1 © blue graphics concept sauer-danfoss plus+1 service tool training 1

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© Blue Graphics Concept Sauer-Danfoss


PLUS+1 Service Tool Training

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Who is who?

• Name• Company• Position• Programming skills• Experience with PLUS+1• Projects

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• This is PLUS+1• Programming example• Example system (what can we test?)• Things to check, how and in what order• CAN, Terminating resistor, CG150• Service Tool Overview

– Safety– CG150 and connection– Checking the MC controller I/O

• Deutch Pin crimping and disconnection

Agenda

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PLUS+1 Controls Platform

Productivity and Performance

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PLUS+1 Controls Platfrom

Content

• Introduction

• Market Trends

• Product and System Information

• Unique Product Features and Benefits

• Key Applications

• Product Literature and Support

• Summary

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• Introduced in 2004

• Growing family of microcontroller and software solutions

• High power family of 12, 24, 38, 50 and 88 pin controllers and I/O modules

• Graphical programming environment


Introduction

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PLUS+1 Family

12-pin 24-pin 38-pin 50-pin 88-pin

Controllers MC012-010 MC024-010 MC038-010 MC050-010 MC088-015

MC024-020 MC050-020

MC050-055

I/O Modules IX012-010 IX024-010

OX012-010 OX024-010

IOX012-010 IOX024-020


Introduction

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• Machine Productivity. Automation of functions to create more efficient vehicles

– Work faster, longer– Less fuel consumption– Engine emission regulation driven advancements

• Development Productivity– More work with smaller design teams– Faster time to market, shorter design cycles– Modularity to increase reuse of designs


Market Trends - Productivity

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• Machine Performance. Ability to differentiate operational functionality

– Smooth, accurate controls– Maximize drive and work output– Comfortable working environment

• Microcontroller Performance– More processor capability required for complex applications– Accurate current controlled outputs– Ability to communicate with multiple subsystems– Software becomes key to machine performance and

differentiation


Market Trends - Performance

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Product and System Information

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• PLUS+1 microcontrollers offer a high performance, rugged platform for machine control

– 150Mhz Texas Instruments DSP processor core

– IP67 enclosure for dust and water ingress protection

– 2 LEDs for visual diagnostics

– Deutsch® electrical connectors

– Multiple mounting configurations


Product and System Information

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Rugged Design for Mobile Off Highway Use

• Temperature range: -40C to +70C• Ingress protection: IP67• Shock: 100g, 6ms, 3 shocks in each of 6 directions• Vibration: 5g RMS, 3 directions (x,y.z)• EMC protection: to 100V/m• Deutsch electrical connectors• CE marked


PLUS+1 Hardware Family

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• PLUS+1 Microcontroller Family



Inputs* Outputs* Optional Features

Product FamilyRated

Current Timing Digital Analog RheostatPWM

(3A max) PVGDigital

(3A max)Application

Keyed Other

MC012-01x 8A 3 3 4 - 2 2 2 Yes High Temp

MC024-01x 8A 5 11 8 2 3 3 3 Yes +Memory

MC024-02x 24A 5 7 6 - 8 8 8 Yes +Memory

MC038-01x 70A 3 14 13 - 8** - 13** Yes -

MC050-01x 40A 6 12 12 4 6 6 12 Yes +Memory

MC050-02x 40A 6 20 14 2 6 6 14 Yes +Memory

MC050-05x 8A 4 33 36 - 2 2 3 Yes ISOBus

MC088-01x 100A 6 32 24 8 32** 10 10 Yes -

* Maximum number available through multi-function configurability ** High Current Outputs available

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• Stand alone applications– PLUS+1 controller effective as stand alone control

solution

• Networked solutions– CAN communications facilitates distributed

architecture– Place control near I/O– I/O modules easily extend control



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• PLUS+1 Input/Output Modules

– Expand the input and output capabilities of a PLUS+1 controller

– Preconfigured CAN messaging makes it easy

– Variants with• Inputs only• Outputs only• Combination of inputs and outputs



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• PLUS+1 I/O modules



Inputs* Outputs*

Product FamilyRated

Current Timing Digital Analog RheostatPWM

(3A max) PVGDigital

(3A max)

