Revision History, Date Version Changes | RoboteQ AX2550/2850

Revision History

Date	Version	Changes

February 1, 2005	1.7	Added Position mode support with Optical Encoder
		Miscellaneous additions and corrections

April 17, 2004	1.6	Added Optical Encoder support

March 15, 2004	1.5	Added finer Amps limit settings
		Enhanced Roborun utility

August 25, 2003	1.3	Added CLosed Loop Speed mode
		Added Data Logging support
		Removed RC monitoring

August 15, 2003	1.2	Modified to cover AX2550/2850 controller design
		Changed Power Connection section

April 15, 2003	1.1	Added analog mode section
		Added position mode section
		Added RCRC monitoring feature
		Updated Roborun utility section
		Modified RS232 watchdog

March 15, 2003	1.0	Initial Release

The information contained in this manual is believed to be accurate and reliable. However, it may contain errors that were not noticed at time of publication. User’s are expected to perform their own product validation and not rely solely on data contained in this manual.

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AX2550/2850 Motor Controller User’s Manual

Version 1.7. February 1, 2005

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RoboteQ AX2550/2850 user manual Revision History, Date Version Changes

Contents

Dual Channel High Power Digital Motor Controller AX2550/2850 Revision History Date Version Changes Revision History AX2550/2850 Motor Controller User’s Manual Section Section Self-Test Display 104 124 152 AX2500/2850 Quick Start What you will need Locating Switches, Wires and Connectors AX2500/2850 Quick Start Connecting to the Batteries and Motors Connecting to the Batteries and Motors Power Control input connected to Action Using the Power Control WireConnecting the R/C Radio Powering On the Controller Powering On the Controller Button Operation Prog and Set button status Function Default Controller Configuration Default Controller ConfigurationChecking and Changing Configurations Parameter Default Values Letter Connecting the controller to your PC using Roborun Obtaining the Controller’s Software Revision Number Obtaining the Controller’s Software Revision Number Exploring further AX2500/2850 Motor Controller Overview Product Description Technical features High Efficiency Motor Power Outputs Technical featuresLow Power Consumption Optical Encoder Inputs AX2850 only Sturdy and Compact Mechanical Design Advanced Safety FeaturesData Logging Capabilities Connecting Power Connecting Power and Motors to the ControllerConnecting Power Controller Power Connecting Power and Motors to the Controller Controller Power Two Powering the Controller using the Motor Batteries Using a Backup Battery Powering the controller from the Motor Batteries Power Fuses Wire Length Limits Electrical Noise Reduction Techniques Power Regeneration ConsiderationsElectrical Noise Reduction Techniques Undervoltage Protection Using the Controller with a Power SupplyOvervoltage Protection Using the Controller with a Power Supply Connecting Power and Motors to the Controller Basic Operation Input Command ModesGeneral Operation Basic Operation Open Loop, Mixed Speed Control Selecting the Motor Control ModesOpen Loop, Separate Speed Control General Operation Selecting the Motor Control Modes Closed Loop Speed ControlClose Loop Position Control Continuous and Extended Current Limitation Current Limit SettingsSetting Continuous High Amps Setting Continuous High Amps Extended Safe Amps Temperature-Based Current LimitationTemperature-Based Current Limitation Programmable Acceleration Surge Current ProtectionRegeneration Current Limiting Programmable Acceleration Command Control Curves Exponentiation curves Exponentiation Parameter Value Selected Curve Left / Right Tuning AdjustmentLeft / Right Tuning Adjustment Emergency Shut Down Using Controller Switches Parameter Value Speed Adjustment Inverted Operation Emergency Stop using External SwitchEmergency Stop using External Switch Using the Inputs to Activate the Buffered Output Special Use of Accessory Digital InputsSelf-Test Mode Self-Test Mode General Operation AX2500/2850 Connections Connecting Sensors and Actuators to Input/OutputsAX2500/2850 Connections Connecting Sensors and Actuators to Input/Outputs AX2500/2850’s Inputs and Outputs Signal Type Use ActivatedAX2500/2850’s Inputs