Motec Systems PDM32 User manual

USER MANUAL
PDM
Power Distribution Modules

MoTeC PDM User Manual
Contents
Introduction........................................................................1
Features...................................................................................................1
System Overview.....................................................................................2
Installation.......................................................................... 3
Mounting..................................................................................................3
Wiring.......................................................................................................4
Battery Positive .............................................................................4
Battery Negative............................................................................5
CAN Wiring....................................................................................5
Input Wiring..............................................................................................5
Output Wiring...........................................................................................6
Output Devices........................................................................................6
Windscreen Wipers.......................................................................6
Solenoids.....................................................................................10
Electronic Devices.......................................................................11
PDM Manager Software Installation......................................................12
Configuration....................................................................14
Configuration File ..................................................................................14
Channels................................................................................................15
Configuration Tree.................................................................................16
Global Setup................................................................................16
Input Pins.....................................................................................17
CAN Inputs..................................................................................18
CAN Output.................................................................................19
Functions.....................................................................................20
Output Pins..................................................................................21
CAN Keypads..............................................................................26
Operation.......................................................................... 27
CAN Bus Bitrate..........................................................................27
Sending and Retrieving Configuration Files................................27
Checking Operation.....................................................................27
Serial Number .............................................................................28
Firmware Versions and Updating................................................28
Password Protection ...................................................................29

PDM User Manual
Standby Mode........................................................................................29
Appendices.......................................................................30
Specifications.........................................................................................30
CAN Input Channel Examples...............................................................32
Fuse Characteristics..............................................................................34
Connectors and Pinout..........................................................................35
PDM16.........................................................................................35
PDM32.........................................................................................36
PDM15.........................................................................................38
PDM30.........................................................................................39
Mounting Dimensions............................................................................40
PDM16.........................................................................................40
PDM32.........................................................................................41
PDM15 and PDM30 ....................................................................42
Wiring.....................................................................................................43
Wire Specification........................................................................43
UTC Wiring for PC Connection ...................................................44
CAN Bus Wiring Requirements...................................................44
CAN Output Messages..........................................................................46
Windows Keyboard Shortcuts ...............................................................52
Glossary.................................................................................................56

MoTeC PDM User Manual
Copyright ©2014 – MoTeC Pty Ltd
The information in this document is subject to change without notice.
While every effort is taken to ensure correctness, no responsibility will be taken for the
consequences of any inaccuracies or omissions in this manual.
PN 63029 V3.3, February 2014

MoTeC Introduction 1
Introduction
The PDMs replace conventional relays, fuses and circuit breakers by
providing electronically switched power to the various electrical systems in the
vehicle, including motors, lamps, ECUs and data systems. This simplifies
wiring and switch requirements, while increasing reliability.
There are four PDM versions: PDM16, PDM32, PDM15 and PDM30.
Throughout this manual all versions will be referred to as the PDM except
where details specific to a particular version are discussed.
Features
PDM16 PDM32 PDM15 PDM30
Inputs 12 23 16 16
8 Amp Outputs 8 24 7 22
20 Amp Outputs 8 8 8 8
Connectors Autosport Waterproof connectors
M6 stud
Case size
Length
Width
Height
130 mm
60 mm
28 mm
180 mm
60 mm
28 mm
107 mm
133 mm
39 mm
107 mm
133 mm
39 mm
•Each output is over-current, short circuit and thermal overload protected
•Outputs are programmable in 1 A steps
•Outputs are controllable via a combination of switch inputs, CAN
messages and logic functions
•Switch inputs are ranging from 0 to 51 V, resolution 0.2 V
•Performing up to 200 logic operations using operators like Flash, Pulse,
Set/Reset, Hysteresis, Toggle, And, Or, Less than, Greater than, Not equal
to, Equal to, True, False etc.
•Performing functions such as flashing indicator lights and controlling
thermo fans and fuel pumps
•Using logic functions to selectively turn off systems during low battery
voltage or engine starting, reducing drain on the battery