IX012-010 - 3 3 6 2 - - -

OX012-010 16A - - - - 6 6 6

IOX012-010 8A 3 3 4 - 2 2 2

IX024-010 - 7 13 12 4 - - -

OX024-010 32A - - - - 10 10 16

IOX024-020 24A 5 7 6 - 8 8 8

* Maximum number available through multi-function configurability

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• Summary:

– Powerful controls for even the most complex applications

– Large family of controllers and I/O modules to match the requirements of the machine

– Rugged design for mobile off-highway use

– Modular CAN based architecture is scaleable to the needs of the application



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• Program logic and signal flow is easily visualized in GUIDE

• Drag, drop, and connect graphical modules on the programming workspace

• Save, and then download your new application to a PLUS+1 controller or display


GUIDE Development Environment

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• Modular software design for maximum flexibility

• Manipulate data at bit level or combine high level functionalities

1. Boolean logic and math functions

2. Filters, PID controls, output drivers

3. Dual path control, automotive control

• Graphical design environment reduces need for formal programming training



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• Description here



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• Sauer-Danfoss provides an extensive software library at each level of programming

• Leverage SD’s application knowledge to create best in class solutions

• Add additional features to create differentiated solutions

• Flexible enough to interface with most any vehicle subsystem or secondary component



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Components (GUIDE)Components (GUIDE)

Function Blocks (GUIDE)Function Blocks (GUIDE)

Compliance Blocks (GUIDE)Compliance Blocks (GUIDE)

Subsystem ApplicationsSubsystem Applications

Vehicle SolutionsVehicle Solutions

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22

33

55

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Application BlocksApplication Blocks44

Math, Logical, Limit, Compare, CAN, E2

PID, Ramp, Filter,PWM Drivers, FNR Switches

PVE, Joystick, Motors and

Pump actuators, Sensors

Core and Plug-ins for Dual Path, Automotive, Hitch, etc.

Integrated, CAN-connected Sub-systems

Dual Path

EDC

Joystick

Included in GUIDEIncluded in GUIDE Keyed ApplicationsKeyed Applications

Dual Path, Automotive,Fan Drive, Transit mixer

Custom Product Custom Product

Dual Path

EDCDual Path

Core Block

Propel Sub-system

Joystick

E DC Dual Path

EDCSteering

Core Block

Steering Sub-systemSensors

Va

lves

Multiple projects, CAN connections

Dual Path

EDCCore

Block

Sub-system softwareJo

ystick

E DC

Ramp

Ramp

AND

Easie

r C

on

trol S

yste

m D

evelo

pm

en

t


Application Software Solutions

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• Fundamental elements for creative graphical programming

• Build your own objects, and create CAN messages

Components - Basic logical building blocks



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• Library of pre-engineered, generic control objects

• User configurable for maximum versatility

Function blocks – Higher level controls



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• Library of pre-engineered, application solutions

• Result of years of Sauer-Danfoss control experience

Application blocks – Core “application level” control



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• Application Blocks– Contain proprietary Sauer-Danfoss

control logic for programmable GUIDE applications

– These blocks are keyed to Application Hardware (keyed blocks can only be downloaded to Application Hardware)

– Content is locked from view

• Plug-ins– Plug-ins can be added to core

Application Blocks by developers– They provide optional functionality or

performance– Plug-ins are also keyed to Application

Hardware

“Core” Application Blocks and Plug-ins

Application Block

(.SCS file format)

Plug In

(.SCS)Keyed Blocks

Inside the

Application

Block



Plug In

(.SCS)

Plug In

(.SCS)

Plug In

(.SCS)

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OK

Standard priced hardware

If the application software key matches the Sauer-Danfoss hardware key, installation to Application Hardware is allowed.

If software keys are not detected, the application may be installed in standard priced hardware.

