CANION

Users Manual 1.0

Art. No.
March 16, 2000
 Table of Contents TOC

Table of Contents............................................................. 3

Introduction...................................................................... 5
About CANION Documentation ..............................................................................5
Scope of this Manual ...........................................................................................5
Intended Use .......................................................................................................5
About the CANION .................................................................................................6
Intended Use .......................................................................................................6
Safety Instructions ...............................................................................................6
Product Identification ...........................................................................................6
Product Identification Label.............................................................................6
Technical Support................................................................................................7
Product Warranty.................................................................................................7

Technical Description ...................................................... 9

Principles of Operation ...........................................................................................9
Introduction ..........................................................................................................9
Important Features and Capabilities ...................................................................9
CANION Hardware ..............................................................................................9
General Description ........................................................................................9
Analog Inputs ................................................................................................10
Digital Inputs..................................................................................................10
Digital Outputs...............................................................................................10
PWM Outputs ................................................................................................10
CANION Software .............................................................................................11
Customizing CANION for Specific Applications ................................................12
Error Handling ...................................................................................................12
Error Detection ..............................................................................................12
Error Management ........................................................................................12
Error Recording .............................................................................................12

Applications ................................................................... 15
Order Picker..........................................................................................................15
Reach Truck .........................................................................................................17

Interfacing to CANION ................................................. 19

Interfacing Input Devices ......................................................................................19
General ..............................................................................................................19
Analog Inputs.....................................................................................................19
General..........................................................................................................19

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TABLE OF CONTENTS

Software Processing of Inputs ......................................................................19

Interfacing Analog Inputs ..............................................................................19
Implementing Open Circuit/Short Circuit Detection ......................................20
Digital Inputs ......................................................................................................21
General Information ......................................................................................21
Digital Inputs Reserved for Standard Truck Functions .................................21
Digital Inputs DI 10 through DI 14 .................................................................21
Interfacing Digital Inputs................................................................................21
Interfacing Output Devices ...................................................................................23
PWM Outputs ....................................................................................................23
General Hardware Description......................................................................23
Operating Modes...........................................................................................23
Interfacing to PWM Outputs (POUT 1 through POUT 9) ..............................24
PWM Output 10 (POUT 10) ..........................................................................25
Digital Outputs ...................................................................................................25
Can Bus Communications ....................................................................................26
Interfacing CANION in a Truck Can Network ....................................................26
CANION in Non-networked Configuration.........................................................26
Power Distribution.................................................................................................28
General Configuration .......................................................................................28

Installation and Wiring .................................................. 31

CANION Installation..............................................................................................31
Mounting CANION in a Vehicle .........................................................................31
Mounting Location .............................................................................................32
Wiring the CANION...............................................................................................33
Introduction ........................................................................................................33
Tools and Equipment Required.........................................................................33
Mating Connector and Contacts....................................................................33
Assembly Tools .............................................................................................33
Wiring the CANION Mating Connector..............................................................34
Wire Size Requirements ...............................................................................34
Crimping Contacts onto Conductors .............................................................34
Installing Crimped Contacts in Connector Housing ......................................34
Mating Connector Pin Assignments..............................................................34

Specifications ................................................................. 37
Electrical Power Inputs & Outputs ........................................................................37
Control Inputs and Outputs...................................................................................37
Environmental Limits ............................................................................................38
Physical Data ........................................................................................................38

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 Introduction 1

About CANION Documentation

Scope of this Manual
This manual provides important design level information on the ACC (Atlas Copco
Controls) CANION (CAN I/O Module). This document addresses the following
topics:
− Principles of operation
− Applications
− Interfacing vehicle controls and sensors to the CANION
− Installing and wiring a CANION
− CANION specifications

Intended Use
This manual is intended for OEM vehicle manufacturers who are designing and
integrating the CANION into a vehicle.

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INTRODUCTION ABOUT THE CANION

About the CANION

Intended Use
Atlas Copco Controls’ CANION units are intended for use in battery powered lift
trucks and similar vehicles. These units are supplied to OEMs for incorporation into
their vehicles and vehicle control systems. OEMs are responsible for insuring that
the CANION is used for its intended purposes only.

Safety Instructions
The CANION is intended for connection to DC battery power sources only.
Always verify before installation that the CANION has the correct article number for
the application. Different CANION models having the same physical appearance
may contain significantly different operating software. Only the article number
uniquely identifies a CANION.
Atlas Copco provides this and other manuals to assist manufacturers in using the
CANION in a correct, efficient and safe manner. Manufacturers must insure that all
persons responsible for the design and use of equipment employing the CANION
have the proper professional skill and apparatus knowledge.