and Outputs Pin Wire Input or Number Color Output Signal Description List and Pin Assignment Connecting devices to Output C Connecting devices to Output C Connecting devices to Output D Connecting external Mosfet and load to Output D Connecting Switches or Devices to Input E Connecting Switches or Devices to Input F Connecting Switches or Devices to EStop/Invert Input Show how to wire the switch to this input Connecting Position Potentiometers to Analog Inputs Connecting Position Potentiometers to Analog Inputs Connecting Tachometer to Analog Inputs Potentiometer wiring in Position mode Temp oC Connecting External Thermistor to Analog InputsConnecting External Thermistor to Analog Inputs Resistance kOhm Using the Analog Inputs to Monitor External Voltages NTC Measured volts = controller reading + 128 * 0.255 Connecting User Devices to Analog InputsConnecting User Devices to Analog Inputs Internal Heatsink Temperature Sensors Internal Voltage Monitoring Sensors Temperature Conversion C Source Code Temperature Conversion C Source Code Connecting Sensors and Actuators to Input/Outputs Use of the LED Display Normal Fault Condition LED MessagesUse of the LED Display Possible Display Motor Comment Normal and Fault Condition LED MessagesMotor Direction Status No Control Fault MessagesFault Messages Self-Test Display Emergency Stop Operation Mode DescriptionMode Description Operation Selecting the R/C Input ModeTypical Wiring Pin Input or Number Signal Output Description Connector I/O Pin Assignment R/C ModeConnector I/O Pin Assignment R/C Mode Input Circuit Description Supplied Cable Description Supplied Cable Description Cabling to R/C Receiver using Full Opto-Isolation Cabling to R/C Receiver with Partial Opto-Isolation Cabling to R/C Receiver with Partial Opto-Isolation Powering the Radio from the controller Partial opto-isolation with Channel 3 electrical diagram Powering the Radio from the controller Wiring for powering R/C radio from controller Operating the Controller in R/C mode Joystick position vs. pulse duration default values Reception Watchdog Reception WatchdogTransmitter/Receiver Quality Considerations Joystick Deadband Programming Joystick Calibration Left/Right Tuning AdjustmentCommand Control Curves Automatic Joystick Calibration Activating the Accessory Outputs Activating the Accessory Outputs Data Logging in R/C Mode Using Channel 3 to activate accessory outputs Data Logging in R/C Mode Operation Use and benefits of RS232 Serial RS-232 Controls OperationUse and benefits of RS232 Must be wired to pin Connector I/O Pin Assignment RS232 ModeMust be wired to pin 13 or pin Serial RS-232 Controls and Operation Extending the RS232 Cable Cable configurationCable configuration Establishing Manual Communication with a PC Communication SettingsBits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Establishing Manual Communication with a PC Entering RS232 from R/C or Analog modeData Logging String in R/C or Analog mode Roboteq v1.7 02/01/05 s Set Motor Command Value RS232 Commands SetRS232 Mode if default RS232 Commands Set B7F Set Accessory OutputsQuery Power Applied to Motors A3F Query Amps Consumed by Motors Query Analog Inputs RS232 Commands Set Query Heatsink TemperaturesQuery Battery Voltages Query Digital Inputs Modify parameter Read and Modify Controller SettingsRead parameter Reset Controller Optical Encoder CommandsCommands Acknowledge and Error Messages Apply Parameter Changes RS-232 Watchdog Command AcknowledgementCommand Error Watchdog time-out RS232 Accessible Parameter Table RS232 Accessible Parameter Table PID Automatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC Mode Analog and R/C Modes Data Logging String Format Data Logging Cables Data Logging Cables Decimal to Hexadecimal Conversion Table Dec Hex Decimal to Hexadecimal Conversion Table 106 Analog Control and Operation Unused Connector I/O Pin Assignment Analog ModeAnalog Control and Operation Connecting to a Voltage Source Connecting to a Voltage SourceConnecting a Potentiometer Selecting the Potentiometer Value = U/R = 5V / 1000 Ohms = 0.005A = 5mA Analog Deadband Adjustment Analog Deadband Adjustment Data Logging in Analog Mode Power-On SafetyUnder Voltage Safety Data Logging in Analog Mode Modified Analog cable with RS232 output data logging for PC 114 Closed Loop Position