MC200 Joystick

Personality

User Manual

Hardware: MC200
1090449,1090449 (100mA)
1090450,1090450 (240mA)
1090451,1090451 (2 A)
1090745 (2.5 A)
Software: S0371200, S0599200
Changes:

Version No. Rel. Date Changes Name

Rev. 1.00 07 Feb 00 - T. Braun
Rev. 1.01 19 Oct 00 Update related to new WebGPI objects, T. Braun
DualProfObj instead of Prof2Obj

Rev. 1.01A 20 Aug 01 Revised Blink Code Translation T. Braun

Rev. 2.00 30 Sept 01 PDA/HC08A Upgrade A. Minar

Table of Contents:

1. User Manual Description ........................................................................... 4

1.1. Picture of MC200 ................................................................................................. 4
2. Description Of Operation .......................................................................... 5
2.1. Inputs/Outputs...................................................................................................... 5
2.2. Basic Operation ................................................................................................... 5
2.3. System Block Diagrams ....................................................................................... 6
3. Configuration and Tuning ......................................................................... 7
3.1. First Configuration on a Prototype Machine Model .............................................. 7
3.2. First Calibration on an Individual Machine ........................................................... 7
3.3. Calibration............................................................................................................ 8
3.3.1 Bi-directional joystick .............................................................................................................8
3.3.2 Valve current threshold ...........................................................................................................8
3.3.3 Disconnecting Sensors.............................................................................................................8
4. WebGPI Screens ........................................................................................ 9
4.1. Title Screen.......................................................................................................... 9
4.2. Main Run Screens ............................................................................................. 10
4.3. Common Buttons ............................................................................................... 11
4.4. System Configuration......................................................................................... 11
4.5. Input Screens..................................................................................................... 12
4.6. Control Screens ................................................................................................. 13

MC200 Joystick Personality 2 Table of Contents

 4.6.1 Profile Setting Parameter.......................................................................................................13
4.6.2 Acceleration / Deceleration Statemachine .............................................................................14
4.7. Output Screens .................................................................................................. 15
4.7.1 Valve Object..........................................................................................................................15
5. Troubleshooting Guide............................................................................ 16
5.1. Troubleshooting Procedure................................................................................ 17
6. Fault Codes .............................................................................................. 18
6.1.1 Description of Blink Code Algorithm ...................................................................................18
6.1.2 Blink Code Translation..........................................................................................................19
7. System Wiring .......................................................................................... 20
7.1. Wiring Guidelines............................................................................................... 20
7.2. Wiring Diagram .................................................................................................. 21

MC200 Joystick Personality 3 Table of Contents

1. User Manual Description
This document describes how to configure and operate the MC200 Joystick Personality. It is intended for
use by the customer and it is maintained by Sauer-Danfoss.
This User Manual does not contain hardware or electrical specifications.

1.1. Picture of MC200

MC200 Joystick Personality 4 Section 2: User Manual Description

2. Description Of Operation
This section describes, in both text and block diagram form, how the MC200 Joystick Personality operates.

2.1. Inputs/Outputs
Analog Inputs Analog Outputs
1) Command input x-axis 1) Valve driver x-axis
three position sensor PWM frequency between 33 and 200 Hz
2) Command input y-axis 2) Valve driver y-axis
three position sensor PWM frequency between 33 and 200 Hz
3) Force Calibration Command

Digital Inputs Digital Output

1) Aggressiveness x-axis
2) Aggressiveness y-axis
3) Output Disable
4) Max. output limitation x-axis
5) Max. output limitation y-axis

2.2. Basic Operation

The MC200 Joystick Personality is designed for dual axis joystick control applications. The application is
based on two bi-directional joystick inputs which are processed individually for an open loop control of
two bi-directional valve outputs (x-/y-axis). The output current is hardware configurable up to 2 amps. The
Sauer-Danfoss WebGPI service program provides for a comfortable parameter setting and monitoring
capability as well.
The following sections refer to the blockdiagram of the MC200 Joystick Personality on the following page.
The analog sensor, i.e. joystick or handle, drives the input voltage between 0 and 5 volts. This voltage will
be used as an input to a Pot3Object to determine a percentage command and a direction.
A digital input (Max. Output Limitation) is provided to turn this actual percentage command to the
maximum command. The new setting will be activated after returning the input command to zero. This
can be done to achieve a higher resolution of the input command in case that the full output range is not
needed. To remove this limitation, the Max. Output Limitation switch should be pressed when the
joystick command is zero.
There is an Output Disable switch to activate or deactivate the outputs depending on the system
configuration. When the button is pushed while the outputs are active, the percentage commands will be set
to zero. To restart the operation, the Output Disable input hast to be switched off again. The switch can
be used e.g. to realize an emergency stop functionality.