2 Introduction
•Providing full diagnostic information, including output currents and
voltages, input voltages, and error status
•Transmitting diagnostic information via CAN to a display or data logging
device or monitoring directly on a PC
•Protected against unauthorised access by a password feature.
Accessories
•MoTeC UTC (USB to CAN adaptor) #61059
(Note: PDMs are not compatible with MoTeC CAN cable)
System Overview

MoTeC Installation 3
Installation
Mounting
When mounting the PDM take into account that the PDM may get very hot
during operation.
Ensure the PDM is mounted in a well ventilated area and not against a hot
surface. For case dimensions see Mounting Dimensions.
The internal temperature is highly dependent on ambient temperature and
also on the total load current—a higher current will cause a higher
temperature.
Tip: The internal temperature can be checked in PDM Manager (see
Operation) or transmitted via CAN to be logged. Allow for sufficient time
for the temperature to stabilise. This may take 30 minutes or more.
If the internal temperature of the PDM exceeds the specified maximum values
(see Specifications), cooling may be achieved by one or more of the following:
•relocating the PDM to a cooler mounting position
•increasing air circulation around the PDM case
•ducting cool air over the PDM case
•fitting a heatsink to the back surface of the PDM case

4 Installation
Wiring
Battery Positive
Battery positive is supplied to the PDM via the single pin connector to suit wire
sizes 16 mm2(6#) or 25 mm2(4#).
The PDM16 and PDM32 use an Autosport connector, PDM15 and PDM30
use a 6 mm eyelet to suit the wire size.
The wire gauge should be chosen according to the wire temperature limit and
acceptable voltage drop. Tefzel wire must not exceed 150 °C.
The temperature of the wire is affected by the ambient temperature, air
circulation, current, wire gauge, the temperature of any surrounding wires and
the covering sheath.
See Wire Specification and Connectors and Pinout for details.
Battery Isolator Switch
Battery positive must generally be connected via an isolator switch or relay.
The isolator must isolate the battery from all devices in the vehicle including
the PDM, starter motor and alternator. The isolator must be rated to handle
the starter motor current.
When the battery is isolated, the engine may continue to run due to power
supplied by the alternator. To avoid this, the isolator switch should have a
secondary switch that is connected to a shutdown input on the ECU.

MoTeC Installation 5
If the ECU does not have a shutdown input, the switch can be connected to a
PDM input. The PDM can then turn off power to the ignition system or the
ECU, which will cause the engine to stop.
Battery Negative
Both of the Batt–pins should be wired to battery negative via 20# wire.
These pins normally only carry the very low operating current, however during
a load dump they carry the load dump current which may be 50 ampere or
higher.
CAN Wiring
The PDM communicates over CAN with other devices connected to the same
CAN bus. The CAN bus must be wired according to CAN Bus Wiring
Requirements.
The PC also communicates to the PDM via the CAN bus. See Connecting the
PDM to a PC.
Input Wiring
The PDM Switch Inputs are intended for use with a switch that is directly
wired between a PDM input pin and a PDM 0 V pin. Each input has an
internal 10 kilo-ohm pull-up resistor to Batt+.
If it is required to connect a switch that is wired to another system in the
vehicle, ensure that the voltage levels are set appropriately as there may be
ground voltage variations between devices.
Tip: If standby current is important, wire the switches so that they are
normally open during standby. This will reduce the standby current.
Input Switch Connected to Battery
When an input is driven from a device that switches to battery, the switch
should if possible, be rearranged so that it switches to 0 V.
If the signal comes from an electronic device such as an ECU that has an
output that can only switch to battery (e.g. a signal that indicates when to turn
the fuel pump on), this might not be possible. In this case an external pull-
down resistor is required. The resistor should be 1500 ohm 0.25 watt and
should be connected between the input pin and the 0 V pin.
The input trigger levels should be set to 4 V and 5 V to guarantee correct
triggering for all possible battery voltages.