Special attention must be paid to information presented alongside this symbol

!
where it appears in this manual.

Product Identification
Product Identification Label
A label (see Figure 1) containing pertinent product identification information is
affixed to the top cover of each CANION module. The product label fields relevant
to product identification are described in Table 1.

Revision Code
AAAAAAAAAA - RRR
Article Number
CAxx01-2Axx CANION
CANION Model
SN: CCCCCCC - NNN
Production lot
Made in Sweden

MANUF. DATE: YYMMDD APPROVED BY: FFF

Sequence number
M P1 P2 P3 P4 P5 T
YY = year Atlas Copco Controls AB

MM= month
DD= day
C0012.CDR

For ACC internal use

Figure 1 CANION Identification Label

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INTRODUCTION ABOUT THE CANION

field description
article number A unique part number assigned to CANION units
with a specific hardware and software
configuration. CANION units with the same
article number and revision code are identical.
revision code Indicates the revision level of the article
CANION model
Installed Options
CANION CAxx01-2Ayy 01 = none
(CAN I/O
Module)
Nominal DC Supply Voltage
24 = 24 VDC
36 = 36 VDC
48 = 48 VDC C0013.CDR

production lot The production lot number (assigned by the

factory) together with the sequence number
yield a unique serial number for each item.
sequence number serial number within a production lot
Manuf. date year, month and day of manufacture

Table 1 Product Label Fields

Technical Support
For additional information on any topic covered in this document, or for additional
information or applications assistance on any Atlas Copco Controls’ product,
contact an Atlas Copco Applications Center listed in the front of this manual.

Product Warranty
Refer to the sales agreement or contract under which the CANION was purchased
for a complete statement of the product warranty.

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 Technical Description 2

Principles of Operation
Introduction
The CANION (CAN I/O Module) is a general purpose micro-controller for CAN Bus
based electric vehicles. CANION has the processing power and memory resources
to function as a truck controller. With its analog and digital I/O and communications
facilities, CANION is well suited to manage truck motion, I/O functions (including
hydraulics), interface to operator controls and control an on-board operator display.
Like all ACC electric vehicle products, CANION is designed for the environment of
the electric vehicle.

Important Features and Capabilities

Designed for the Environment of the Electric Vehicle
CANION modules are available for operation at all standard battery voltages from
24 to 48 VDC. All models include built-in undervoltage, overvoltage and reverse
polarity protection.
Bi-level Digital Outputs Conserve Energy and Extend Actuator Life
Two bi-level outputs utilizing PWM (Pulse Width Modulation), provide two level
current control, a higher pull-in current and lower holding current.
Proportional Outputs for controlling Proportional Hydraulic Valves
Eight power outputs with current feedback provide 0 - 100% output for precise
control of proportional hydraulic valves
Digital and Analog Inputs for Interfacing Flexibility
With fourteen digital and four analog inputs, the CANION accommodates a wide
spectrum of control inputs and sensors

CANION Hardware
General Description
Figure 22 shows a block diagram of the CANION hardware configuration. A
Motorola 68HC08 series micro-controller performs the CPU functions. Operating
and application software reside in on-board flash memory. User-adjustable
parameters are stored in EEPROM.
The CPU monitors a large array of inputs (both digital and analog) and controls a
number of outputs. All inputs are filtered and provided with diode overvoltage
protection. Outputs are buffered. The PLD (Programmable Logic Device) provides
the capability for software control with hardware override of PWM outputs. CANION
operating software scans inputs and updates outputs once per millisecond.
The internal power supply produces all voltages required by internal components
and a source of +5 VDC for use as an analog reference voltage. A standard
CANopen interface is provided for communications over the CAN Bus. All user
connections are made to a single 42 pin connector.

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TECHNICAL DESCRIPTION PRINCIPLES OF OPERATION

CAN CAN
Bus interface
output
drivers
digital
outputs
analog (5)
inputs CPU
Current feedback
(4) signal
digital conditioning
flash
inputs eeprom PWM
(14) RAM output
PLD PWM
Monitor devices
outputs
(10)
(DI 10-14)
Overcurrent

Vbatt + power (to all devices)

filter
supply
Vbatt -

+5 VDC S0010.CDR

Figure 2 CANION Block Diagram

Analog Inputs
Two (2) differential and two (2) single ended inputs are provided. The analog inputs
provide an ideal interface to analog vehicle controls and sensors.

