HARDWARE

APC122 : Advanced Programmable Controller

SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
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PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
DANA. BY ACCEPTING THIS INFORMATION THE BORROWER AGREES THAT IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED.

APC122

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 TABLE OF CONTENTS
1. 1. HARDWARE BLOCK DIAGRAM ........................................................................................ 4
1.1 LIMITS AND STANDARDS ..................................................................................................... 5
1.2 SAFETY ............................................................................................................................. 7
1.3 ELECTRICAL CHARACTERISTICS.......................................................................................... 8
1.3.1 Digital inputs (DI0 – DI7) ............................................................................................. 8
1.3.2 Analogue inputs (resistive and voltage inputs) (ANI0-ANI3) ....................................... 8
1.3.2.1 Resistive analogue inputs ............................................................................................... 8
1.3.2.2 Voltage analogue inputs ................................................................................................. 8
1.3.3 Reference voltage (VREF_5V) .................................................................................... 9
1.3.4 Speed inputs (SPIN0–SPIN1) ..................................................................................... 9
1.3.5 Outputs (AO0-AO8) ..................................................................................................... 9
1.3.6 Speedometer output (SPEED0_OUT) ........................................................................ 9
1.3.7 Safety Relay ................................................................................................................ 9
1.3.8 Watchdog .................................................................................................................... 9
1.4 PHYSICAL DIMENSIONS .................................................................................................... 11
2. INSTALLATION GUIDE .................................................................................................... 14
2.1 CONNECTOR ............................................................................................................... 14
2.2 MECHANICAL MOUNTING .................................................................................................. 16
2.3 MATING CONNECTOR AND WIRING HARNESS ...................................................................... 21
2.4 REQUIRED WIRE THICKNESS ON THE MATING CONNECTOR ................................................. 22
2.5 BATTERY PLUS CONNECTIONS (TERMINAL 20,45,60) ........................................................ 23
2.6 PLOAD SIGNAL (TERMINAL 21) ........................................................................................ 24
2.7 POWER GROUND TERMINALS (TERMINAL 5,44) .................................................................. 26
2.8 SIGNAL GROUND TERMINALS ............................................................................................ 26
Analogue inputs (terminal 13, 24, 26, 28) .............................................................................. 28
2.8.1 Speed sensor inputs (terminal 9, 11) ....................................................................... 28
2.8.2 Communication links (terminal 36) ............................................................................ 28
2.9 VOLTAGE REFERENCE OF 5V (TERMINAL 15) ..................................................................... 28
2.10 DIGITAL INPUTS (TERMINAL 52-59) ................................................................................... 28
2.11 ANALOGUE INPUTS (TERMINAL 14,25,27,29) ..................................................................... 28
2.11.1 Resistive inputs ..................................................................................................... 28
2.11.2 Voltage inputs ....................................................................................................... 29
2.12 SPEED SENSOR INPUTS (TERMINAL 10,12) ........................................................................ 29
2.12.1 Inductive sensors .................................................................................................. 29
2.12.2 Magneto Resistive sensors ................................................................................... 29
2.12.3 Hall effect sensor .................................................................................................. 30
2.13 OUTPUTS (TERMINALS 01,03,17,18,31,33,35,46,48)........................................................ 31
2.14 DISPLAY .......................................................................................................................... 31
2.15 COMMUNICATION LINES .................................................................................................... 31
3. GENERAL WIRING DIAGRAM ......................................................................................... 33

4. SAFETY REMARKS .......................................................................................................... 34

4.1 GENERAL INSTRUCTIONS.................................................................................................. 34
4.2 CONVENTIONAL USE ........................................................................................................ 34
4.3 NOTES ON THE INSTALLATION POINT AND POSITION ........................................................... 34
4.4 NOTES ON TRANSPORT AND STORAGE .............................................................................. 34
4.5 NOTES ON CIRCUITRY AND ON WIRING .............................................................................. 35
4.6 SAFETY FEATURES IN THE CONTROLLER ............................................................................ 35

SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
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DANA. BY ACCEPTING THIS INFORMATION THE BORROWER AGREES THAT IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED.

APC122

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 5. DISCLAIMER ..................................................................................................................... 35

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DANA. BY ACCEPTING THIS INFORMATION THE BORROWER AGREES THAT IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED.

APC122

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 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

Outputs
#9 CAN

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
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.

SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
DANA. BY ACCEPTING THIS INFORMATION THE BORROWER AGREES THAT IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED.