6 Installation
Output Wiring
All outputs are high side type outputs; they switch Batt+ to the output pin.
They all have hardware thermal overload protection, fault logic and over-
current logic.
Paralleled Outputs
Two or more output pins can be connected in parallel to increase current
capacity. Outputs that are connected in parallel must all be of the same type;
either all 8 Amp or all 20 Amp outputs.
Wire Gauges
The wire gauge must be chosen to suit the current consumed by the
connected device and to ensure that the voltage drop is acceptable. On long
runs it may be necessary to use a heavier gauge wire to minimise voltage
drop.
The wire gauge must also be compatible with the connector pin; using a
smaller than recommended wire gauge may result in a poor crimp.
Suitable wire gauges are 24# to 20# for the 8 Amp outputs and 20# to 16# for
the 20 Amp outputs. See Wiring for details.
Output Devices
Windscreen Wipers
The PDM can drive windscreen wiper motors; however the PDM cannot be
connected to both the fast and slow motor windings at the same time. The
voltage generated by the slow winding during fast operation will cause braking
of the motor and possible damage to the PDM.
A wiper unit can be wired in a number of ways. The following schematics are
shown for 'common-ground' wiper units. For 'common-positive' wiper units the
schematics must be adjusted accordingly.
1. OEM Controller Method

MoTeC Installation 7
The wiper unit can be wired using an OEM wiper controller with the PDM
supplying the power only.
The OEM controller performs the intermittent and motor braking functions.
2. Two Switch Method
The wiper unit can be wired in a simple two switch arrangement; one switch
for power and the other to select fast or slow. The PDM supplies power only.
Wiper motor braking is performed by the combination of the park switch and
the on/off switch.
This arrangement cannot perform intermittent operation since the wiper will
not park if the PDM simply removes power.
The switches must be able to handle the wiper motor current (typically
4 ampere).
3. Relay Method
The two switch method can be modified for intermittent operation by replacing
the on/off switch with a relay. The PDM controls the relay to perform the
intermittent function. This requires two PDM outputs; one to supply power and
the other to control the relay.
Motor braking is performed by the combination of the park switch and the
relay switch.
The PDM must be configured with the appropriate logic to perform on/off and
intermittent operation based on the state of the control switches.

8 Installation
Slow operation can be achieved using the switch or using intermittent
operation to give a similar effect which avoids the need for a high current
switch.
The fast/slow switch and on/off relay must handle the wiper motor current
(typically 4 ampere). The control switches can be low current types since they
only connect to PDM inputs.
4. Direct Method
The wiper unit can be wired directly to the PDM as long as it is only connected
to one output.
In this method the park switch is wired directly to a PDM input so the park
logic must be configured in the PDM.
This method requires the use of Output 9 which performs motor braking. The
PDM performs motor braking by momentarily shorting the output to ground
when the output turns off.
The PDM must be configured with the appropriate logic to perform on/off and
intermittent operation based on the state of the control switches.
Slow operation can be achieved using a switch between the fast and slow
windings as used in the other methods or intermittent operation can be used
to wipe less frequently.
The control switches can be low current types since they only connect to PDM
inputs.
5. Direct Method with Linked Channels – PDM Version 2
Hardware
The PDM Version 2 hardware has additional functionality to simplify
windscreen wiper motor control.
This method requires the use of Output 9 which provides special wiper
functionality:
- Output 9 is isolated whenever the user nominated linked high speed
wiper output is turned on. This protects Output 9 from the high voltage
generated by the slow winding, and also prevents Output 9 from

MoTeC Installation 9
braking the motor when the high speed winding is turned on. The
linked high speed wiper output can be configured in the Output 9
settings.
- Output 9 performs motor braking by momentarily shorting the output
to ground when the output turns off.
The PDM must be configured with the appropriate logic to perform on/off,
speed selection, intermittent operation and wiper parking based on the state
of the control switches and park switch input.
The diagram below shows an example sequence of wiper operations. The
wiper slow condition is setup to operate the slow winding when the wiper
switch is on, or when the wiper is not parked. When the linked fast winding
output is on, Output 9 is held off even though the condition driving output 9 is
still true.
Wiper slow
input
Out 9 held off while
linked output is on Parking
Wiper fast
input
Wiper park
switch input
Wiper slow
condition
Out x (High
Winding)
Out 9 (slow
winding)
Consider when implementing wiper control logic:
- The condition for the slow winding output (Output 9) can remain true
even when the fast winding output is on.
- The wiper should always be parked from the slow winding output
(Output 9) so that motor braking can be used.