Digital Inputs
Fourteen (14) full voltage digital inputs are provided for interfacing truck functions
(switches, contacts, etc) operating from full battery voltage.

Digital Outputs
Five (5) digital outputs are reserved for interfacing to low level electronics devices
such as displays and micro-controllers.

PWM Outputs
Ten (10) PWM power outputs are provided for controlling electrical and hydraulic
devices and actuators. Eight of these power outputs utilize current feedback,
enabling closed loop control of proportional valves and similar types of analog
actuators. The capability to program pull-in current, holding current and pull-in time
for each output, enables less costly low voltage (12 volt) actuators to be operated
from truck battery voltage and conserves power.
The two remaining PWM outputs are similar except they do not provide current
feedback.

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TECHNICAL DESCRIPTION PRINCIPLES OF OPERATION

CANION Software
CANION, as previously stated, is a general purpose micro-controller capable of
implementing specific behavior through incorporation of vehicle-specific software.
Figure 3 shows the CANION software structure and organization.

Function Application software Function

module module

Interface

Scheduler

I/O Handler PWM Hander CAN Hander Display Handler

CANION Hardware

C011.CDR

Figure 3 CANION Software Organization

The Scheduler and a group of handlers interact directly with the CANION hardware.
The scheduler is a simple task manager & scheduling routine. Tasks performing
time-critical functions may be scheduled to run every millisecond. Tasks of a less
critical nature run at multiples of one millisecond.

The I/O Handler reads, filters and stores the current value of analog and digital
inputs. Digital inputs are scanned once per millisecond. Analog inputs are
selectively scanned at an interval of two to eight milliseconds.

The CAN handler implements CAN communications according to the CANopen

protocol.

PWM power outputs are managed by the PWM Handler. Specific functions
performed by the PWM handler include pull-in and hold current selection, and
closing the current loop on current controlled outputs.

CANION base system source code is written in ANSI-C and compiled using the
“Cosmic C” compiler and linker. An on-board monitor program provides standard
Monitor functions including I/O and memory interrogation. This feature is useful for
testing and debugging board level application software.

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TECHNICAL DESCRIPTION PRINCIPLES OF OPERATION

Customizing CANION for Specific Applications

The CANION is customized for a specific vehicle or task by creation of an
“application layer” of software that is unique and specific to the application. ACC
has developed reusable control software modules for number of basic truck
functions including:
− Battery discharge monitor
− Truck speed proportional steering
− Mast height proportional speed limiting
− Non-linear Joystick to speed conversion with adjustable deadband.
Vehicle applications are built upon these available functions along with custom
software as required for the application. ACC’s staff of electric vehicle specialists
are well equipped to write application level software to customer’s requirements or
assist and support customers who prefer to develop their own application software.
ACC can provide code for the base system software that the user can integrate into
his application software.

Error Handling
Error Detection
Utilizing a combination of hardware and software implementations, CANION
provides built-in error/fault detection and management capability. Table 2
summarizes the CANION's error/fault detection capabilities and methods.
item method
CANION Operational Hardware Watchdog timer must be
periodically reset by software command
Analog Inputs Input values monitored for open circuit,
short circuit and loss of reference
voltage
PWM outputs Current feedback monitored for open
circuit and short circuit conditions
CAN communications CRC check of every message
DC supply Monitored for voltage within range for
normal operation
Table 2 CANION Fault/Error Detection

Error Management
CANION, as the truck controller, typically executes a pre-programmed response
comprised of messages to other truck components and manipulation of its I/O when
an error is detected to bring the vehicle to a safe condition. Through the facilities of
the on-board PLD (Programmable Logic Device), some of CANIONS digital inputs
may be logically connected to PWM outputs, thereby providing direct hardware
disable capability.

Error Recording
The CANION retains an error log of its internal errors as well as error codes
received from all of its clients. The information logged includes an error code and
time stamp for each error. The error log is accessible at CANION's CAN Object

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TECHNICAL DESCRIPTION PRINCIPLES OF OPERATION

dictionary.