STOP

Keyed software blocks can only be loaded onto keyed Application Hardware

Keyed Application Hardware

Subsystem Application for PLUS+1 Application Hardware programming template (.P1P file format)

Subsystem Application portable to other PLUS+1 controllers, applications (.SCS file format)

Application Block

(.SCS file format)

Input

Map

Fault Handler, Calibration, other supporting functions

Input

Conditioning Blink

Code

BlockPlug In

(.SCS)

Output

Drivers

Output

Map

Keyed Blocks

Inside the

Application

Block

Plug In

(.SCS)

Plug In

(.SCS)

Plug In

(.SCS)(GU

IDE

Pro

gram

mab

le)

(GU

IDE

Pro

gram

mab

le)

(GU

IDE

Pro

gram

mab

le)

(GU

IDE

Pro

gram

mab

le)

(GUIDE Programmable)

(GU

IDE

Pro

gram

mab

le)



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Subsystem Applications• Complete application software solution• Facilitates rapid development of machine controls• Tested solutions manage development risk• GUIDE is used to tailor the application for vehicle requirements



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• Specific PLUS+1 products, characterized by Compliance Blocks

• Tested, fast and convenient to use, documentation included

PLUS+1 Joystick, CAN outputPLUS+1 Pressure Sensor

Compliance Blocks - Software blocks for PLUS+1 products


PLUS+1 Compliance

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Over 40 PLUS+1 Compliance Blocks:

Pumps, motors, valves, sensors, displays and HMI products are represented in software, tested and optimized by Sauer-Danfoss

Example: Optimized Pump Tuning

0.00 0.150.05 0.200.10 0.25 0.350.30 0.40 0.45

Sw

as

hp

late

An

gle

Time (mS)

Non-optimized tuning parameters

Optimized tuning parameters stored in Compliance Block


PLUS+1 Compliance

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• PLUS+1 Compliance Blocks:

– Shorten development time

– Provide a tested solution

– Ease start-up issues

– Provide optimized performance


PLUS+1 Compliance

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• Use Service Tool to download your GUIDE application to the PLUS+1 controller

• Monitor, view and adjust parameters

• Use Designer Service Tool to build custom screens

PC to CANbus Gateway


Service Tools

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• Fully customizable service solutions

– Add ‘check points’ at any place in the application

– Design PC screens to meet the need of the user (developer, service technician, etc.)

– Password access capabilities

– CAN bus interface provides access to all controllers in a system

– .dll option for OEM service tool integration


Service Tools

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• PC based service tool uses USB to CAN communication– CG150 USB – CAN gateway– USB ports on DP210, DP250 or DP600 displays


PC Communications

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Key Applications

• Ideally suited for mobile off-highway equipment

• Flexible enough for many control system needs

• Stand alone control or CAN based distributed controls

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• Technical Information• Data Sheets


Product Literature

• Family Brochure

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• Application software Library

• PLUS+1 Compliance

• Documentation

• eLearning

• Classroomtraining

• Email support &web site FAQ

• Helpdesk telephone support

Components (part of GUIDE)Components (part of GUIDE)

Function Blocks (Library)Function Blocks (Library)

Compliance Blocks (Library)Compliance Blocks (Library)

Sub-system ApplicationsSub-system Applications

Vehicle Solutions (R&D)Vehicle Solutions (R&D)

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PVE, Joystick, ED Motors, H1 Pump, Sensors


Integrated, auto CAN-connected Sub-systems

Dual Path

EDC

Joystick

ReleasedReleased In DevelopmentIn Development


R&D ProjectR&D Project

Dual Path

ED

CDual PathCore Block

Propel Sub-system

Joystick

ED

C

Dual Path

ED

CSteeringCore Block

Steering Sub-system

Sensors

Valves

Multiple projects, automated CAN connections

Dual Path

ED

C

Core Block

Sub-system software

Joystick

ED

C

RampRamp

AND

Easie

r C

on

trol S

yste

m D

evelo

pm

en

t

Components (part of GUIDE)Components (part of GUIDE)

Function Blocks (Library)Function Blocks (Library)

Compliance Blocks (Library)Compliance Blocks (Library)

Sub-system ApplicationsSub-system Applications

Vehicle Solutions (R&D)Vehicle Solutions (R&D)

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22

33

55

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PVE, Joystick, ED Motors, H1 Pump, Sensors


