502/503/507 SERIES Pedal Position Sensors TYPICAL APPLICATIONS: Accelerator pedal sensor for electronic throttle control systems Features/Benefits: • Field proven in heavy truck and light vehicle applications • Customer defined outputs Up to 3 analog or switch outputs Up to 65° electrical output • Multiple package options Clockwise or counterclockwise rotation Integrated connector or wire harness Choice of mounting configurations TYPICAL SPECIFICATIONS: ELECTRICAL Linearity (absolute): Rotation (electrical): Typical Input Voltage: Overall Voltage: Maximum Current Draw: Total Resistance: ± 2.5% Up to 65° 5 VDC 18 VDC 5.0 mA each output 1 - 5 kΩ, ± 30% MECHANICAL Rotor Return Torque: Mechanical Shock: 10 - 70 Nmm 25 g DURABILITY Operating Temp. Range: Life Cycles: Dither: Vibration: Thermal Shock: -40º to 85ºC > 3 x106 cycles ≥ 25 x 106 @ 25ºC, 1º stroke 10 to 2000 Hz @ 0.2 to 1.6 g’s, 8 hrs. each plane -40º to 85ºC, 500 shocks ENVIRONMENTAL Salt Spray: Humidity: 96 hours (5% NaCl) 144 hours @ 95% RH NOTE: These standard specifications have been met on existing production-tooled units that are tested on precise test equipment. Details are available including failure criteria. This data sheet does not constitute a warranty that the product will meet the above specifications while used in specific applications or attached to specific test equipment. These products are covered by one or more of the the following US and/or foreign patents: US 5,309,134; US 5,460,035; TW 76793; MX 187314; JP 3022169; IT 0632253 B2; FR 0632253 B2; DE 69425705.2; US 5,520,044; US 5,539,373; US 5,557,493; US 5,661,890; US 5,684,407; US 5,757,179; JP 3457086; DE 670471; US 5,798,639; JP 3457085; DE 670472; US 5,905,198; JP 3273052; GB 500223; DE 69204179; US 5,982,170; US 6,018,992; US 6,040,756; US 6,188,216; US 6,211,668; JP 3455706; GB 1008835; FR 1,008,835; DE 1008835; US 6,222,359; US 6,228,288; US 6,289,602; US 6,304,078; US 6,372,358; US 6,392,529; US 6,414,584; US 6,500,018; US 6,515,472; GB 1260788; FR 1260788; EP 1260788; DE 1260788; US 6,617,377; US 6,992,478. Other US and foreign patents pending. ctscorp.com 05 PILOT ] 502 Series RECOMMENDED MOUNTING ENDED MOUNTING CE DETAIL (CCW) 16.21 ±0.5 -A7.52 ±0.38 3.25 ±0.38 DRIVE SLOT 3.25 ±0.38 DRIVE SLOT 16.21 ±0.5 12.83 ±0.40 12.83 ±0.40 75%u4% PEDAL POSITION CONNECTOR HARNESS SENSOR 4X 30vu5v 30° 7950 PPS2C CLCONNECTOR 0.76 PIN K 1000 PPS2 1.1551%/DEG. 5.26 ±0.05 V out 2 A [3] 43.69 SALES OFFICES: North America CTS Automotive Products 40.42 ±0.38 2701 Cambridge CtSC Auburn Hills, MI 48326-2563 USA ± 0.15 Tel: 248-475-9400 -A15.65 ±0.38 ± 0.2 3.39 Fax: 248-475-9403 ± 0.3 1.32 ±0.05 DIMENSIONING AND TOLERA ASME Y14.5M-1994 MULTI AND SECTIONAL VIEW D ASME Y14.3M-1994 PIN "A" 40.42 ±0.38 THIS DOCUMENT IS UNCONTROLLED THIS DOC IN UNLESS STAMPED "CONTROLLED UNLES CO 40.42 ±0.38 DENOTES CTS INTERNAL SPEC SENSOR TRAVEL (41v) GENERAL TOLERANCE 60° u0.5v RANGE (mm) 6.68 ±0.25 55.44 22.8 ±0.50 2.29 MOUNTING SURFACE 30° LOW END O 18.01 0v INDEX 8.2° SECTION B-B 2X R 5.78 u0.30 [5] 4616 34.37 ±0.45 >PBT-(GF20 + GB20)< [2] E [4] [1] 2 F 4 D G C A J H 3 5 B CL connector K 5 6 4 6 5 7 47° ANGULAR ± 41° u3v MECHANICAL ROTATION WITH PACKARD ELECTRIC P/N 1206 6317. XX.XX 34° XX.XX XX.XX 8 6 RANGE RANGE (mm( 0 TO0 5TO .250 .250+ TO 5+ TO 20 1.000 1.000+ T 20+ TO 50 2.5 50+ 2.5+ ANGULAR ± MAT'L. MAT'L. FINISH- FINISH- REFERENCE- REFERENCE DR. BY- DR. BY- THIRD SCALE- SCALE- SUBJECT TO TOOL QUALIFICATION. DIMENSION IS GIVEN OF NOT SUBJECT TO TOOL QUALIFICATION. NOT SUBJECT DIMENSION TO TOOL IS QUALIFICATION. GIVEN DIMENSION ISNOT GIVEN SHEET FOR INFORMATIONAL/MANUFACTURING PURPOSES ONLY. FOR INFORMATIONAL/MANUFACTURING FOR INFORMATIONAL/MANUFACTURING PURPOSES ONLY. PURPOSES ONLY. MEASUREMENTS ARE REQUIRED INITIALLY FOR NEW TOOLING. MEASUREMENTS ARE REQUIRED MEASUREMENTS INITIALLY FOR ARE NEW REQUIRED TOOLING.INITIALLY FOR NEW TOOLING. DEVIATION MUST BE REVIEWED BY THE CTS SUBSTANTIAL DEVIATION MUST SUBSTANTIAL BE REVIEWED DEVIATION BY THE CTS MUST BE 0.53 REVIEWED CTS X 45vuBY 5vTHE SUBSTANTIAL >PBT-(GB20+GF20)< CORE PRODUCT TEAM TO ASSURE CORE THAT PRODUCT FUNCTION TEAM TO IS NOT ASSURE THAT FUNCTION IS CORE NOT PRODUCT TEAM TO ASSURE THAT FUNCTION IS NOT SIZE COMPROMISED. COMPROMISED. COMPROMISED. 