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 Applications 3

Order Picker
Figure 4 illustrates an application of the CANION along with other ACC electric
vehicle components in an order picker. In this configuration, a CANION module
(CANION #1) serving as the truck controller, processes inputs from operator
controls and from sensors on the vehicle. CANION #1, under the direction of a
vehicle-specific control program, monitors and coordinates the operation of other
truck components interconnected on a CAN Bus. The Operator Dashboard that
interfaces to CANION #1 provides status and diagnostic information for the
operator and serves as an entry point for operating parameters.
A second CANION (CANION #2) in the vehicle base functions as a remote I/O
controller. CANION #2 controls the hydraulic valves (both on/off and proportional)
and the main electrical contactor based on commands from CANION #1.
Two AC SuperDrives (Traction Drive and Lift Pump Drive) control AC induction
motors driving a traction wheel and hydraulic pump for the lift system. They
respond to vehicle control commands from CANION #1.
An Advanced Power Steering (APS) unit with integral motor, gear reducer and
control electronics, controls vehicle steering. CANION #1 converts steering wheel
input to steering commands that are communicated to the APS. Totally automatic
steering may be implemented with the addition of a Wire Guidance Unit which
tracks a signal emitted from a buried wire and supplies steering commands directly
to the APS.
With its high electrical noise immunity, high data rate, extensive data checking and
automatic error correction capability, the CAN Bus is well suited for
communications in electrically powered vehicles. A three wire CAN Bus cable
handles communications between the operator platform and vehicle base, thereby
greatly simplifying the size of the drape cable and the associated manufacturing
and maintenance cost.

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APPLICATIONS ORDER PICKER

Operator Dashboard

CANION #1
(truck controller)

Steering Sensor
Steering Wheel

Foot Switch Control

Height Sensor

CAN Bus
Wire Guidance
Unit Main Contactor

Lift Pump Drive CANION #2

Hydraulic Valves & Controls
Lift Pump Motor
Traction Drive
Safety Brake
Advanced Power Steering
Traction Motor
Wire Guidance
Sensor Head
s0009.CDR

Figure 4 Order Picker

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APPLICATIONS REACH TRUCK

Reach Truck
Figure 5 illustrates a configuration for a reach truck in which a single CANION
functions as overall truck controller. In this implementation (see Figure 6) all
operator controls (except the steering handle) interface to the CANION. The
CANION controls all electrical actuators and hydraulic valves (both proportional and
on/off). The CANION controls and monitors the lift, traction and steering functions
via the CAN Bus. Other sensors required for truck management interface directly to
the CANION. An operator dashboard which may include a numeric display,
indicators and controls interfaces directly to the CANION.

Electrical & hydraulic

actuators & sensors

Multi-function Handle

Operator Dashboard

Steering Handle
or wheel ENTER

CANION
Traction Drive Lift Pump Drive
Main Contactor
CAN Bus
Lift Motor & Pump
Traction Motor
Hydraulic Valves & Controls
Electronic Power
Steering S0024.CDR

Steering Angle
potentiometer

Figure 5 Reach Truck

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APPLICATIONS REACH TRUCK

height
dashboard seat limit
holding switch CAN Bus
brake
ENTER

AC SuperDrive
traction
drive

Advanced
power
steering

multi-function
handle traction
CANION motor

lift height
sensor

steering
encoder wheel or
handle

AC SuperDrive
lift drive

main aux.
contactor contactor

lift motor
S0022.CDR & pump
hydraulics manifold
& valves

Figure 6 CANION as Truck Controller in a Reach Truck

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 Interfacing to CANION 4

Interfacing Input Devices

General
The CANION provides four (4) analog and fourteen (14) digital inputs for interfacing
to vehicle controls and sensors. This section provides design level information for
interfacing commonly used controls and sensors to the CANION.

Analog Inputs
General
Joysticks, potentiometers and similar analog devices producing speed, braking, lift
and steering commands interface to four (4) CANION analog inputs. Two analog
inputs are differential and two are single ended inputs. Since differential inputs
provide greater common mode noise cancellation, analog inputs with a large
common mode noise component or whose common mode noise component would
have the most detrimental effect on vehicle performance should be connected to
differential inputs.
For all analog inputs, the analog to digital conversion is ratiometric. A +5VDC
reference source is supplied by the CANION. Refer to the "Specifications" for
details on analog input characteristics and ratings.

Software Processing of Inputs

Following digital conversion, analog inputs may receive additional software
processing depending on the function they perform in the vehicle. For example,
software routines correct the raw converted input from a joystick controlling vehicle
speed for zero offset and perform scaling based on offset and scaling parameters
supplied by the user.

Interfacing Analog Inputs

Figure 7 illustrates the configuration for a two axis joystick interfaced to the
CANION's differential inputs. A potentiometer with 10 Kohm nominal resistance is
recommended. Twisted pair wiring should be used for all signal inputs.

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INTERFACING TO CANION INTERFACING INPUT DEVICES

joystick
(or similar analog
input device)

CANION

6
+5V OUT
21 +AN1
20
-AN1

35 +AN2
34 -AN2
C0001.CDR

Figure 7 Circuit Configuration for Differential Inputs

The circuit configuration For single ended inputs is shown in Figure 8. Here also, 10
Kohms is the recommended value for the external resistance.