MC200 Joystick Personality 5 Section 2: Description Of Operation

The profile of the percentage command is adjustable with a digital input (Aggressiveness). One of two
configurable profiles can be selected. Whenever the switch is actuated, the percentage command will be
adjusted immediately to the new setting - without returning the input to zero before. The output value of
the profile block is still a command in percent.
The profiled percent command is then input to an Acceleration/Deceleration Statemachine where it is
processed by a linear ramp function. Depending on changes of the input command and the direction signal,
the ramps time constant will be adjusted to preconfigured values for acceleration, deceleration and
different states like Forward, Reverse etc. The output is ramped to zero if the Output Disable switch goes
to off, if the neutral direction is commanded, or if there is a fault. After any such condition, both joysticks
have to be returned to a position where the inputs are zero before the outputs are enabled again.
Finally there is a Valve object to convert the percentage command and the direction into a current
setpoint for the output driver. The valve thresholds are preset with a certain value in the paramter menu of
the corresponding object. There is also the option to force a valve calibration by holding the Force
Calibration switch during power up the unit or by selecting the Set All Defaults function of WebGPI.

2.3. System Block Diagrams

Max Output
Limitation X-Axis Max
X-Command
Set Max Percent
Output
Percent

Scaled
Profiled Rate Limited
X-Command X-Command Current Actual
Joystick X-Command X-Command
Percent Percent Y-Command X-Current
% 1 Percent Percent
X-Axis X mA mA
Y

Pos X-Command 1
I
Pot3DB Direction Profile2 X
Acc/Dec Valve
Profile X-Axis State Rate Limited
X-Command
Direction

Output Disable

System
Force Valve Calibration Config.

Max Output
Limitation Y-Axis Max
Y-Command
Set Max Percent
Output
Percent

Scaled
Profiled Rate Limited
Y-Command Y-Command Current Actual
Joystick Y-Command Y-Command
Percent Percent Y-Command Y-Current
% 1 Percent Percent
Y-Axis X mA mA
Y

Pos Y-Command 1
I
Pot3DB Direction Profile2 X
Acc/Dec Valve
Profile Y-Axis State Rate Limited
Y-Command
Direction

MC200 Joystick Personality 6 Section 2: Description Of Operation

3. Configuration and Tuning
This section describes what needs to be configured and how to configure the MC200 Joystick Personality.

3.1. First Configuration on a Prototype Machine Model

This section describes how to configure the MC200 Joystick Personality for specific machine model. The
configurations can be saved and made into the defaults for a machine model. WebGPI is required to
perform most of the actions.
1. Apply power to the MC200 and establish connection to WebGPI service program. It is not necessary
to have the machine running yet.
2. Set the default parameter by pushing Set All Defaults.
3. Calibrate both joystick inputs like it is described in the following section.
4. Open Input, Control and Output folder one after another and step through all parameter settings to
check the defaults.
5. Disconnect WebGPI if changes are made and restart the MC200.
6. Connect WebGPI again and start the machine.
7. Calibrate the valve drivers like it is described in the following section.
8. Run the application and and make parameter adjustments with WebGPI as needed.
9. To create a hexfile with the new default parameter settings push the corresponding WebGPI button.

3.2. First Calibration on an Individual Machine

Once the defaults have been established from the previous section, there is only a few steps to calibrate the
MC200 Joystick Personality for each machine.
Note: This process can be done without running the WebGPI serviceprogram.
1. Apply power to the MC200. It is not necessary to have the machine running yet.
2. Calibrate both joystick inputs like it is described in the following section.
3. Start the machine.
4. Calibrate the valve drivers like it is described in the following section.

MC200 Joystick Personality 7 Section 3: Configuration and Tuning

3.3. Calibration
This section describes how to calibrate the MC200 Joystick Personality.
The only sensors which have to be calibrated are the two analog inputs for the joystick commands. All
other analog inputs are used as a switch and do not require any calibration.

