Danfoss MCE102A Automotive Controller Instruction Manual

: May 15, 2024
: Danfoss

Table of Contents

Danfoss MCE102A Automotive Controller
Product Usage Instructions
Frequently Asked Questions
DESCRIPTION
ORDERING INFORMATION
TECHNICAL DATA
THEORY OF OPERATION
AUTOMOTIVE CONTROL SYSTEM DIAGRAM
CUSTOMER SERVICE
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Danfoss MCE102A Automotive Controller

Danfoss-MCE102A-Automotive-Controller-PRODUCT

Specifications

Ordering Information

Device Number| Supply Voltage| Output Current| Internal Connector Type| Voltage/Current Setpoint Range| Miscellaneous
---|---|---|---|---|---
MCE102A1007| 12 Vdc| .14 amp| Packard| 200 to 900 Hz| External Inch Pot

Environmental Data

Vibration: Withstands vibration test from 5 to 2000 Hz in each axis. Resonance dwell for one million cycles.
Rain: Performs within specification limits after being showered from all directions by a high-pressure hose.
Shock: Withstands 50 Gs for 11 milliseconds in three mutually perpendicular axes.

Product Usage Instructions

Installation

Ensure the power supply matches the required voltage range specified in the technical data.
Connect the controller to the appropriate internal connector type as per the ordering information.

Operation

Apply power within the specified voltage range.
Set the output current within the allowed range for your model.

Maintenance

Regularly check for any signs of damage or wear on the controller.
Keep the controller clean and free from debris.

Frequently Asked Questions

Q: What is the maximum output voltage?

A: The maximum output voltage to the load shall be the supply voltage less three volts up to rated load current.

Q: How do I protect against reverse voltage?

A: The device is equipped with a series diode that protects against reverse voltage up to 50 Vdc.

Q: What is the operating supply voltage range?

A: The operating supply voltage is 11 to 15 Vdc, with an optional range of 24 to 30 Vdc with added components.

DESCRIPTION

The MCE102A automotive controller enables hydrostatically powered vehicles to operate in a manner similar to a car’s automatic transmission. The automotive control maintains a definite relationship between the engine r.p.m. and the swashplate angle (i.e, displacement) of the variable displacement pump used in the hydrostatic transmission. The transmission ratio (displacement of the pump/displacement of the motor) increases with increasing engine r.p.m. Vehicle speed is obtained by depressing the throttle pedal which controls the vehicle engine r.p.m.

ORDERING INFORMATION

DEVICE NUMBER| SUPPLY VOLTAGE| OUTPUT CURRENT| INTERNAL SETPOINT RANGE| CONNECTOR TYPE| MISCELLANEOUS
---|---|---|---|---|---

MCE102A1007

|

12 Vdc

|

.14 amp

|

200 to 900 Hz

|

Packard

|

External Inch Pot

TECHNICAL DATA

ELECTRICAL

SUPPLY VOLTAGE

12 Vdc nominal (11 to 15 Vdc range)
24 Vdc nominal (22 to 30 Vdc range)

OUTPUT CURRENT

1.0 amps maximum in auto mode (12 Vdc models)
0.7 amps maximum in auto mode (24 Vdc models)

OUTPUT VOLTAGE

System supply voltage less 3 volts, maximum (limited by a series resistor on some models).

REVERSE VOLTAGE PROTECTION

A series diode protects against reverse voltage up to 50 Vdc

SHORT CIRCUIT PROTECTION

1.4 to 2.0 amps (12 Vdc models)
0.8 to 1.2 amps (24 Vdc models)
Shorted load of more than 2 minutes may degrade device at elevated temperature. Output limited by a series resistor on some models.

ENVIRONMENTAL

VIBRATION

Withstands a vibration test designed for mobile equipment controls consisting of two parts:

Cycling from 5 to 2000 Hz in each of the three axes
Resonance dwell for one million cycles in each of the three axes Run from 1 to 10 Gs. Acceleration level varies with frequency.

HUMIDITY

After being placed in a controlled atmosphere of 95% humidity at 38° C (100° F) for 10 days, the controller will perform within specification limits.

RAIN

After being showered from all directions by a high-pressure hose down, the controller will perform within specification limits.