CANION
Analog sensors
6
+5V OUT
36 +AN3

37 +AN4
7
Analog Gnd.
C0002.CDR
Note: Analog Gnd. Is
internally connected to B-

Figure 8 Circuit Configuration for Single Ended Inputs

Implementing Open Circuit/Short Circuit Detection

The CANION provides the capability to implement open/short circuit detection for
any analog input. This safety function requires an unused portion of the
potentiometer’s range at the clockwise and counterclockwise extremes for short
and open circuit fault detection in the potentiometer and associated wiring.
For Joysticks (or similar devices) with built-in mechanical stops, the mechanical
stops should be adjusted to limit travel of the wiper to less than 100% (typically
10% to 90%) of full range. If potentiometer travel cannot be limited to less than
100%, two 1Kohm resistors (R1 and R2 in Figure 9) should be inserted in close
proximity to the joystick. Internal signal processing software treats input above or

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INTERFACING TO CANION INTERFACING INPUT DEVICES

below the travel limits as an open or short circuit condition. Adjustable parameters
permit the error thresholds to be set according to the characteristics of the input
device.

joystick
(or similar analog
input device)
CANION

R1
6
+5V OUT
21
AN1+
20 AN1-
7 Analog Gnd.
R2 C0004.CDR

Figure 9 Differential Input with Additional Resistances for Open/short Circuit Detection

Digital Inputs
General Information
The CANION provides fourteen (14) digital inputs for interfacing truck functions
(switches, contacts, etc) operating at full battery voltage. Refer to the
"Specifications" for details on digital input characteristics and ratings.

Digital Inputs Reserved for Standard Truck Functions

DI and D2 are reserved for standard truck control functions. Refer to Table 3 for a
description of the reserved digital inputs.
Function name input description

Enable_in DI 1 General interlock for enabling vehicle motion-

related functions
Start Switch DI 2 Indicates state of vehicle key switch

Table 3 Reserved Digital Inputs

Digital Inputs DI 10 through DI 14

Digital inputs DI 10 through DI 14 have additional functionality which permits them
to input directly to the control logic for the CANION's PWM outputs (see ). The
control logic which is implemented in the PLD (Programmable Logic Device)
requires the PLD to be factory programmed for the desired configuration.

Interfacing Digital Inputs

Figure 10 illustrates the typical circuit configuration for digital inputs operated from
battery supply voltage. All digital inputs are internally pulled down to ground, so an

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INTERFACING TO CANION INTERFACING INPUT DEVICES

open input is seen as a logical zero.

B+

CANION
function a
(on)
DI 1
function b
(off)
DI 2
function c
(off)
DI 3

DI 14
C0003.CDR

Figure 10 Input Circuit for Digital Inputs Operated from Battery Voltage

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INTERFACING TO CANION INTERFACING OUTPUT DEVICES

Interfacing Output Devices

PWM Outputs
General Hardware Description
The CANION provides ten (10) PWM (Pulse Width Modulated) outputs capable of
controlling a variety of devices on the vehicle such as:
− Relays or contactors
− Proportional valves
− Two position valves
− Lights and indicators
− Electro-mechanical brakes
− Fans, horns, etc
The PWM outputs are organized into 4 groups. Each group shares a common
current overload detection circuit. Three of the groups utilize a shared current
feedback indication for the group. Each output (except POUT 10) includes a built-in
free-wheeling diode for inductive discharge protection. Table 4 provides details on
the configuration of each group.
group Comprised of Current feedback
1 POUT 1, POUT 2 yes
2 POUT 3, POUT 4 yes
3 POUT 5, POUT 6, POUT 7, POUT Yes
8
4 POUT 9, POUT 10 no
Table 4 Grouping of PWM Outputs

The current feedback value is available to a software algorithm regulating current in

the output circuit. The over-current output connects directly to the PWM output
control logic. When an over-current condition occurs, all outputs in the affected
group are disabled.
The CANION may be configured to enable external override of the PWM outputs
(see "Digital Inputs DI 10 through DI 14". This requires the internal PLD
(Programmable Logic Device) within the CANION to be factory programmed for the
desired control configuration.

Operating Modes
A PWM output may be configured to operate in either of the following modes:
− Current control mode
− Pull-in and hold mode
In current control mode, actual device current is measured and the current
regulation software adjusts the output's duty cycle as necessary to maintain current
through the output at the commanded value. Current control mode is normally used
for controlling proportional valves and similar current sensitive devices.