37 ±0.15 VG 2 SHEET LIFE TESTING). THESE LIMITS APPLY THROUGHOUT LIFE TESTING). THESE LIFE LIMITS TESTING). APPLY THROUGHOUT THESE LIMITS APPLY THROUGHOUT D DR SIZE THE "INPUT SHAFT ROTATION". THE "INPUT SHAFT ROTATION". THE "INPUT SHAFT ROTATION". MISSISSAUGA, ONTARIO, CANA 51.17 ±1 8) THIS DRAWING (XX.XX) REPRESENTS THE CTS(XX.XX) RECOMMENDED 8) THIS DRAWING REPRESENTS 8) THIS DRAWING THE CTSREPRESENTS RECOMMENDED THE CTS RECOMMENDED NON-MANDATORY FEATURES: NON-MANDATORY FEATURES:(XX.XX) NON-MANDATORY FEATURES: NAME: NAME: NOT SUBJECT TO TOOL QUALIFICATION. FEATURES DEFINED NOT SUBJECT TO TOOL NOT SUBJECT FEATURES TO TOOLDEFINED QUALIFICATION. FEATURES DEFINED ANYQUALIFICATION. DEVIATION MUST MOUNTING CONFIGURATION. MOUNTING ANY DEVIATION CONFIGURATION. MUST ANY DEVIATIONMOUNTING MUST CONFIGURATION. PEDAL POSITION SE BY THESE DIMENSIONS ARE RECOMMENDED FOR TOOL BY THESE DIMENSIONS ARE RECOMMENDED BY THESE DIMENSIONS FOR TOOL ARE RECOMMENDED FOR TOOL 8X SIZE BE REVIEWEDDESIGN BY CTS ENGINEERING FOR DESIGN AND MANUFACTURING, BUT ARE NOT REQUIRED. BE REVIEWED BY CTS ENGINEERING BE REVIEWED FOR BY CTS APPROVAL. ENGINEERING FOR APPROVAL. AND MANUFACTURING, DESIGN BUTAPPROVAL. ARE ANDNOT MANUFACTURING, REQUIRED. BUT ARE NOT REQUIRED. [7]EXCEED MEASUREMENT IS NOT REQUIRED. OMISSION OF FEATURE PART NO: PART NO: MEASUREMENT IS NOT REQUIRED. MEASUREMENT OMISSION IS OF NOT FEATURE REQUIRED. OMISSION OF FEATURE [9] THE SCREW HEAD DIAMETER SHOULD NOT 8.6mm.. [9] THE SCREW HEAD DIAMETER [9] THE SCREW SHOULD HEAD NOTDIAMETER EXCEED 8.6mm.. SHOULD NOT EXCEED 8.6mm.. MUST NOT ADVERSELY AFFECT MUST PART NOT FUNCTION ADVERSELY OR AFFECT PART FUNCTION OR MUST NOT ADVERSELY AFFECT PART FUNCTION OR NO502-99-032 PART OF THIS DRAWING MAY BE O NO. OPERATION NO. NO.REQUIREMENTS. OPERATION TOOL NO. TOOL NO. DIMENSIONAL DIMENSIONAL REQUIREMENTS. DIMENSIONAL REQUIREMENTS. Japan CTS Japan, Inc. Kanagawa-ku, Yokohama 15 13 13 14 12 14 Japan Tel: (81) 45-450-2363 Fax: (81) 45-450-2241 SC R 7 ± 0.5 VIEW A 1v VIEW A Europe B.O.M. 4645 O 30.15 [1] CONNECTOR TO6317. MATE [1] CONNECTOR TO MATE [1] CONNECTOR WITH PACKARD TO ELECTRIC MATE WITH P/N PACKARD 1206 6317. ELECTRIC P/N 1206 CTS Corporation, U.K. Ltd. NO DRAFT [2] JULIAN DATE CODE [2] IN THIS JULIAN LOCATION DATE CODE IN THIS LOCATION [2] JULIAN DATE CODE IN THIS LOCATION [3] PART NUMBER IN THIS LOCATION. [3] PART NUMBER IN THIS [3] PART LOCATION. NUMBER IN THIS LOCATION. High Blantyre, Glasgow [4] CORRESPONDS TO APPROX.