APC122

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 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 125 mA
Radiated EM energy ISO 11452-2:2004 V. polarization 80 -1000 MHz 125 V/m
AM modulation H. polarization 400- 1000 MHz 125 V/m
Immunity 2 2004/104/EC
Radiated EM energy ISO 11452-2:2004 V. polarization 800 - 2000 MHz 125 V/m
Pulse modulation H. polarization 800 - 2000 MHz 125 V/m
Electro-static discharge 1 ISO 13766:2006
Contact Discharge ISO 10605:2001 Testlevel IV 8kV class A behaviour
Air Discharge ISO 10605:2001 Testlevel IV 15kV class A behaviour
Electro-static discharge 2
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 IV class A behaviour for 12
ISO 7637-2:2004 and 24 V applications.
Voltage transient emission test ISO 7637-2:2004 Supply voltage: 27V ON/OFF switching
6. Short Circuit Protection
To GND SAE J1455:2006 All terminals(1) (short is applied when the
unit is powered.)
To GND All terminals(1) (short is present when the
unit is switched on)
To Vbat SAE J1455:2006 All terminals(2) (short is applied when the
unit is powered.)
To Vbat All terminals(2) (short is present when the
unit is switched on)
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 = 2.9Ω + 1.5mH
Mutual coupling test ASAE EP455 Power source lines:
450 exp[-t/(14E-6)]sin(2π*10E6t) V
Signal lines:
+/-400 exp[-t/(14E-6) V
8. Sealing IEC 60529 IP65, IP67, IP69K

SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
DANA. BY ACCEPTING THIS INFORMATION THE BORROWER AGREES THAT IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED.

APC122

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 9. Dry heat tests
Storage temperature 24h @ -55°C followed by 24h @ 105°C
High temperature soak test 96h @ 85°C powered
Low temperature soak test 96h @ -40°C powered
Operating temperature 7x 48h cycle, variant on SAE J1445 t°
profile between -40°C and 85°C,
powered
Thermal shock 1 3x 8h cycle, variant on SAE J1445 t°
profile, powered
Thermal shock 2 100 cycle, between -55°C and 90°C, not
powered
10. Shock
Handling drop test SAE J1445:2006
Operational shocks 1 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
Operational shocks 2 IEC 60068-2-29 100 bumps positive and negative
Amplitude: 40 g, ½ sine
Duration: 6 ms
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
in each direction.
Frequency range: 10 to 150 Hz
sweep rate: 1 oct/min
direction: 3 orthogonal axes
Wide random vibration test 1 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
Wide random vibration test 2 IEC 60068-2-35 Duration: 24 hours
Direction: 3 orthogonal axes
Profile:
10 Hz : 0.005 g2/Hz
150 Hz : 0,060 g2/Hz
220 Hz : 0.080 g2/Hz
350 Hz : 0.040 g2/Hz
Resonance search test 1 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.
Resonance search test 2 Frequency range from 10 to 2000Hz.
Constant acceleration 4g.
Sweep rate : 1oct/min.

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APC122

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 Direction: 3 orthogonal axes.
Duration: examine each resonance point
Q>=5. Dwell the vibration frequency for
30 minutes at each resonanance point.
12. Corrosive atmosphere
Humidity 24h cycle, variant on SAE J1445
humidity profile
Humidity soak 240 hours at RH of > 96%
Icing cycle Between -40°C and +85°C, 24 hours
85/85 relative humidity test Duration: 21 days @85°C and RH=85%
Salt spray test IEC60068-2-11 Duration: 48h
Chemical resistance test BS7691 Coat once a day for a duration of 3 days.
Overview chemicals:
Diesel, Hydraulic oil, ethylene glycol 50%
aqueous solution, Urea Nitogen, NPK
fertilizer 3x 15% each

Ozone chamber test ASTM D1171-99 Duration: 46 hours

(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 APC122 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 Safety
Based on calculation following the ISO 13849:2006 and the IEC TR 62380:2004 standard, the
controller is SIL 2 capable depending on the system configuration. The calculation takes into
account an ambient temperature of 85°C.

SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
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APC122

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 1.3 Electrical Characteristics

1.3.1 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

1.3.2 Analogue inputs (resistive and voltage inputs) (ANI0-ANI3)

There are 4 analogue inputs. These inputs can be configured as following :
2 voltage and 2 resistive inputs.
4 voltage inputs.
4 resistive inputs.