3.3.1 Bi-directional joystick

The message Not Calibrated on the WebGPI screen indicates, that a calibration of an analog input
command is required. To calibrate a three position sensor (e.g. joystick) the following three actions must
be performed in any order:
Hold the sensor in the neutral position for at least three seconds.
Hold the sensor in the maximum position for at least three seconds.
Hold the sensor in the minimum position for at least three seconds.
The message Not Calibrated on the WebGPI will disappear when all three positions correspond with the
parameter settings of the joystick input (Pot3 Object). In case that the calibration fails, the voltage range
of the analog input has to be checked.

3.3.2 Valve current threshold

The message Not Calibrated on the WebGPI screen indicates, that a calibration of a current threshold is
required. To calibrate the current thresholds, press and hold the Force Calibration input during start-up.
Release the switch after the machine is running. Then slowly increase the command of the corresponding
joystick in forward direction until a movement just begins to occur. Now press the Force Calibration
switch to store the present output current as the new threshold value. The same procedure has to be
repeated for the threshold current of the reverse direction. The message Not Calibrated on the WebGPI
will disappear after both directions are calibrated.

3.3.3 Disconnecting Sensors

If a sensor is disconnected while the power is still on, a fault is indicated by the red Status LED (See
Fault Codes). In addition, the calibration points are set to zero and the calibration state is changed to
uncalibrated. When the sensor is reconnected, the calibration procedure needs to be repeated in order to
put the sensor back into the calibrated state.

MC200 Joystick Personality 8 Section 3: Configuration and Tuning

4. WebGPI Screens
This section explains all screens specific to the MC200 Joystick Personality. For help with general
WebGPI screens, see the WebGPI User Manual.

4.1. Title Screen

This is the screen that appears when the micro is connected and the Application button is pressed. The
table of contents is shown here with all folders open. Each clickable item will be explained one by one in
the following sections.
A click on the Main item opens the main run screen where all important system variables are displayed.
The parameter screens have online help. Simply click the Help Disabled option in the Choice menu and it
will switch to Help Enabled. Now when the user enters a parameter screen and moves the mouse over a
variable input box or variable name, text will pop-up to describe the variable and/or its units of measure.
The Set All Defaults option in the Choice menu will set all changeable parameters to the factory defaults.
Any changes made in any of the screens will be lost.

MC200 Joystick Personality Section 4: WebGPI Screens

4.2. Main Run Screens
The Main Run screen consists of the system block diagram and boxes with values updated continuously.

This screen gives an overview of all important system variables. Each value can be selected for the
datalogging function with a single mouse click on the field. Use the View pulldown menu to get to the
datalogging screen. The data can be stored on the harddisk for further investigations (e.g. with Excel).

MC200 Joystick Personality 10 Section 4: WebGPI Screens

4.3. Common Buttons
There are three buttons that are common to most adjustment screens, and they are only described here:

, , and . The SetDefaults button resets all values in the current

adjustment screen to the factory defaults. The Get button retrieves the current values from the controller
(this is usually done automatically). The Send button sends the values displayed on the adjustment screen
to the controller.

4.4. System Configuration

The configuration screen provides for different settings related to the specific functionality of the
application. Both outputs have this screen in common. All other settings can be adjusted individually.

PWM Frequency (Hz): The PWM output frequency can be adjusted between 80 and 200Hz
Load Resistance X-/Y-Axis It is possible to adjust the load resistance individually for each axis; it is
always recommended to use the defaults for standard valves; In that case
the software determines the load resistance depending on the MC200
hardware configuration.
Output Disable Switch The logic of the Output Disable switch can be changed between Active
On and Active Off.
Axis related to Output Depending on the customer requirements it is possible to select the outputs
Disable which can be disabled with the Output Disable input. If only one output
is selected in this menu, the other one will be always enabled by default.
Max Available Current The maximum available current is a read only value that shows the
(mA): maximum current the controller is able to produce depending on the
hardware configuration.

MC200 Joystick Personality 11 Section 4: WebGPI Screens

4.5. Input Screens
The two available input screens allow access to the input object parameters (e.g. x- and y-joystick).

The top three rows contain the calibration ranges in volts for each position of the command input. Only the
first and third columns should be modified, the center column values are filled in by the micro during the
calibration procedure. For example in the high side row, the 100% forward value will be calibrated
somewhere between 3.9 And 4.9 volts, currently 4.5.
The neutral deadband is the voltage on each side of the neutral calibration point where the state is still
considered neutral. Fault detection time is the amount of time in seconds that a fault must be present
before a fault is declared. The fault status is displayed in the lower left corner of the table. The upper and
lower deadband percents are the ranges of voltage where the output is 100%. This can be used to ensure
maximum output is reached, even if the input doesn't quite reach the high side calibration value.