Mode Selecting the Position Mode Sensor Mounting Closed Loop Position ModePosition Sensor Selection Potentiometer wiring Potentiometer wiringUsing Optical Encoders in Position Mode Sensor and Motor Polarity Important Safety Warning Adding Safety Limit Switches Safety limit switches interrupting power to motors Using Current Limiting as Protection Control Loop Description Control Loop Description PID tuning in Position Mode Closed Loop Speed Mode Selecting the Speed Mode Closed Loop Speed Mode Using Optical Encoder for Speed Feedback AX2850 onlyTachometer wiring Tachometer or Encoder Mounting Speed Sensor and Motor Polarity Speed Sensor and Motor Polarity Adjust Offset and Max Speed AX2500/2850 Motor Controller User’s Manual 127 PID tuning in Speed Mode PID algorithm used in Speed mode PID tuning in Speed Mode 130 Optical Incremental Encoders Overview Installing Connecting Using Encoder ModuleOptical Incremental Encoders Overview Installing, Connecting and Using the Encoder Mod Recommended Encoder Types Pulse Frequency in Hz = RPM / 60 * PPR Installing the Encoder ModuleInstalling the Encoder Module Position of Encoder Module on Controller’s main board Pin Name Cable Color Connecting the EncoderConnecting the Encoder Voltage Levels, Thresholds and Limit Switches Motor Encoder Polarity Matching Wiring Optional Limit Switches Wiring Optional Limit Switches Using the Encoder Module to Measure Distance Using the Encoder to Measure Speed Using the Encoder to Measure Speed Using the Encoder to Track Position Distance = Destination Counter value / Divider RS232 Communication with the Encoder Module ?q or Q n RS232 Encoder Command SetRead Encoder Counter ?Q0 Read Speed Set/Reset Encoder Counters and Destination RegistersRS232 Encoder Command Set Or !Q n Read Speed/Distance Read Encoder Limit Switch StatusRead Distance ?w or ?W Switch ValueRead / Modify Encoder Module Registers and Parameters Address Parameter Description Size Access Controller replies, value is Register Description Encoder Hardware ID code Counter Read/Write Mailbox Switch StatusSpeed or Distance 1 or Counter 1 Time Base 1 Counter Read Data FormatSpeed 1 Encoder Threshold Encoder Testing and Setting Using the PC Utility FFFFFF15 Encoder Module Parameters Setting Encoder Testing and Setting Using the PC Utility Viewing Encoder Data Updating the Encoder SoftwareExercising the Motors Programming Methods Configuring Controller using SwitchesProgramming using built-in Switches and Display Entering Programming Mode Configuring the Controller using the Switches Special Case of Joystick Calibration Restoring factory defaultsChanging parameters Exiting the Parameter Setting Mode Programmable Parameters List Order Letter Description Possible Values default Pages Programmable Parameters List 158 System Requirements Using the Roborun Configuration UtilityDownloading and Installing the Utility Connecting the Controller to the PC Using the Roborun Configuration Utility Roborun Frame, Tab and Menu Descriptions Roborun Frame, Tab and Menu Descriptions Getting On-Screen Help Parameter Selection and Setting, and Special FunctionsFile and Program Management Commands Loading, Changing Controller Parameters Controls Settings Acceleration Setting Power SettingsLeft/Right Adjust Effect of Digital Inputs Joystick Timing Analog or R/C Specific SettingsDeadband Viewing the Parameters Summary Closed Loop Parameters Optical Encoder Operation Optical Encoder OperationRunning the Motors Measurement Motor Power settingRun/Stop Button Running the Motors Real-Time Strip Chart RecorderInput Status and Output Setting Transmit and Receive Data Logging Data to Disk Connecting a Joystick Parameter Header Data type/range Measured Parameter Loading and Saving Profiles to Disk Operating the AX2500/2850 over a Wired or Wireless LANViewing and Logging Data in Analog and R/C Modes Operating the AX2500/2850 over a Wired or Wireless LAN Roboserver screenshot when idle Updating the Controller’s Software Creating Customized Object Files Objectmaker creates controller firmware with custom defaults Creating Customized Object Files 176 Mechanical Dimensions Mechanical SpecificationsMechanical Dimensions Thermal Considerations Mechanical SpecificationsMounting Considerations Wire Dimensions Wire DimensionsWeight Wire Gauge Outside Diameter Color Length 180