1.3.2.1 Resistive analogue inputs

Parameter
Range 0 – 5KΩ
Internal pull-up to Vsens 9 KΩ
Vsens 14 V
Accuracy 1% full scale
Maximum input voltage 48 V
Maximum reverse polarity voltage -24 V
Fault detection capability Yes, related to input
range

1.3.2.2 Voltage analogue inputs

Parameter
Range 0–5V
Accuracy 1% full scale
Maximum input voltage 48 V
Max. reverse polarity voltage -24 V
Fault detection capability Yes, related to input
range

SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
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APC122

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 1.3.3 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

1.3.4 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

1.3.5 Outputs (AO0-AO8)

Parameter
Number 9
Current range* 0 – 4A
Minimum Load resistance 4Ω
Fault detection capability Yes
PWM Modulation frequency 40 - 1200 Hz
* minimum current to detect that a load is connected to the output is 10 mA.

1.3.6 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

1.3.7 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.

1.3.8 Watchdog

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 Based on IEC61508, in order to increase safety, an external watchdog is used to check the
correct behaviour of the microprocessor.

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 1.4 Physical dimensions
Dimensions: 234 x 181 x 48 mm³
Weight : approx. 0,85 kg

Note that the mating connectors and wiring harness of the APC122, as shown in the drawings
and pictures of section 1.3 Physical dimensions, will not be supplied together with the APC122.
The 94 pins connector is not used for the APC122.
The 60 pins mating connector can be ordered from a local supplier or can be ordered from
Dana under separate part number.
The wiring harness has to be ordered from a local supplier (for production).
Or can be ordered from Dana under separate part number (for prototype vehicles only).
See section 2.3 Mating connector and wiring harness.

TOP VIEW :

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 APC122 – TOP VIEW with and without connector

SIDE VIEW :

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 BOTTOM VIEW :

APC122 – BOTTOM VIEW with and without connector

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 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

This is the mating connector of the 60-pole connector:

1 CPA
5 Lever
12 Secondary lock
13 Cover

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DANA. BY ACCEPTING THIS INFORMATION THE BORROWER AGREES THAT IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED.

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SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
DANA. BY ACCEPTING THIS INFORMATION THE BORROWER AGREES THAT IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED.

APC122

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 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). This to
avoid that water can ingress via the seal of the cover into the controller.

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 Note that the mating connectors of the APC122, as shown in the above drawing, will not be
supplied together with the APC122.
The 94 pins connector is not used for the APC122.
The 60 pins mating connector can be ordered from a local supplier or can be ordered from
Dana under separate part number.
See section 2.3 Mating connector and wiring harness.

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SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
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SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
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 The 60-pole connector pin assignment is as follows:

Pin Name Function Pin Name Function

01 AO7 (1) Analogue output 7 31 AO1 (1) Analogue ouput 1 without
without current feedback current feedback
02 GND_AO7 GND for AO7 32 GND_AO1 Analogue output 1 ground
03 AO8 (1) Analogue output 8 33 AO0 (1) Analogue output 0 without
without current feedback current feedback
04 GND_AO8 GND for AO8 34 GND_AO0 Analogue output 0 ground
05 GND Battery ground 35 AO6 (1) Analogue 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 Analogue input 3 ground 43 GND_SPEEDO Signal GND
14 ANI3 Analogue input 3 44 GND Battery ground
15 VREF_5V Reference voltage 5V 45 VP_PWR Permanent power supply
16 GND_AO5 Analogue output 5 46 AO4 (1) Analogue output 4 without
ground current feedback
17 AO5 (1) Analogue output 5 47 GND_AO4 Analogue output 4 ground
without current feedback
18 AO3 (1) Analogue output 3 48 AO2 (1) Analogue output 2 without
without current feedback current feedback
19 GND_AO3 analogue output 3 ground 49 GND_AO2 Analogue output 2 ground
20 VS_PWR Switched power supply 50 GND_AO6 Analogue 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 Analogue input 0 55 DI4 (2) Digital input 4
26 GND_ANI1 ANI1 ground 56 DI3 (2) Digital input 3
27 ANI1 Analogue input 1 57 DI2 (2) Digital input 2
28 GND_ANI2 ANI2 ground 58 DI1 (2) Digital input 1
29 ANI2 Analogue input 2 59 DI0 (2) Digital input 0
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

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 2.3 Mating connector and wiring harness

The Mating connector can be ordered from a local supplier :

Tyco Part number

Receptacle 60 pins 284742-1
Pin for 0.50 – 0.75 mm² 968221-1
Pin for 0.75 – 1.50 mm² 1241608-1
Cavity plug for 0.50 – 0.75 mm² 284583-1
Cavity plug for 0.75 – 1.50 mm² 1394872-1

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.