MC200 Joystick Personality 12 Section 4: WebGPI Screens

4.6. Control Screens

4.6.1 Profile Setting Parameter

Control screens allow access to control object parameters.

The parameters in this menu are used to adjust the profile of the command input. There are two different
profile settings available. The breakpoints can be set individually by changing the numbers in the red or
green fields respectively or by using the standard drag and drop mouse function on the plots in the
diagram. The brekpoint values in the table will be adapted automatically if the mouse dragging is used.
An external input is used to switch between the two profiles. If the input is disabled, the parameter setting
for Profile 1 is active.
Note: The profiles can be switched while the system is running. Aggressive parameter settings could cause
unexpected machine behaviour.

MC200 Joystick Personality 13 Section 4: WebGPI Screens

4.6.2 Acceleration / Deceleration Statemachine
The Accel/Decel State Machine parameters affect the acceleration and deceleration of the machine.

Here the acceleration and deceleration rates are set up for all conditions. The values are in milliseconds
and refer to time from 0 to maximum output for accel and time from maximum to 0 output for decel. So if
a time of 2000 milliseconds (2 seconds) is selected for accel, it will take 1 second to get to 50% output and
2 seconds to get to 100%.
There are default values that can be loaded with Set Defaults button. The Send and Get buttons send and
load data to and from the micro. The Start Realtime button displays the actual in- and outputs of the
object.in the blockdiagram. The button then turns to Stop Realtime (see above).

MC200 Joystick Personality 14 Section 4: WebGPI Screens

4.7. Output Screens

4.7.1 Valve Object

X Input Min (per million): Minimum input command. Do not change.

X Input Max (per million): Maximum input command. Do not change.
Y Output Max (mA): Maximum output current. This value should not exceed the max possible
current displayed in the valve configuration table.
Theshold (mA): Threshold current is the value in milliamps where the output starts to have
an effect on the device it is controlling. These values can be automatically
calibrated.
Fault Detection Time (s): Fault detection time is the length of time a fault must be present before it
is declared
Error Theshold (mA): The valve error check is only active if the output current is greater than the
error threshold
Error Percent (%): The error between setpoint and actual current has to be greater than the
error percent of the setpoint to indicate a valve error.
Status The status of the valve object is displayed in the lower left corner of the
table. In case that the error check routine realizes an open circuit the status
will change to Out Of Range.

MC200 Joystick Personality 15 Section 4: WebGPI Screens

5. Troubleshooting Guide
This section outlines a strategy that can be used to solve problems in the control system. A common
technique used in problem-solving is exchanging components. However, a very important element
necessary to the timely and successful conclusion of this activity is the correct selection of the
malfunctioning component. A thorough understanding of the entire system and an elimination process
leading to the malfunctioning component is absolutely necessary before starting the exchange activity.

Reduce the random exchange of components by carefully analyzing the symptoms, and then conducting
tests to determine which of the elements in the system is likely to be the problem. The technician should
use the flow chart below as a guide to locate the problem.

Since it is new, the electronic controller is often the first component targeted for exchange. However, the
malfunction of an electronic controller is extremely rare and, therefore, it should be the last component
considered for replacement. In fact, the electronic controller has an internal ability to diagnose itself and
the connections attached to it. This information can be very helpful in finding the problem area. If the
electronic controller is responding to commands and not giving diagnostics that indicate an internal
problem, the likelihood that the problem is internal to the electronic controller is remote.

MC200 Joystick Personality Section 5: Troubleshooting Guide

5.1. Troubleshooting Procedure

All other
System function No Controller Type Power Led On System Led
Controllers

DC2, S2X Off Off

Abnormal

On Power Led

Off On
Check Power
OK Replace Controller Solid Off or
to Controller
Solid On
Status Led

ON
Off
Mode Led
Blinking
Off Status Led
0.5 Hz

See description of
display codes Spare
Blinking
controller Blinking
Code
available? 10Hz
Yes
No

Check all
external
switches w/
Blinking
Spare
Code No application
controller
Not OK See description of loaded. Download
blink algorithm in application or
next section replace controller.