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INTERFACING TO CANION INTERFACING OUTPUT DEVICES

B+ B+

POUT 1

POUT 2

Current feedback VFB

(To CPU)
RFB

Over-current
(to PWM control) C0005.CDR

Figure 11 Current Feedback and Over-current Detection (Group 1)

With Pull and hold mode, the percentage of battery voltage applied to the load is
controlled. A control algorithm applies a specified percentage of pull-in voltage for a
specified time at turn-on then reverts to a specified holding level. User-adjustable
parameters control pull-in percent, pull-in time and hold percent. Pull and hold
mode is normally used to control relays, contactors and similar on/off devices. It
also enables lower cost standard voltage contactors to be utilized on vehicles
operating from higher battery voltages.

Interfacing to PWM Outputs (POUT 1 through POUT 9)

Figure 12 shows the general configuration for interfacing to PWM outputs. The
arrangement is the same for standard on/off devices and proportional valves. Refer
to "Specifications" for PWM output voltage, current and power ratings.

B+

CANION

42
Device POUT 1

1
Device POUT 2

15 POUT 3
Device

Device 26
POUT 9
C0006.CDR

Figure 12 Interfacing Devices to PWM Power Outputs

The vehicle designer must be aware of the following restrictions regarding the use
of current control mode and assignment of proportional valves to PWM outputs:

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INTERFACING TO CANION INTERFACING OUTPUT DEVICES

− Due to the shared current feedback (see Figure 11), only one output operating in
current control mode may be active at any time in a PWM output group (see
Table 4). More than one current control mode output may exist within an output
group as long as no more than one output is on at any time.
− Current control mode is not available in Output Group 4 (see Table 4).

PWM Output 10 (POUT 10)

POUT 10 is reserved for controlling a main contactor. This output has no free-
wheeling diode. External components for suppressing the inductive discharge of
the contactor coil must be provided (see Figure 15).

Digital Outputs
Five (5) digital outputs (DO 1 - DO 5) are reserved for interfacing to low level
electronic devices such as micro-controllers and displays. The interfacing
requirements and methods vary depending on the specific device to be interfaced
and the application software supporting the device. Designers should consult ACC
for interfacing details when utilizing these digital outputs.

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INTERFACING TO CANION CAN BUS COMMUNICATIONS

Can Bus Communications

Interfacing CANION in a Truck Can Network
For truck wide CAN networks ACC recommends using an isolated CAN Bus power
supply to power all CAN devices possessing an isolated CAN interface. ACC
products with an isolated CAN Interface include the APS (Advanced Power
Steering) and AC SuperDrive. The CANION employs a non-isolated CAN Bus
interface. Figure 13 illustrates the wiring configuration for a CANION, ACS and AC
SuperDrive on a CAN network.
The CAN Bus must be wired in a “Daisy chain” arrangement as shown in Figure 13.
Twisted pair wiring is required for the CAN H and CAN L signals. Both physical ends
of the CAN Bus must be terminated with 120 ohm resistances. A service device
connector in a safe, convenient location should be included in the wiring
configuration.

CAN PWR EXT CAN GND

CAN PWR EXT CAN GND

CAN PWR EXT
APS AC SuperDrive
B+ CAN GND CAN L CAN H
CAN L CAN H
CAN H

CAN L
CAN -
Power
Supply + 120
(8 - 24 VDC) 120
CAN L CAN H

CANION
C0007.CDR
Service Device
Connector
B-
(single connection to B-)

Figure 13 CANION Connection to a Truck CAN Network

CANION in Non-networked Configuration

When a CANION is operating as an independent truck controller and the CAN Bus
is used principally for communications during maintenance and servicing, a non-
isolated CAN Bus configuration may be used. Figure 14 illustrates the typical
interconnection of a CANION and a service device on a non-isolated CAN Bus.
Twisted pair wiring is required for the CAN H and CAN L signals. The service device
connector should be placed in a safe, convenient location. Both physical ends of
the CAN Bus must be terminated with 120 ohm resistances.