± 0.5°ANGULAR POSITION. [4] CORRESPONDS TO [4] APPROX. CORRESPONDS ± 0.5°ANGULAR TO APPROX. POSITION. ± 0.5°ANGULAR POSITION. O 19.08 ±0.05 [5] FIXTURE [5] FIXTURE DESIGNS TO [5]HAVE FIXTURE MODIFIED DESIGNS PILOT TO AND HAVE MODIFIED PILOT AND DESIGNS TO HAVE MODIFIED PILOT AND 4 RIBS Scotland, U.K. CLOCKING HOLES SO AS NOT TO CRUSH SENSOR CLOCKING HOLES SO AS CLOCKING NOT TO CRUSH HOLES SO SENSOR AS NOT TO CRUSH SENSOR RIBS. SEE PRODUCT ENGINEERING. RIBS. SEE PRODUCT ENGINEERING. RIBS. SEE ENGINEERING. 3.45 PRODUCT ±0.1 VG Tel: +44 (0)1698 505050 NOT EXCEED THE [6] THE INPUT SHAFT SHALL [6] THENOT INPUT EXCEED SHAFTTHE SHALL NOT EXCEED [6] THETHE INPUT SHAFT SHALL NON-MANDATORY DIMENSIONS: NON-MANDATORY NON-MANDATORY DIMENSIONS: 2:1 25.37 ±0.25DIMENSIONS: FOLLOWING END PLAY FOLLOWING LIMITS: ±0.2 AXIAL, END PLAY LIMITS: ±0.2 AXIAL, FOLLOWING END PLAY LIMITS: ±0.2 AXIAL, -B- Fax: +44 (0)1698 506050 1 1 RADIAL( ±0.4 AFTER AXIAL, ±0.2 RADIAL AFTER± 0.1 RADIAL ( ±0.4 AXIAL, ±0.2 RADIAL AFTER ±0.2RADIAL ± 0.1 RADIAL ( ±0.4 AXIAL,± 0.1 D 5v MAX. XXXX B-B 2X OSECTION 5.2 l O 0.38 M A B T C T 50+ 2.64 VIEW A O 35.58 SECTION B-B 5+ TO 20 20+ TO 50 R 23.22 2X O9 TOL. (mm) 0 TO 5 4X 1.52 -A- 4 SC LINEAR DIMENSION UNIT mm. in. DO NOT SCALE DRA 6.68 ±0.25 503 Series 3 3 NO PART OF THIS DRAWING MA REPRODUCED BY ANY MEANS WITH PERMISSION OF C CTS CORPOR AUTOMOTIVE PRODUCTS. 43.69 [2] 25° 60° NOTE: u0.5vPOINT SLOPE LINEARITY 60° u0.5 ISv±3.34% 6.68 ±0.25 1 -C- HEADQUARTERS: CTS Automotive Products O 11.23 O 11.23 1142 W. Beardsley Ave. Elkhart, IN A 46514 USA 4X 1.27 Tel: 574-389-2700 3.99 3.99 Fax: 574-295-7810 VIEW C VIEW C 5.26 ±0.05 -C- O 11.23 C PIN "A" DETAIL 4:1 PIN "A" VIEW C 2X R 6.68 5.26 ±0.05 SYM. BY CK. DATE REVISION O 5.64 O 5.64 O 5.64 A ENGINEERING RELEASE 03/01/06 VG YW l O 03/16/06 0.10 MVG A YWB 2.521%/DEG. l O 0.10 M A B T lC OM0.10 MB A PPS1 B T C MWAS PPS1 2.3529%/DEG. A4X 1.27 43.69 [2] R 17.42 ±0.25 2X R 6.68 -C- [3] 0.76[2] -B- 15° ROTOR SLOT CL [3] CLCONNECTOR 0.76 32.8° SENSOR MECHANICAL HIGH END STOP PEDAL TRAVEL ROTATION(DEGREES) 2X R 6.68 30° C O 30.38 ±0.076 4 RIBS R 17.42 ±0.25 -BR 17.42 ±0.25 2.49 3.12 DRIVE BLADE GND 2 NOTE: OVERALL AND SERIES RESISTANCE TOLERANCES ARE u35% -2.8° 0° INDEX 1.2° O 30.38-B±0.076 4 RIBS 1.27 C L 15%u2% -8.2° O 30.38 ±0.076 4 RIBS 25.8° 23.8°4X V in 2 PIN J LCONNECTOR 34.96%u2% SENSOR