The Mating connector can also be ordered from Dana under part number 4505147.
1x 4505147 contains components for 5 connectors:

Tyco Part number Qty

Receptacles 60 pins 284742-1 5x 1 = 5
Pins for 0.50 – 0.75 mm² 968221-1 5x 36 = 180
Pins for 0.75 – 1.50 mm² 1241608-1 5x 24 = 120
Cavity plugs for 0.50 – 0.75 mm² 284583-1 5x 30 = 150
Cavity plugs for 0.75 – 1.50 mm² 1394872-1 5x 15 = 75

For production, the wiring harness has to be ordered from a local supplier.

For prototype vehicles, an 8 m wiring harness can be ordered from Dana. This wiring
harness contains the Tyco connector (incl. pins) and 60 wires of 8 m. The numbered
wires are connected to the Tyco connector on one end and they are loose on the other
end. The part number for this prototype wiring harness is 4503644. Note that this
wiring harness can not be ordered for production.

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.

SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
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PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
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 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
48 P/N 1241608-1 AWG16 - 1,50mm2 A
49 P/N 1241608-1 AWG16 - 1,50mm2 A

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THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
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 Pin number Contact type Wire thickness Cable tree
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 APC122 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 APC122 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
- power outputs
20,60

PLOAD

21
Ignition key
APC122

- +

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 an automotive fuse of 15 A.The maximum

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PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
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 allowable resistance between the connector of the APC122 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
APC122

- +

For the both solutions the terminal 45 (permanent supply terminal) must be
connected directly to the 12V/24V battery via an automotive fuse of 3A. Only this way,
the APC122 can save valuable information during power down periods (auto power-off
functionality).

Remark: The automotive fuse on the permanent supply must have at least an I²t value
of 7 A²s.

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.
To switch on the controller, the PLOAD signal must have high level that is equal to the
battery supply voltage.To powerdown the controller the level of this signal must drop
below 3 volts.
If the PLOAD pin is the only signal connected to the supply line coming from the
ignition key, the following figure shows the connection diagram.

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 PLOAD P21

+ _

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 In most of the cases other devices are also connected to this supply line. When the
ignition key is opened, the voltage on this supply line drops below the 3 volts due to the
internal resistance of these devices. In this case it is probably not necessary to have a
connection to the battery minus to powerdown the controller. However, when using this
connection diagram it is necessary to check whether the voltage drops below 3 volts
fast enough. It is required that this occurs in less then 0,5 seconds.

PLOAD P21

+ _
OTHER UNITS

Internal resistance
other units

2.7 Power ground terminals (terminal 5,44)

These terminals are the APC122'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 analogue 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-APC122 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 APC122 connector pin to the split

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 point and go from there with (smaller) dedicated wires to the individual sensor
return paths.

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 Analogue 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.

2.8.1 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.

2.8.2 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 Analogue inputs (terminal 14,25,27,29)

Four analogue inputs are available on the APC122. 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.

SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
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 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 APC122 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).

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 APC122 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.

SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
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 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 APC122 will report the fault as a
short circuit.
Incorrect mounting also results in loss of speed, but is not detected by the APC122
hardware, and thus can cause improper transmission control.

2.12.3 Hall effect sensor

The APC122 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 APC122. The detection is based on the current the
sensor draws from the power supply.

The next picture shows the correct diagram :

SPINx Vcc HALL speed sensor

APC120 620Ω 1/4W HALL detector

Out

Gnd
SIGGND

Remark: If the APC122 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 :

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THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
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 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
APC122. 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 APC122. This causes ground noise
which can significantly degrade the measurements of the analogue inputs. On the
APC122, 9 PWM are available.

The terminals 1, 3, 17, 18, 31, 33, 35, 46 and 48 are the outputs.
The returning terminals are 2, 4, 16, 19, 32, 34, 47, 49 and 50.

2.14 Display
It is possible to connect a display to the APC122. 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

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THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
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 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.

SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
DANA. BY ACCEPTING THIS INFORMATION THE BORROWER AGREES THAT IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED.

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 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
0
+ 10
speed in n
9
-
51
+
8 LIN DISPLAY
+ 12
n 36
speed in 11 -
-

CAN BUS
42 CANL
+
n out 22
speedo out 43 CANH
-
23
GND
36
3A 45
RS232 BUS
15A 20, 21, 60 06 RXD
Drive TXD
5, 44 39

+ - 36 GND
+12V

SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
DANA. BY ACCEPTING THIS INFORMATION THE BORROWER AGREES THAT IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED.

