DVC50 Universal I/O

DVC50 Universal I/O Expansion Module

The DVC50 Universal I/O Module is an expansion module that is designed to operate in conjunction with a DVC10 Controller Module. Its large number of inputs and outputs make it ideal for the applications that may need additional proportional outputs with local or remote closed loop capabilities. A +5Vdc reference voltage is provided to supply power to external sensors. Four analog (0 to 5Vdc) and two analog/pulse (0 to 5Vdc) inputs can interface to a number of different types of sensors including joysticks, potentiometers and pulse sensors. Eight digital inputs are provided for a multiple of switch type inputs. The outputs are the same as the DVC10 Module including 6 high-side (sourcing, on/off) and 3 PWM outputs. The DVC50 communicates to the DVC10 through the CAN Bus and utilizes the RS-232 port for setting the MAC ID (node) and for device monitoring. The controller is packaged in a small rugged enclosure and encapsulated to withstand extreme harsh environments.

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TECHNICAL DATA

Analog/Pulse Inputs – Qty (2)

These inputs can be configured as analog (0 to +5Vdc) or pulse (0 to +5Vdc) inputs. A +5Vdc reference is supplied with each input for an external sensor. These inputs have 10-bit resolution.

PROGRAMMABLE MODES

A. Input Modes

1. Analog (0 to +5Vdc)

2. Pulse (0 to +5Vdc)

a. Pulse Timeout – sets a flag if a pulse has not been detected for a certain amount of time.

b. Pulses Per Rev – used for calculating RPM.

* Note - The maximum speed for per input is 7khz.

3. Counter Mode - For Counter pulse inputs, setup the Min and Max counts under Count Limits. The output value will be a

percent Min to Max count. The counter value may be read or set by the application. The counter is incremented on every falling

edge of the pulse input.

B. Joystick Configuration

1. Enable Center - sets up upper and lower configuration for single axis joystick.

2. Dead band – Sets the % of dead band at center.

C. Voltage Calibration – Setting for the actual voltage received at the input (Min, Center and Max).

D. Voltage Limits – sets the Min a Max limits of the input. A flag is set when these limits are met. This feature detects unwanted conditions

so that the controller can be safely programmed to a default condition.

* Note – The input will go high if the input is open (no connection).

E. Invert Output – Simply inverts the output control with respect to the input command.

F. Enable Ramps – applies ramping to the input.

G. Scaling – sets the offset and gain to the input which results to meaningful data displayed in the Loader Monitor.

ANALOG INPUTS – Qty (4)

The Analog inputs have a range of 0 to +5Vdc. A Pot Reference output (+5Vdc reference) is supplied with each Analog input. All Analog inputs have 10-bit resolution.

PROGRAMMABLE MODES

A. Joystick Configuration

1. Enable Center - sets up upper and lower configuration for single axis joystick.

2. Dead band – Sets the % of dead band at center.

B. Voltage Calibration – Setting for the actual voltage received at the input (Min, Center and Max).

C. Voltage Limits – sets the Min a Max limits of the input. A flag is set when these limits are met. This feature detects unwanted conditions

so that the controller can be safely programmed to a default condition.

D. Invert Output – Simply inverts the output control with respect to the input command.

E. Enable Ramps – applies ramping to the input.

F. Scaling – sets the offset and gain to the input which results to meaningful data displayed in the Loader Monitor.

DIGITAL INPUTS – Qty (8)

All digital inputs are sinking inputs (connect to voltage to turn on). The voltage required to turn on this input is between 3.0Vdc and 32Vdc (see Figure 1). All Digital inputs are connected internally to PWR COM through a series resistor (> 10K ohm).

* This is a common example of a Digital Input connection.

+5Vdc REFERENCE – Qty (6)

All Analog and Analog/Pulse inputs have a corresponding +5Vdc output. The maximum current capability is 120ma (sum of all six +5Vdc references). A 5 x 20mm 125ma fuse is located at the back of the module for over-current protection.

Note: Connecting this output to greater than +5Vdc may cause permanent damage to the DVC50 module.

OUTPUTS – Qty (9)

The outputs are designed to give the user a great deal of flexibility. The software gives the user the ability to control the sourcing voltage (HS OUT) to the positive side of the coil and control the PWM sinking capability (PWM OUT) to the negative side of the coil.

HIGH-SIDE OUTPUTS (HS OUT) – Qty (6)

These outputs are designed to source (supply) power supply voltage when activated. Each output is short protected and has open detection. The maximum current capability is 3Amps.

PWM OUTPUTS (PWM OUT) – Qty (3)

These outputs are designed to sink current to ground at a PWM frequency. Each output can be configured for a specified current range for maximum current sensing resolution (10 bit). See the DVC10 Ordering Guide for typical current ranges. All outputs are short circuit protected and most current ranges have open circuit and short circuit detection (see Current Range Details for more information).

A. Current Ranges – Each PWM output can be configured to a current range, which will produce the maximum current sensing resolution.

* Note: Current ranges “L”, “H”, and “D” are short circuit protected but do not have short circuit detection.

OUTPUT GROUPS (3)

The outputs are divided up into 3 output groups. Each output group has (2) High-Side outputs and (1) PWM output.