MECHANICAL LOW END STOP P/N 4645 30° V out 1 PIN D DRIVER TRAVEL SENSOR ROTATION P/N 4645 2.49 C GND 1 v P/N 4645 15° V in 1 1000 PPS1 2.521%/DEG. 7.5%u2% v v v ROTATION (DEGREES) v v 2° RELATIVE ANGLE PIN B PIN F v PEDAL SENSOR OUTPUT 73.4v MECH. ROTATION 2.49 4X 30vu5v v DRIVER TRAVEL SENSOR ROTATION 73.4v MECH. ROTATION LOAD CIRCUIT ECU PIN G 3900 PPS1 V OUT v O 5.64 l O 0.38 M A B T C T 15° 73.4v MECH. ROTATION ROTATION (DEGREES) 45.09 45.09 12.83 ±0.40 DRIVER TRAVEL SENSOR ROTATION v v v O 5.64 O 5.64 l O 0.38 M A B T lCOT0.38 M A B T C T B 4X 30vu5v ELECTRICAL SCHEMATIC v v PEDAL SENSOR OUTPUTPEDAL SENSOR OUTPUT -A7.52 ±0.38 3.25 ±0.38 DRIVE SLOT [9] O 8.6 45.09 ROTATION (DEGREES) v -A-16.21 ±0.5 7.52 ±0.38 v v 58.3 DIMENSIONAL DETAILS (TYPICAL): v LINEARITY u2% 0% v v APP2 7.5% u 4% LINEARITY u2% 0% v ROTOR/DRIVE BLADE INTERFACE DETAIL (AT NOMINAL) NOT TO SCALE ROTOR/DRIVE BLADE INTERFACE DETAIL 6.21 ±0.25 (AT NOMINAL) NOT TO SCALE 15% u3% APP2 7.5% u 4% LINEARITY u2% 0% 0.6371%/DEG. 0.6371%/DEG. APP2 45.8 48.3 W.O.T. 7.5% u 4% 9.4 9.4 SENSOR OUTPUT 15% u3% 1.2742%/DEG. 38.4% u 6% 0.6371%/DEG. B 100% 15% u3% CL ROTOR CL DRIVER CL ROTOR CL DRIVER 2.36 DRIVER INTERFACE DETAIL (CCW) 38.4% u 6% 1.2742%/DEG. 58.3 -5.2 C.T. -2.7 0 DATUM 2XM4.0 BOLT 9.4 l O 0.50 M A B T ROTOR/DRIVE BLADE --C-INTERFACE DETAIL 6.21 ±0.25 6.21 ±0.25 (AT NOMINAL) O 30.25 ±0.05 PILOT NOT TO SCALE --B-- [5] 38.4% u 6% -15.2 R0.76 36 ±0.052XM4.0 BOLT l 0.10 A BMTA B T BT l OT0.50 [4] --C-- 2.36 DRIVER R0.76 0.8° SERIES RESISTANCE APP1+APP2: 1K Ω u50% APP1 APP1 1.2742%/DEG. -15.2 R0.76 2.36 DRIVER CL ROTOR CL DRIVER SERIES RESISTANCE SERIES RESISTANCE APP1+APP2: 1K Ω u50% APP1+APP2: 1K Ω u50% 0.8° APP1 58.3 0.8° CL OF --B-- CL OF --B-- OVERALL RESISTANCE APP1: 5.1KΩ u35% APP2: 10.2K Ωu45% 45.8 48.3 W.O.T. 502/503/507 SERIES OF --B-- (E) APP1 GROUND (F) APP1 SIGNAL (E) APP1 GROUND (F) APP1 SIGNAL OVERALL RESISTANCE OVERALL RESISTANCE APP1: 5.1KΩ u35% APP1: 5.1KΩ u35% APP2: 10.2K Ωu45% APP2: 10.2K Ωu45% 45.8 48.3 W.O.T. -15.2 (E) APP1 GROUND (F) APP1 SIGNAL 4.19 MIN. -5.2 C.T. -2.7 0 DATUM [6] 4.19 MIN. O 9.4 ±0.2 l O 0.25 T A B T -5.2 C.T. -2.7 0 DATUM [6] 43.69 4.19 MIN. [6] O 9.4 ±0.2 B T l O 0.25 T A B T 8 2X 0.76 7 9 9 10 8 10 11 11 9 12 10 12 13 REPRODUCED BY ANY MEANS WITHOUT T PERMISSION OF C CTS CORPORATION AUTOMOTIVE PRODUCTS. 