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 4. Safety remarks

4.1 General instructions

– Reliable operation cannot be guaranteed if samples or prototypes are used in series

production machines.
– The suggested circuits do not imply any technical liability for the whole system on the
part of Dana.
– Incorrect connections could cause unexpected signals at the outputs of the controller.
– Dangerous malfunctions may result if the control electronics are opened or modified or
the wiring is adapted without authorization.
– In addition, the application-specific documents (connection diagrams, software
descriptions, etc.) are to be observed.
– No components that are defective or not working properly should be used. If
components fail and/or exhibit malfunction, they must be replaced immediately.
– The controller warms up above regular ambient temperature during operation. To
prevent risks due to high temperatures, it should be attached and protected before it is
touched.
– Incorrect programming of the APC may create potential sources of danger while the
machine is in operation. It is the responsibility of the machine manufacturer to
determine dangers of this type in a risk assessment. Dana assumes no liability for risks
of this type.

4.2 Conventional use

– Operation of the controller APC must generally occur within the operating ranges
specified and released in this data sheet, particularly with regard to voltage,
temperature, vibration, shock and other described environmental influences. Use
outside of the specified and released boundary conditions may result in danger to life
and/or cause damage to components which could result in consequential damage to
the complete system.
– Damages which result from improper use and/or from unauthorized, unintended
interventions in the device not described in this data sheet render all warranty and
liability claims with respect to the manufacturer void.

4.3 Notes on the installation point and position

– Do not install the controller near parts which generate considerable heat (e.g. exhaust).
– Install the controller in such a way that the connector is pointing downwards. This
ensures that any condensation water can drain.
– A sufficiently large distance to radio systems must be maintained.
– All connectors must be unplugged from the electronics during electrical welding
operations.
– The controller must not be electrostatically charged, e.g. during painting operations.
– Radio equipment and mobile telephones must not be used in the driver's cab without a
suitable antenna or near the control electronics.
– Cables/wires must be sealed individually to prevent water from entering the controller.

4.4 Notes on transport and storage

SPICER, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
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 – Controllers must be stored in mean relative humidity of 60% at a temperature between
-10°C and +30°C. Briefly, for 100 hours, a storage temperature range of -20°C to
+40°C is permissible.
– After a storage time of more than 5 years, the controller must be examined by the
manufacturer before it is used.
– The controller must not be used if it has been dropped, as damage that is not visible
could still affect its reliability.

4.5 Notes on circuitry and on wiring

– The lines used for speed sensors are to be twisted.

– Cables to the electronics must not be routed close to other power-conducting lines in
the machine or vehicle.
– The electronics and the power outputs of a controller must be fed from the same power
source.
– The wiring harness should be fixated mechanically in the area in which the controller is
installed (spacing < 150 mm). The wiring harness should be fixated such that a phase
excitation with the controller occurs (e.g. at the controller mounting point).

4.6 Safety features in the controller

– The input circuits for speed and analog signals partially feature circuits that are
mutually electrically isolated. Through appropriate input connections, the
microcontroller and, when used, the software diagnostic function can detect faults.
– Faults in the supply voltage are detected by internal monitoring.
– All output signals can be monitored by the microcontroller.
– The internal watchdog module centrally switches off all proportional and switched
outputs in the event of disturbances to the program execution.

5. Disclaimer
Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and
software described. Since variance cannot be precluded entirely, we cannot guarantee full
consistency. However, the information in this publication is reviewed regularly and any
necessary corrections are included in subsequent editions.

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, DANA CONFIDENTIAL / PROPRIETARY INFORMATION. DO NOT COPY THIS INFORMATION, EITHER ELECTRONICALLY OR HARDCOPY. RESTRICT CIRCULATION OF THIS DOCUMENT TO
THOSE WITH RESPONSIBILITY TO REVIEW / RESPOND AS REQUESTED. CONTACT R. VANSTRAELEN AT SPICER IF YOU HAVE ANY QUESTIONS. ANY ACCESS TO THIS DOCUMENT OUTSIDE THE
PRIMARY ELECTRONIC SOURCE IS UNCONTROLLED, UNLESS STAMPED, INITIALED AND DATED. THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION THAT IS PROPERTY OF SPICER,
DANA. BY ACCEPTING THIS INFORMATION THE BORROWER AGREES THAT IT WILL NOT BE USED FOR ANY PURPOSE OTHER THAN THAT FOR WHICH IT IS LOANED.

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