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INTERFACING TO CANION CAN BUS COMMUNICATIONS

Service Device
Connector

CANION

CAN L CAN H
CAN H

CAN L

120 C0008.CDR
120

Figure 14 CANION Connection to a Non-isolated CAN Bus

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INTERFACING TO CANION POWER DISTRIBUTION

Power Distribution
General Configuration
Figure 15 shows a general schematic for battery power distribution in a truck
system comprised of a CANION, AC SuperDrive and APS. CANION, functioning as
the truck controller, controls the main contactor and distribution of battery power to
other truck components. Normally, CANION closes the main contactor after the
APS and AC SuperDrive(s) have successfully completed their power-up and
initialization without error and their internal capacitors are pre-charged.

key
switch
F1

D1
B+
R1 = 10
D2
main 14
contactor
B+
3
emergency DI 2
stop
CANION

40
POUT 10
F2
B-
28
F3
B+
B+
F4
APS

B- B-

AC SuperDrive
8 1

L K1

B+
on-board
fuse
+ U V W B-

C0009.CDR

B-

Figure 15 Battery Power Distribution to a CANION, AC SuperDrive and APS

Resistor R1 provides current limited path for pre-charging the internal capacitors in

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INTERFACING TO CANION

the AC SuperDrive and APS when power is first turned on via the key switch. Diode
D1 blocks the power stored in the filter capacitors of the APS and AC SuperDrive
from supplying power to the key switch circuit when the key switch is opened.
Diode D2 suppresses the discharge voltage of the main contactor.

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 Installation and Wiring 5

CANION Installation
Mounting CANION in a Vehicle
The CANION is housed in a cast aluminum box that may be mounted on a flat
surface. Built-in mounting tabs with pre-drilled holes are provided for securing the
CANION to the vehicle. Figure 16 shows the CANION mounting dimensions and
clearances required for the mating connector and wiring.
The mountinghole diameter is 5mm.

Figure 16 CANION Mounting Dimensions and Clearances

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INSTALLATION AND WIRING CANION INSTALLATION

Mounting Location
A CANION may be mounted in any location that satisfies the CANION
environmental requirements (see "Environmental Limits"). Either vertical or
horizontal mounting is acceptable. Since the CANION has no periodic maintenance
or servicing requirements, accessibility for maintenance or adjustments is not
required.

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INSTALLATION AND WIRING WIRING THE CANION

Wiring the CANION

Introduction
This section provides recommended techniques and practices for wiring a CANION
into a vehicle in a CAN Bus based application. The vehicle manufacturer's
schematics and diagrams always supercede the information presented in this
manual.
All user signal and power connections to a CANION are made to a 42 pin
connector that plugs into a mating connector on the controller.

Tools and Equipment Required

Mating Connector and Contacts
A mating connector housing and 42 contacts are required for wiring to a CANION.
These components may be procured from ACC as a kit (ACC P/N 19N426A). The
connector housing and contacts may also be procured from the connector
manufacturer.
Table 5 provides a description and ordering information for the mating connector kit
and individual components. When ordering components from the manufacturer, 36
small gauge contacts and 6 medium gauge contacts are required to fully populate a
connector housing.
description Part number supplier Quantity Wire size Insulation dia.
(per item) mm2 mm
Mating Connector Kit 19N426A ACC
42 pin housing 1
(36 small gauge and
6 medium gauge
cavities)
Contact, small gauge 45 0.5 - 1.4 - 2.11
1.0
Contact, medium 8 1.5 - 2.11 - 3.1
gauge 2.5
Individual Components
42 pin housing 1-96728-1 AMP Inc. 1
(36 small gauge and
6 medium gauge
cavities)
Contact, small gauge 1-962945- AMP Inc. 1 0.5 - 1.4 - 2.11
2 1.00
Contact, medium 1-927777- AMP Inc. 1 1.5 - 2.11 -
gauge 1 2.5 3.11
Table 5 Mating Connector and Contacts Ordering Information

Assembly Tools
A hand-operated crimping tool, two (2) die sets and two (2) pin extraction tools are
required to wire and assemble a mating connector. Table 6 provides details on a
complement of hand tools recommended for this purpose.

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INSTALLATION AND WIRING WIRING THE CANION

description Manufacturer Part number

Hand tool AMP Inc. 539635-1
Die set for small gauge AMP Inc. 539663-2
contacts
Die set for medium gauge APM Inc. 539674-2
contacts
Extractor for small gauge AMP Inc. 726534-1
contacts
Extractor for medium gauge AMP Inc. 726519-1
contacts
Table 6 Tools for Wiring Mating Connector Assembly

Wiring the CANION Mating Connector

Wire Size Requirements
Two sizes of contacts that accept conductors with cross-sections and insulation
diameters listed in Table 5 are used. Due to the low power levels of some signals,
pre-tinned copper wire is recommended for all low power level control wiring.