10 Installation
- Set the High Time and Low Time to 0.00s in the park switch input pin
configuration so that the wiper is parked as soon as possible after
reaching the park position.
An sample configuration for this method is included with PDM Manager.
Note: Version 2 hardware is indicated by the symbol 2 next to the engraved
serial number on the PDM case.
Solenoids
The current drawn by a normal single coil solenoid ramps up from zero to its
steady state value over a period of time. The time taken to do this depends on
the inductance and resistance of the solenoid but is normally very short (less
than 0.1 second). This has no effect on the PDM.
A solenoid will generate a voltage spike when turned off; this is clamped and
absorbed by the PDM. The amount of energy absorbed by the PDM depends
on the inductance and current in the solenoid. The PDM is capable of
absorbing the energy of most normal solenoids in a vehicle.
Two Stage Solenoids
Some solenoids have two windings; one is used to turn the solenoid on, the
other is used to hold it on once it has switched. This ensures optimum turn on
characteristics with minimum holding current.
The current drawn by the turn on winding may be higher than the current
drawn by the holding winding. Ensure the Output Load is well clear of 100%
during turn on and during holding.
Starter Solenoids
In many cases it is possible to run starter solenoids from a single 20 Amp
output even though they typically draw more than 20 ampere (possibly as
much as 40 ampere).
The Over-Current Shutdown feature allows excess current for a period of
time. This feature will shut down the output after about 10 to 20 seconds of
cranking. See the Over-Current Shutdown section for details.
The wire can be rated for 20 ampere, also ensuring that the starter motor
does not overheat during excess cranking. A larger wire gauge might be
required if the voltage drop is not acceptable.
Alternatively two 20 Amp outputs may be paralleled allowing cranking for any
period of time (subject to overheating of the starter motor).

MoTeC Installation 11
Electronic Devices
The PDM can supply power to electronic devices such as engine
management systems, data acquisition systems, radios etc.
Many electronic devices will have a short inrush current. The PDM will largely
ignore this due to the Output Load filtering. See the Over-Current Shutdown
section for details.
The PDM provides reverse battery protection and load dump clamping to
protect itself and the connected devices.
Ignition Systems
Inductive Ignition Systems
Most inductive ignition systems draw a peak current of about 8 ampere,
some draw as much as 20 ampere; however the average current is much
lower.
In most cases inductive ignition systems can be connected to an 8 Amp
output however the Output Load current must be checked to ensure it
stays well clear of 100%.
The average current will increase with increasing RPM so the Output Load
should be checked at maximum RPM.
CDI Ignition Systems
CDI ignition systems can draw peak currents of as much as 50 ampere. It
is recommended that all CDI ignition systems are connected to a 20 Amp
output.
The average current will increase with increasing RPM so the Output Load
should be checked at maximum RPM.
Engine Management Systems
The current drawn by an engine management system will depend on the type
of loads it is connected to and the operating conditions.
Fuel injectors draw current in pulses. The maximum average current drawn by
the fuel injectors is when they are at maximum duty cycle.
For servo devices such as Drive by Wire motors maximum current is drawn
when making large transitions.
Check that the Output Load is clear of 100% under worst case operating
conditions, i.e. when the injectors are operating at maximum duty cycle, servo
devices are making large transitions and any auxiliary loads are drawing
maximum current.