A. Programmable Features

1. Dither Amplitude

2. Dither Frequency

3. Ramp Up and Ramp Down

4. PID setting for current regulation and I/O functions.

5. Min and Max current

6. Output Group Selection

7. Process selection including: Current regulation, Enable process PI, Enable current ramps, and PWM Duty cycle mode.

* Note – See the DVC10 Programming User Guide for more details on programmable features.

INPUT/OUTPUT FUNCTIONS – Qty (6)

There are six Input/Output Functions that can be programmed individually. The I/O Function gives the user the ability to change the response of the output with the change of the input (see sample screen below). The input and output being controlled must be both resident to the DVC50. The input and output is based on 0 to 100% (Min. to Max.). Different adjustable points on the response curve give the user full flexibility to control non-linear responses. These functions are adjustable while the controller is running in order to adjust unknown output characteristics.

* Note – See the DVC10 Programming User Guide for more details.

LOCALIZED CLOSED LOOP FUNCTIONS

All inputs have the ability to be used in a closed loop configuration with the outputs locally. Most closed loop configurations such as speed and rpm control require very fast response times. Closing the loop locally, instead of over the CAN Bus, will result in the response needed for these configurations.

COMMUNICATIONS

A. The DVC50 has two communication ports:

1. Can Bus 2.0B – This port is used to communicate to other DVC modules as well as an ECM (engine control module).

2. RS-232 serial port is used for:

a. Downloading and uploading software.

b. Monitoring the functions of the DVC50.

c. Setting parameters on the fly (fine-tuning).

POWER SUPPLY

A. The DVC50 Power Input has the following features:

1. Voltage Input Range: 8.0Vdc to 32Vdc

2. Reverse polarity protection and transient protection up to 1.5K Watts Peak Pulse Power Dissipation

3. More than one power and ground pin must be used if driving over 8 amps (at one time).

INDICATORS

A. Digital Input Status (Qty 8) (Green) – Turns on when the corresponding input is activated. Inputs can be programmed as active high or

low.

B. High-Side Output Driver Status (Qty 6)(Green) – Turns on when the corresponding High-side output is activated. Blinks once per second

for an open circuit. Blinks four times per second for a short circuit.

C. PWM Output Driver Status (Qty 3) (R/G) – This LED displays duty-cycle status for the corresponding PWM output. The LED will display

from red to green as the duty-cycle changes from 0% to 100% (50% displaying yellow).

D. Module Status (MS) (Qty 1) (R/G)

1.Off – There is no power applied to the Module.

2.On green – The module is operating in a normal condition.

3.Flashing green – Device in standby state. May need commissioning.

4.Flashing red – Recoverable Fault.

5.On red – Module has an unrecoverable fault.

6. Flashing Red/Green – Device is in self-test.

G. Network Status (NS) (Qty 1) (R/G)

1. Off - Device in not on-line.

2. Flashing green – Device in on-line but has not established connection to other nodes.

3. On green – Device in on-line and has established connection to other nodes.

4. Flashing red – One or more connections are in a timed-out state.

5. On red – The device has detected an error that has rendered it incapable of communicating on the network.

PACKAGING

A. Physical Size: 6.2L” x 4.75W” x 1.65H” encapsulated module.

B. Each module has two mounting holes 4.0” a part. Each mounting hole has an I.D. of 0.325”.

C. Weight: 1 lb. 7 oz.

CONNECTORS

A. The DVC50 uses the Metri-Pack 150 series (or compatible) sealed electronic header designed for severe under hood environments.

1. 30-pin Header (P16) Used for sensor signal inputs.

2. 18-pin Header (P17) Used for the power supply and output connections.

B. 5-pin CAN Bus (DeviceNet compliant) connector

1. Pins are gold plated brass machined from solid stock.

2. Protection rating – Nema 1,3,4,6P, and IEC IP 68.

MATING CONNECTOR KITS or Mating Connector Assemblies with flying leads for Start-up applications

A. Mating for 30-pin Header and 18-pin Header

1. Connector, 30-pin Female (P16) Delphi Packard P/N – 12034398

2. Connector, 18-pin Female (P17) Delphi Packard P/N – 12040921

3. Terminals, Female Delphi Packard P/N – 12103881

4. Plugs Delphi Packard P/N – 12034413

DVC Series 48-pin Connector Kit, HCT P/N: 999-10077

Includes the following:

1 - Connector, 30-pin Delphi Packard

1 - Connector, 18-pin Delphi Packard

60 - Terminals, Delphi Packard

25 – Plugs, Delphi Packard

B. Mating for CAN Bus connector (P18)

1. 5-pin Female Micro-style DeviceNet compliant connector.

C. Mating to the RS-232 Port – The RS-232 port is accessed through the 30-pin connector at (P16). A DVC Slave Serial Port Adapter is available to connect to the 30-pin Female mating connector. A DVC RS-232 Cable can be used to interface from the DVC Slave Serial Port Adapter to a PC. Drawings for these two cables are supplied for user assembly; otherwise they are available from the HCT.

* Note: The DVC Slave Serial Port Adapter comes with a plug. The plug is used to keep the cable weather-tight when not

connected to peripherals.

1. DVC Slave Serial Port Adapter, HCT P/N: 999-10082

2. DVC RS-232 Cable Assembly, HCT P/N: 999-10075

ENVIRONMENTAL

· Operating Temperature: -40 Celsius to 85 Celsius

· Storage Temperature: -40 Celsius to 85 Celsius