Crimping Contacts onto Conductors

Select and install the die set for the contact type to be crimped (see Table 6) into
the crimping tool. Prepare each conductor for crimping as shown in Figure 17.
Insert a contact into the crimping tool. Position the bare end of a conductor into the
wire barrel of the contact. Crimp the contact onto the wire.

Figure 17 Preparation of Conductor for Crimping

Remove and inspect the crimped contact. As illustrated in Figure 18, the insulation
must extend beyond the end of the insulation barrel but not into the wire barrel and
all strands must be captured in the wire barrel. (Fig. 18 is not inserted).
Figure 18 Contact with Wire after Crimping

Installing Crimped Contacts in Connector Housing

Insert the crimped contact into the mating connector cavity with locking lance
oriented as shown in Figure 19. Push the contact into the cavity until locking lance
clicks into engagement in its mating recess inside the contact cavity. Tug lightly on
the inserted connector to verify that it is in position. (Fig. 19 is not inserted).
Figure 19 Inserting Contact into Connector Cavity

Mating Connector Pin Assignments

Table 7 lists the generic pin assignments for the CANION. Figure 20 illustrates the

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INSTALLATION AND WIRING

numbering of the CANION mating connector.

Pin # Designation Pin # Designation

1 POUT-2 22 CAN H
2 DI 1 23 CAN L
3 DI 2 24 DO 5
4 DI 3 25 DO 2
5 DI 4 26 POUT 9
6 + 5V OUT 27 POUT 6
7 Analog Gnd. 28 B- (Battery -)
8 CAN Gnd. 29 POUT 4
9 DI 14 30 DI 9
10 DO 4 31 DI 10
11 DO 1 32 DI 11
12 POUT 8 33 DI 12
13 POUT 5 34 -AN2
14 B+ (battery +) 35 +AN2
15 POUT 3 36 +AN3
16 DI 5 37 +AN4
17 DI 6 38 DI 13
18 DI 7 39 DO 3
19 DI 8 40 POUT 10
20 -AN1 41 POUT 7
21 +AN1 42 POUT 1

Table 7 CANION Connector Signals and Pin Assignments

42 41 40 39 38 37 36 35 34 33 32 31 30 29

28 27 26 25 24 23 22 21 20 19 18 17 16 15

14 13 12 11 10 9 8 7 6 5 4 3 2 1

Wiring Side View C0010.CDR

Figure 20 CANION Mating Connector Pin Numbering

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 Specifications 6

Electrical Power Inputs & Outputs

CAN24 CAN36 CAN48
Supply Voltage
nominal value [VDC] 24 36 48
operating range [VDC] 16.8 - 25.2 - 33.6 -
31.2 46.8 62.4
peak transient (< 100 [VDC] 36 54 72
us)
absolute min. (< 100 [VDC] 9.12 13.7 18.2
ms)

Control Inputs and Outputs

CAN24 CAN36 CAN48
Analog Inputs
Quantity 2 differential inputs
2 single ended inputs
input range [VDC] 0 - 5.0
Description RC filter, diode overvoltage
protection
Analog Reference
Nominal voltage [VDC] 5.0
Current capacity [mADC]
Digital Inputs
Quantity 14
logic low [VDC] {??}
logic high [VDC] > 15.0 , < 63.0
input current [mADC]
Description RC filter with 3 db attenuation
@ 500 Hz,
pulldown resistance to gnd.
Digital Outputs
Should logic high be quantity 5
</= VBATT max. load current [mADC]
max. load voltage [VDC] 50
PWM Power Outputs - with current feedback
quantity 8
Peak load current [ADC] 4
(sinking)
Cont. load current [ADC] 2
(sinking)
Combined output current [ADC]
(all PWM outputs)
max. load voltage [VDC] 60
PWM Frequency [kH ]
Z 1.0

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SPECIFICATIONS ENVIRONMENTAL LIMITS

CAN24 CAN36 CAN48

description Free wheeling diode,
overcurrent protection, current
feedback
PWM Power Outputs - without current feedback
quantity 2
Peak load current [ADC] 4
(sinking)
Cont. load current [ADC] 2
(sinking)
max. load voltage [VDC] 60
PWM Frequency [kH ]
Z 1.0
description overcurrent protection

Environmental Limits
CAN24 CAN36 CAN48
Temperature
operational [deg -25 - +55
C]
storage [deg -40 - +70
C]
Mechanical
sealing enclosure fulfils IP54 (IP64
optional)

Physical Data
CAN24 CAN36 CAN48
dimensions (see Figure 16)
weight [kg 0.9 (2)
(lb)]
Operating position any

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