Integrated, auto CAN-connected Sub-systems

Dual PathDual Path

EDC

Joystick

EDC

Joystick

ReleasedReleased In DevelopmentIn Development


R&D ProjectR&D Project

Dual Path

ED


Propel Sub-system

Joystick

ED

C

Dual Path

ED

CSteeringCore Block

Steering Sub-system

Sensors

Valves


Dual Path

ED


Propel Sub-system

Joystick

ED

C

Dual Path

ED

CSteeringCore Block

Steering Sub-system

Sensors

Valves


Dual Path

ED

C

Core Block

Sub-system software

Joystick

ED

C

Dual Path

ED

C

Core Block

Sub-system software

Joystick

ED

C

RampRamp

RampRamp

ANDAND

Easie

r C

on

trol S

yste

m D

evelo

pm

en

tEasie

r C

on

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yste

m D

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PLUS+1 Tools


Product Support

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• Self-paced GUIDE programming training, always available on line

• E-learning supplements, or substitutes for available classroom training

• Develop and save virtual applications on line without a GUIDE license


Product Support – On-line Training

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Summary

• High power family of 12, 24, 38, 50 and 88-pin controllers and I/O modules

Scalable for any application

• GUIDE graphical programming environment Customizable software solutions

• Extensive Sauer-Danfoss application software library For best in class performance and fast time to market

• Full array of product support options Your strongest partner for machine controls

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PLUS+1 GUIDE Training

• Set up Software and Hardware• Prepare and make a new program• Set up Service Tool• Set up a diagnostic file

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Software

• Download from www.sauer-danfoss.com • Run “PLUS+1 GUIDE……setup.exe”• Starting at V4.0 you can now have multiple versions of

GUIDE installed

http://www.sauer-danfoss.com/

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License

• Go to: Tools>License Manager• Use Help• License types:

– Full license– Service Tool Design license– Service Tool built in license (for download and debugging)

• Each user can use the license on a desktop and a laptop.

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Side panels and compiling messages

Select pop-up or fixed panels by clicking here.

Enable/disable panels here.

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Setup a new project (program)

• Create a new project• Select hardware• Load the template

– An “empty” program that compiles– All inputs and outputs available

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New project

• Go to: File>New

Type in a name for your project.

Create a new unique folder for each project created.

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Install Hardware Files

• Go to: Setup>Install Hardware• Categories of Hardware files (.hwd):

– Programmable• Controllers• Displays• Inverters

– Non programmable• I/O modules• Compliance blocks

• Install all for a category with a .PAC-file.

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Install Function Libraries

• Go to: Setup>Install Function Library

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Select hardware

Right click

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Load template

• All graphical files has got .SCS as extension

Right click

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Setting the backup interval

• Go to: Setup>Options

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Options, Shortcuts

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Bus and page

A bus. Contains many signals (wires)

A page. Usually made with blue lines

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Top view pages in the template

Joystick, pressure sensor etc

The program Valves, lamps etc

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Node number for Service Tool

Node number for Service Tool

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Components

• The smallest part of a program• To get help

1. Highlight the component2. Press F1

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Where can I get help?

• Help Contents and User Manual has got the same info

Pdf-format

Opens Help Contents

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Documents in the Hardware file

• Data sheet• Application Programming Interface Specification (API

Specification)

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Data sheet

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Input types

Type Range Max input

Value in GUIDE

Digital in 5 – 36 Volt read as True

36 Volt False/True

Multifunctional in

0 – 5 Volt0 – 36 Volt0 – 10000 Hz 2ch encoder (2 inputs)Digital

36 Volt 0 – 5000 mV0 – 36000 mV0 – 10000 Hz0 – 4000 HzFalse/True

Analog in 0 – 5 Volt0 – 10000 Ohm

36 Volt 0 – 5000 mV0 – 10000 Ohm

Analog in 5 Volt 0 – 5 Volt 25 Volt 0 – 5000 mV

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Output types

Type Range Max current

Value in GUIDE

Digital out 0 or supply voltage 3 A MC88 6A

False/True

Multifunctional out

0 – 100% duty cycle0 – 3 A0 or supply voltage

3 A 0 – 10000 x 0.01%0 – 30000 x 0.1 mAFalse/True

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Multiple Supply or Ground pins

• Maximum current for a pin is 8 Amps.• If the total output load is more than 8 Amps, then you

need to use more power pins in parallel.