Check all
OK Fix external external
Not OK
switches switches w/
voltmeter

Check
hydraulic OK
system

Generic Trouble
Not OK Shooting procedure

OK

Need to Connect
to PC with Fix hydraulic
WebGPI for online system
diagnostic

MC200 Joystick Personality 17 Section 5: Troubleshooting Guide

6. Fault Codes
When the controller detects a fault condition, it signals the specific fault using the red Status LED and the
yellow Mode LED (shown below). Under normal conditions with no error present, the red LED is off and
the yellow LED blinks at a 1 Hz rate. If no application code is loaded in the controller, the red LED is off
and the yellow LED blinks at a 10 Hz rate. All other errors (those specific to the application) are decoded
by observing blink codes generated by the red and yellow LEDs.

Yellow LED (Mode) Red LED (Status) System Status:

10 Hz blink rate Off No application loaded
1 Hz blink rate Off Application loaded and no error
1 Hz blink rate 4 bit blink code to describe fault Application loaded and error

6.1.1 Description of Blink Code Algorithm

If the yellow LED blinks at an unvarying 1 Hz rate and the red LED is blinking, the cause of the fault can
be decoded from the red LED alone as follows:
The red LED will flash a four bit sequence, followed by a pause, followed by the four bit sequence, the
pause, and so on. The long flash, symbolized by a -, lasts approximately one second. The short flash,
symbolized by a , lasts approximately one-half second. The pause between the four bit sequence lasts
approximately 3.5 seconds. If more than one fault exists, each fault will be displayed in sequence before
being repeated.

MC200 Joystick Personality Section 6: Fault Codes

 6.1.2 Blink Code Translation

Fault Flash Bit Device at Fault Cause of Fault Machine Response

Code Sequence
1 Bi-directional command input Voltage signal is out of No current will be driven on
for x-axis range or input is not neither output until fault is
calibrated. cleared.
2 Bi-directional command input Voltage signal is out of No current will be driven on
for y-axis range or input is not neither output until fault is
calibrated. cleared.
3 Valve output driver of X-axis Valve output is not Output current is ramped to
calibrated or output current zero; Output will be disabled
out of range due to an open until fault is cleared out.
or short-circuit
4 Valve output driver of Y-axis Valve output is not Output current is ramped to
calibrated or output current zero; Output will be disabled
out of range due to an open until fault is cleared out.
or short-circuit
= short flash
= long flash

MC200 Joystick Personality 19 Section 6: Fault Codes

7. System Wiring

7.1. Wiring Guidelines

1. Protect all wires from mechanical abuse. Wire can be run in flexible metal or plastic conduits.

2. Use 85C wire with abrasion resistant insulation. 105C wire should be considered near hot
surfaces.

3. Use #18 gauge wire or greater. #14 or #16 wire is preferred.

4. Separate high current wires such as solenoids, lights, alternators, or fuel pumps from control
wires.

5. Run wires along the inside of, or close to, metal machine frame surfaces where possible. This
simulates a shield, which will minimize the effects of EMI/RFI radiation.

6. Do not run the wires near sharp metal corners. Consider running the wire through a grommet
when rounding a corner.

7. Do not run wires near hot machine members.

8. Provide strain relief for all wires.

9. Avoid running wires near moving or vibrating components.

10. Avoid long, unsupported wire spans.

11. Twist all sensor lines. (About one turn every 4 inches or 10 cm.)

12. Use harness anchors which will allow wires to float with respect to the machine frame rather
than rigid anchors.

MC200 Joystick Personality 20 Section 7: System Wiring

7.2. Wiring Diagram

MC 200
Packard Connector

Battery + A1
A
Sensor Power A2 Forward Coil
X-Axis
B
Battery - A3
Terminals (+) C
Reverse Coil
Valve 0 + B1 Sensor
X-Axis
D
Valve 0 - B2
A
Valve 1+ B3 Forward Coil
B
Y-Axis
TxD C1
C
RxD C2 Reverse Coil
Y-Axis
D
Boot C3 125

Analog In 0 D1
Joystick X-Axis

1K
Analog In 1 D2
125

Digital In 3 D3 125

Digital In 4 E1
Joystick Y-Axis

1K
Analog In 2 E2
125

Valve 1- E3
Output Enable
Digital In 0 F1

Digital In 1 F2
Max Output
Digital In 2 F3
Limitation X-Axis

Max Output
Limitation Y-Axis

Profile X-Axis

Profile Y-Axis

Terminals (+)

Force
Ignition Calibration
Fuse 4A

1
2
3
Diagnostic Connector
4
(Sub-D, 9pin, socket)
5 DB9
6
Terminals (-) 7
8
Battery
9
12/24V

K28406

MC200 Joystick Personality 21 Section 7: System Wiring