11 15 DIMENSIONING AND TOLERANCIN ASME Y14.5M-1994 1 MULTI AND SECTIONAL VIEW DRAW ASME Y14.3M-1994 0.8 ±0.28 46.44 8.5 ±0.25 THIS DOCUMENT IS UNCONTROLLED IN HARD UNLESS STAMPED "CONTROLLED COPY" IN O 4.2 DENOTES CTS INTERNAL SPECIAL C -C- O 4.81 ±0.05 LINEAR DIMENSION UNITS mm. in. 2X 0 0.56 X 45° -10 China CTS Shanghai Shanghai, 200122 P.R. China Tel: 86-21-33688630 Fax: 86-21-33688627 -A- RANGE (mm) r 0.25 0 TO 5 5+ TO 20 2X 9.83 [1] 10-WAY 2X5 150 SERIES METRI-PACK. GEOMETRY RESEMBLES PACKARD P/N 12045808 TO BE COMPATIBLE WITH PACKARD P/N 12065425. [2] PIN ALLOCATION (REFERENCE): E F 507 Series (UNUSED) PPS1 OUTPUT D G PPS2 SUPPLY PPS1 GROUND C H (UNUSED) (UNUSED) 20+ TO 50 2X 6.02 50+ 23.42 ±0.25 B J PPS1 SUPPLY PPS2 GROUND A K (UNUSED) PPS2 OUTPUT FINISH- .250+ TO 1.000 1.000+ TO 2.5 2.5+ 4616 N/A VG India 2:1 1 1 CTS Automotive, Delhi D Gurgaon - 122002 ACCELERATOR PEDAL SE Haryana, India 503-99-046 Tel: +91 14124 431133015 1 Fax: +91 124 4311100 DR. BY- XX.XX NON-MANDATORY DIMENSIONS: 4 5 6 7 8 9 All dimensions metric (mm) unless otherwise indicated 10 11 SHEET SIZE NON-MANDATORY FEATURES: 12 THIRD ANGL SCALE- NOT SUBJECT TO TOOL QUALIFICATION. DIMENSION IS GIVEN FOR INFORMATIONAL/MANUFACTURING PURPOSES ONLY. MEASUREMENTS ARE REQUIRED INITIALLY FOR NEW TOOLING. SUBSTANTIAL DEVIATION MUST BE REVIEWED BY THE CTS CORE PRODUCT TEAM TO ASSURE THAT FUNCTION IS NOT COMPROMISED. AT u523d.s01 Date: 10/5/07 Revised: 02/19/08 0 TO .250 REFERENCE- (XX.XX) 3 RANGE ( in.) MAT'L. NAME: NOT SUBJECT TO TOOL QUALIFICATION. FEATURES DEFINED BY THESE DIMENSIONS ARE RECOMMENDED FOR TOOL DESIGN AND MANUFACTURING, BUT ARE NOT REQUIRED. MEASUREMENT IS NOT REQUIRED. OMISSION OF FEATURE MUST NOT ADVERSELY AFFECT PART FUNCTION OR DIMENSIONAL REQUIREMENTS. 2 GENERAL TOLERANCE 0.15 0.2 0.3 0.5 ANGULAR ± 9.5 ±0.25 3 ALL DIMENSIONS ARE METRIC UNLESS OTHERWISE NOTED. [4] CTS P/N AND MATERIAL IDENTIFICATION LASER ENGRAVED IN THIS AREA. [5] CTS DATE CODE HEAT STAMPED IN THIS AREA.. 6 CUSTOMER PROVIDED MECHANICAL INTERFACE MUST CONFORM TO CTS DWG 503-61-006 [7] MATERIAL IDENTIFICATION IN THIS LOCATION. 1 DO NOT SCALE DRAWIN TOL. (mm) PART NO: NO. 13 OPERATION TOOL NO. OF R AU PR MISSISSAUGA, ONTARIO, CANADA