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API Specification

• Example: C1p06.DigIn

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Zooming and change view

• Mouse operations– Scroll wheel - Zoom In/Zoom Out– Hold right key + move up to the right – Zoom in– Hold right key + move down to the left – Zoom out– Right click – That position will be the new center of the drawing without

changing the zoom level

• Keyboard operations– Page Up/Page Down - Zoom In/Zoom Out– Home – Zoom to fit drawing

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Enter and leaving a page

• PLUS+1 GUIDE has got a “Top-Down” structure• Moving down one level in the structure is called Enter

– Press E and click on a page

• Moving up one level in the structure is called Leave– Press L

• The program is split into pages

Inputs Application OutputsUnit_ConfigTop Level

OS C2p12_MFOut……………………

1 level down

OS2 levels down C2p12……………………

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Page Navigator

• Enter a page by double-clicking

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Inputs page

1 level down in Inputs page

Top Level

Bus connection between levels

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Digital input

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Pull up/Pull down

Digital Input Biasing

Inside the Plus 1Controller

0. No Pull Up or Pull Down

5 Volts

> 5 Volts

There must always be aconnection to the inputpin.

1. Pull Up

5 Volts

Bias to 5 Volts, so switchmust switch to ground.

2. Pull Down

5 Volts

> 5 Volts

Bias to Ground, soswitch must switch to avoltage more than 5volts, typically supply.



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Multifunctional input

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Settings for digital reading on MF in

Digital Input Hystersis

DigInConfigLow

DigInConfigHigh

Volts Input Signal

Status ON

Status OFF

Time

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Analog input

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Signals from operating system

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Outputs

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Multifunctional output

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Duty cycle

• Example: 24V supply, 90% duty cycle = 21.6V

10% duty cycle

50% duty cycle

90% duty cycle

0V

Supply voltage

PWM frequency

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How to connect to a Multifunctional output

Constants connected to outputs to be able to compile

To use DigOut, disconnect the False component

To use OutputValue, disconnect the Typed Constant

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Feedback from outputs

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Drawing commands

• R (Route) - Make a bus or wire connection– K – Change between red and green (bus or wire)

– F9 – Drop a bus or wire without connecting

• V (View Logical Net) – Cross reference. Trace a wire or a bus through pages

• S (Stretch) – Extend or compress a part of a drawing

• M (Move) – Almost the same as Stretch

• C (Copy) – Copy within the same page

• Ctrl C/Ctrl V – Copy and Paste. Copy between pages or projects

• Q (Query) – Edit (text, data types etc.)

• Delete key – Delete

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Drawing commands

• Spend some minutes trying out the drawing commands• After that, replace the Template to start from scratch

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Functional description

Pressure sensor

MC24-10

C2p05 C2p09

Give an alarm if pressure is higher than 150 bar

Range: 0 – 300 bar

Output range: 0 – 5 Volt

Program: Check if input signal is higher than 2500 mV

Alarm lamp

>

2500

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Application

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PLUS+1 Hitch Control Example

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LEDs on the I/O-module

• I/O-module LEDs

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LEDs of IX module

LEDs of IX modulePotential for IX modules to not go online. If voltage

is applied to an IX module input pin prior to the module being powered on, there is a possibility that the module CPU will not power up. The module is not damaged and will power up and operate normally once power is removed from the input pins. It is recommended that either the IX module’s 5 Vdc sensor power be used to power sensors or that power is removed from the input pins until the module is powered up.

520L0719 • Rev JA • Aug 2010

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Checking the “Grounding” of the System

With the volt meter

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Safety and the Service Tool

• When using the Service Tool connected to a running machine one may have the potential to control the outputs of the PLUS+1 which could mean moving the machine or machine parts.

• When using the Service Tool connected to a running machine, make sure the machine is in a safe state. This could mean the machine be put up on blocks before testing so that if the wheels move unexpectedly no one would be hurt.

• Make sure people are not close to or working on parts that could move when using the Service Tool on a running machine.