SHOCK

50 Gs for 11 milliseconds. Three shocks in both directions of the three mutually perpendicular axes for a total of 18 shocks.

OPERATING TEMPERATURE

20 to 65° C (-4 to 149° F)

STORAGE TEMPERATURE

30 to 65° C (-22 to 149° F)

PERFORMANCE

MAXIMUM OUTPUT VOLTAGE

The maximum output voltage to the load shall be the supply voltage less three volts up to rated load current.

MAXIMUM OUTPUT CURRENT

With the output terminal shorted to ground, the maximum output current shall be from 1.4 to 2.0 amps (12 Vdc models) or 0.8 to 1.2 amps (24 Vdc models), depending on temperature.

OPERATING SUPPLY VOLTAGE

11 to 15 Vdc, or 24 to 30 Vdc optional with added components

SUPPLY CURRENT

1.1 amps maximum (except for shorted loads) (12 Vdc models)
0.8 amps maximum (except for shorted loads) (24 Vdc models)

VOLTAGE RANGE

The controlled voltage decreases from supply minus 3 volts down to zero.

SENSITIVITY

The sensitivity control changes the proportioning band from 4% (turned clockwise) to 75% (turned counter clockwise) of calibrated r.p.m. The proportioning band is defined as the change necessary to reduce output voltage from 100% to 20% of rated output. Sensitivity control may be removed and replaced with a fixed resistance in some models.

THEORY OF OPERATION

The automotive controller monitors engine r.p.m. as a variable frequency through the alternator or pulse pickup. The controller’s calibration (point of maximum displacement) is at or near the r.p.m. at which the engine is capable of maximum horsepower. The output is directed to the pump displacement control through a double-pole double-throw center off switch. For vehicle forward, neutral and reverse, see Automotive Control System Diagram. Between low idle and low r.p.m., the engine is well below setpoint (see Controller Output Vs. Engine RPM and Reverse Acting Controller), which the controller interprets as a lugged condition; consequently there is no propel. As engine r.p.m. increases, the controller output increases, the rate of increase being determined by the gain setting of the controller. The engine r.p.m. that corresponds to the maximum ratio is determined by the engine r.p.m. calibration potentiometer. Vehicle speed will continue to increase with increasing engine r.p.m. even though the transmission ratio remains unchanged above the high r.p.m. calibration point. The transmission ratio is proportional to engine r.p.m., and overhauling loads resulting in high engine r.p.m. will keep the pump at full angle, resulting in dynamic braking limited by the engine horsepower absorption. Therefore, to guarantee adequate braking, the vehicle mechanical brake must be applied. The automotive controller is adaptable to applications with either medium or heavy duty transmissions. Additional features such as HI/LOW range, reverse acting, pressure transducer turn down, lead/lag and inching may also be incorporated into the system. The feedback circuit may be modified to accept a dc signal. 4 to 20 mA from a pressure transducer or 0 to 6 Vdc from a tachometer are two types of dc signals acceptable for feedback. The unit may be modified to provide decreasing output for increasing r.p.m.

AUTOMOTIVE CONTROL SYSTEM DIAGRAM

CONTROLLER OUTPUT Vs. ENGINE RPM

REVERSE ACTING CONTROLLER

*MCE102A1007 (1014) (1147) AUTOMOTIVE**

MCE102A1022 SLAVE RATIO

MCE102A1113 LEAD/LAG FILTER MCE102A1105 (1139) LEAD/LAG FILTER MCE102A1030 REVERSE ACTING, 24 VOLT, 4 – 20 mA INPUT MCE102A1097 (1121) WITH LEAD/LAG FILTER MCE102A1071 REVERSE ACTING, 24 VOLT, 4 – 20 mA INPUT (TERMINALS)

CUSTOMER SERVICE

NORTH AMERICA

ORDER FROM

Danfoss (US) Company
Customer Service Department
3500 Annapolis Lane North
Minneapolis, Minnesota 55447
Phone: (763) 509-2084
Fax: (763) 559-0108

DEVICE REPAIR

For devices in need of repair or evaluation, include a description of the problem and what work you believe needs to be done, along with your name, address and telephone number.

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