec_TRDec

y EE_SysX_AccDec_TRInc

Service Tool

Interface

(continued)

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 2013 19

PID Algorithm Parameters

The PID function parameters:

y EE_SysX_PID_Range

y EE_SysX_P_Gain

y EE_SysX_I_Gain

y EE_SysX_D_Gain

Limit drum speed. Maximum and minimum for the drum speed:

y EE_SysX_Min_DrumSpeed_Discharge

y EE_SysX_Max_DrumSpeed_Charge

Service Tool

Interface

(continued)

Technical Information Transit Mixer Controller (TMC)

11061324 • Rev CA • Sep 201320

Engine RPM Request Proﬁle

The proﬁle for the requested diesel engine RPM:

y EE_SysX_EngRPM_Request_X1

y EE_SysX_EngRPM_Request_X2

y EE_SysX_EngRPM_Request_X3

y EE_SysX_EngRPM_Request_X4

y EE_SysX_EngRPM_Request_X5

y EE_SysX_EngRPM_Request_X6

y EE_SysX_EngRPM_Request_Y1

y EE_SysX_EngRPM_Request_Y2

y EE_SysX_EngRPM_Request_Y3

y EE_SysX_EngRPM_Request_Y4

y EE_SysX_EngRPM_Request_Y5

y EE_SysX_EngRPM_Request_Y6

The maximum and minimum value for the RPM request is set by the value in the proﬁle.

Service Tool

Interface

(continued)

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Danfoss Transit Mixer Controller (TMC) User guide

Danfoss Transit Mixer Controller (TMC) User guide

Danfoss Transit Mixer Controller (TMC) User guide

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