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CG 150

• Interface the CAN bus with 9-pin D-SUB connector• Designed for USB 2.0, backward compliant with USB 1.1• Microsoft Windows XP, Windows 2000, Vista & Windows 7• Plug and Play installation• Part Number 10104136

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Things to check, how and in what order

NON-invasive checks from beginning of signal path to end – LEDs

• MC controllers and Displays, user configurable but normally: green=powered on, Red flashing=can bus error) (power up, flash red/green then green)

• RED and GREEN LED go off right after power up… may need ECU recovery • I/O expanders (flickering green and flickering red = ok, can bus communication)• PVEs (Green=ok, Solid RED=internal fault, flashing red=signal is out of range)

– Re-calibrate machine recent update to the PLUS+1 program– Two displays with different contrasts (SETTINGS)– Checking input and output signals with the Service tool– Checking “open” output pins of the MC controller, may read voltage

when the output pin is off if the load is not connected, this is normal– Checking for Connectivity in Electrical System– Analog sensors and Joysticks– “Hot Plugging” Machine power should be off when connecting

PLUS+1 modules to mating connectors.– Proper grounding of system

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MC Controller connection to CG 150

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Service Tool Over View

• COMMUNICATION– ON LINE / OFF LINE MODE– GREEN LIGHT AT BOTTOM OF SCREEN– GATEWAY = DISPLAY / SAUER DANFOSS CG150– BAUD RATE DOWNLOAD 250K DEFAULT

• WILL NEED MORE THAN THE FREE LICENSE TO CHECK SYSTEMS WITHOUT A DEDICATED SERVICE TOOL PROGRAM

• DESIGN LOG• Power controller off/on and power computer off/on

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PLUS+1 MC CONTROLLER I/O

– “Name” of devices on CAN Bus– Obtain the pin number and configuration– ECU recovery … RED and GREEN LED go off right after power up – PLUS+1 Inputs

Digital Input (active = 1 = True)Analog Input (0 – 32767)Volts (mV) (ranges: 0-368 mV, 0-5250 mV, 0-36000 mV)Rheostat Input (Ohm)

Frequency Input (Hz) – PLUS+1 OUTPUTS:

Digital OutputProportional Output

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Checking the “Grounding” of the System

• logging the MF output pin feed back current on start up

• If the power is on to the system you start logging and cycle power. The Service Tool will go back to logging quick enough to see the "Null Offset" work.

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With the Service Tool

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• Growing family of microcontrollers, displays, and joysticks• High power family of 12, 24, 38, 50 and 88 pin controllers

and I/O modules

• http://www.sauer-danfoss.com/Products/MobileElectronics/Microcontroller/PLUS1Microcontrollers/index.htm

PLUS+1 hardware products


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PLUS+1 Family

12-pin 24-pin 38-pin 50-pin 88-pin

Controllers MC012-010 MC024-010 MC038-010 MC050-010 MC088-015

MC024-020 MC050-020

MC050-055

I/O Modules IX012-010 IX024-010

OX012-010 OX024-010

IOX012-010 IOX024-020

PLUS+1 hardware products


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Service Tool

• Download program• Read signals in the system• Set parameters in the system• Create diagnostic files (.P1D)

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Set up the Service tool

• Connect appropriate Gateway (CG150, DP600)• Make sure the CAN bus terminating resistors are in

place (2 x 120 ohm).• Open Service tool.• Check communications parameters• Scan system• Design a Log file to view the checkpoint signals

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SauerDanfoss CG150 Gateway

CAN bus connection USB

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Install CG150 Gateway

• Insert USB connector• Drivers come with PLUS+1 GUIDE installation

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Open Service Tool

• How to open Service Tool from GUIDE

This or this

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Select Gateway

Physical Gateway, select this!

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Select File Download

or

102

Select controller

103

Select file and Start Download

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Trainer Break Out Box

C1p06 C2p06 C2p05 C2p07

Pot 0 – 5V

105

Service tool screen

Connection statusGateway and channel

Baud rate setting

Requested Log period

Actual Log period

Requested Log period setting Log to a file

Scan system

Play a saved Log file

106

Make a new Log Function

Right click

Give the Log Function a name

107

Open Design Screen

When highlighted press Enter to go to Design Screen

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Design Screen

109

Recover ECU

• Used if a controller has become inaccessible

110

ECU status

• The warning icon is used when the ECU is:– Not scanned– In boot loader mode– Error during System Scan– Created with a HWD or GUIDE that is not officially released

111

Decimal values range

Data Type Min Max Comment

U8 0 255

S8 -128 127

U16 0 65,535

S16 -32,768 32,767 Most common

U32 0 4,294,967,295

S32 -2,147,483,648 2,147,483,647

BOOL False True