12 Installation
CAN Keypads
The CAN Keypads continuously communicate with the PDM which will
prevent the PDM from entering its low power standby mode.
Options for powering the keypads include:
- Configuring the PDM to always power the keypads.
This allows buttons on the keypads to be used for master startup
functions, but the PDM would never enter standby mode.
To minimize battery drain, the isolator would need to be turned off (eg.
during vehicle transport or storage)
- Wiring a master switch or ignition key input to the PDM.
All outputs (including the keypad power) would be configured to turn
off when the master switch or key is turned off.
This allows the PDM to enter standby mode, minimizing battery drain.
PDM Manager Software Installation
The PDM Manager software is used to:
•Change the PDM configuration
•Monitor the PDM operation including the output currents and
diagnostics
•Test the outputs by manually turning them off and on
•Set and unlock security password
•Update the firmware
PC Requirements
PDM Manager runs under Windows XP or Vista operating systems. The
minimum recommended PC specification is a Pentium 90 with 16 MB RAM
and a USB port.
Installing PDM Manager Software
•Go to the MoTeC website at www.motec.com and navigate to
downloads/software/latestreleases/PDM Manager software
OR Locate PDM Manager software on the MoTeC Resource Disc
•Save the selected file in your preferred location (for example desktop)
•When downloading is finished, double click on the file and select run
•Follow the instructions on the InstallShield Wizard

MoTeC 13Installation
•To start the program after installation, click
Start > All Programs > MoTeC > PDM Manager
Updating PDM Manager Software
Software updates are available to give access to the latest features.
Download the latest software version from the website and follow the software
installation instructions to update to the new version.
To update the associated firmware in the device select Update Firmware from
the Online menu. For more information refer to Operation.
Connecting the PDM to a PC
The PC communicates with the PDM via the CAN bus.
The connection to the CAN bus is via USB through a MoTeC UTC.
To connect through a UTC, a mating connector for the UTC must be wired to
the PDM's CAN bus.
Refer to UTC Wiring for PC Connection and CAN Bus Wiring Requirements
for more information.
The PC must connect to the PDM at the configured PDM CAN bitrate. Refer
to the Operation section for details about CAN bitrate configuration.
Note: The MoTeC CAN cable (#61021) cannot be used with the PDM.

14 Configuration
Configuration
The PDM requires various settings to be configured such as the maximum
current settings for the outputs and the circumstances in which to turn the
outputs on.
The configuration settings are stored in a configuration file on the PC.
Changes to the PDM configuration are performed ‘Offline’, i.e. without the PC
communicating with the PDM. The changes are saved in the configuration file
on the PC. The file must be sent to the PDM before the changes take effect.
See Operation.
Configuration File
From the File menu the following options are available:
•New: creates a new configuration file
•Open: selects an existing configuration file
Right-click the configuration file to Rename, Delete, Send to a disk etc.
•Close: closes the current configuration file
•Save: after a new configuration has been defined, it should be saved with
a meaningful name
•Save as: can be used to create a copy of an existing configuration file by
giving it a new name
•Check Channels: verifies that all channels are correctly generated
•Exit: exits the program
To create a new configuration file
•On the File menu, click New.
•Select the PDM type and enter the Serial Number
The serial number can be found on the PDM label
This will open the Configuration Tree panel and the Channels panel.
Tips:
•The most recently used files appear at the bottom of the File menu.
This is often the easiest way to open an existing file.
•When changing the PDM type all configured inputs and outputs settings
will be transferred to the relevant pin number in the new PDM type.
•Configuration files can be password protected, preventing unauthorised
retrieving and sending of configuration files.

MoTeC Configuration 15
Channels
Channels are used to link the various systems within the PDM configuration.
For example: The input pin system generates two channels for each
configured input pin. Depending on the state of the input pin the input channel
value will be zero or one.
The channel can be selected to directly control a particular output. It can also
be used as an input to a Condition. This is a complex logic function that
combines a number of channels to create a new channel. This new channel
can then be used to control an output, or as an input to another condition.
Each channel can only be generated once, but may be used by multiple
outputs and conditions.
Channel Names
Each channel has a name to identify it. By including a dot between parts of
the channel name, channels are arranged in a tree structure.
For example: Indicators.Left and Indicators.Right would appear as Left and
Right under a node called Indicators.
The use of a dot between parts of the channel name is optional. The channel
list will be a simple flat list rather than a tree structure if it is not used.