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RoboteQ AX2550/2850 user manual Advanced Safety Features, Data Logging Capabilities

Models: AX2550/2850

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AX2500/2850 Motor Controller Overview

•100A up to 30 seconds

•80A extended

•High current operation may be extended with forced cooling

•250A peak Amps per channel

•16kHz Pulse Width Modulation (PWM) output

•Auxiliary output for brake or clutch

•Heat sink extruded case

Advanced Safety Features

•Safe power on mode

•Optical isolation on R/C control inputs

•Automatic Power stage off in case of electrically or software induced program fail- ure

•Overvoltage and Undervoltage protection

•Regeneration current limiting

•Watchdog for automatic motor shutdown in case of command loss (R/C and RS232 modes)

•Large, bright run/failure diagnostics on 7 segment LED display

•Programmable motor acceleration

•Built-in controller overheat sensor

•Motor temperature sensing and protection

•Emergency Stop input signal and button

Data Logging Capabilities

•13 internal parameters, including battery voltage, captured R/C command, tempera- ture and Amps accessible via RS232 port

•Data may be logged in a PC, PDA or microcomputer

Sturdy and Compact Mechanical Design

•Built from aluminum heat sink extrusion with mounting brackets

•Efficient heat sinking. Operates without a fan in most applications.

•7” (178mm) long (excluding mounting brackets) by 5.5” wide (140mm) by 1.8” (40mm) high

•-20o to +70o C operating environment

•3.3 lbs (1500g)

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AX2500/2850 Motor Controller User’s Manual

Version 1.7. February 1, 2005

Image 24

RoboteQ AX2550/2850 user manual Advanced Safety Features, Data Logging Capabilities, Sturdy and Compact Mechanical Design

Contents

Dual Channel High Power Digital Motor Controller AX2550/2850Revision History Date Version ChangesRevision History AX2550/2850 Motor Controller User’s Manual Section Section Self-Test Display 104 124 152 AX2500/2850 Quick Start What you will needLocating Switches, Wires and Connectors AX2500/2850 Quick StartConnecting to the Batteries and Motors Connecting to the Batteries and MotorsUsing the Power Control Wire Connecting the R/C RadioPower Control input connected to Action Powering On the Controller Powering On the ControllerButton Operation Prog and Set button status FunctionDefault Controller Configuration Checking and Changing ConfigurationsDefault Controller Configuration Parameter Default Values LetterConnecting the controller to your PC using Roborun Obtaining the Controller’s Software Revision Number Obtaining the Controller’s Software Revision NumberExploring further AX2500/2850 Motor Controller Overview Product DescriptionTechnical features Technical features Low Power ConsumptionHigh Efficiency Motor Power Outputs Optical Encoder Inputs AX2850 onlyAdvanced Safety Features Data Logging CapabilitiesSturdy and Compact Mechanical Design Connecting Power and Motors to the Controller Connecting PowerConnecting Power Controller Power Connecting Power and Motors to the ControllerController Power TwoPowering the Controller using the Motor Batteries Using a Backup Battery Powering the controller from the Motor BatteriesPower Fuses Wire Length LimitsPower Regeneration Considerations Electrical Noise Reduction TechniquesElectrical Noise Reduction Techniques Using the Controller with a Power Supply Overvoltage ProtectionUndervoltage Protection Using the Controller with a Power Supply Connecting Power and Motors to the Controller Input Command Modes General OperationBasic Operation Basic OperationSelecting the Motor Control Modes Open Loop, Separate Speed ControlOpen Loop, Mixed Speed Control General OperationClosed Loop Speed Control Close Loop Position ControlSelecting the Motor Control Modes Current Limit Settings Setting Continuous High AmpsContinuous and Extended Current Limitation Temperature-Based Current Limitation Temperature-Based Current LimitationSetting Continuous High Amps Extended Safe Amps Surge Current Protection Regeneration Current LimitingProgrammable Acceleration Programmable Acceleration Command Control Curves Exponentiation curvesLeft / Right Tuning Adjustment Left / Right Tuning AdjustmentExponentiation Parameter Value Selected Curve Emergency Shut Down Using Controller Switches Parameter Value Speed AdjustmentEmergency Stop using External Switch Emergency Stop using External SwitchInverted Operation Special Use of Accessory Digital Inputs Self-Test ModeUsing the Inputs to Activate the Buffered Output Self-Test Mode General Operation Connecting Sensors and Actuators to Input/Outputs AX2500/2850 ConnectionsAX2500/2850 Connections Connecting Sensors and Actuators to Input/Outputs Signal Type Use Activated AX2500/2850’s Inputs and OutputsAX2500/2850’s Inputs and Outputs Pin Wire Input or Number Color Output Signal Description List and Pin AssignmentConnecting devices to Output C Connecting devices to Output CConnecting devices to Output D Connecting external Mosfet and load to Output DConnecting Switches or Devices to Input E Connecting Switches or Devices to Input FConnecting Switches or Devices to EStop/Invert Input Show how to wire the switch to this inputConnecting Position Potentiometers to Analog Inputs Connecting Position Potentiometers to Analog InputsConnecting Tachometer to Analog Inputs Potentiometer wiring in Position modeConnecting External Thermistor to Analog Inputs Connecting External Thermistor to Analog InputsTemp oC Resistance kOhmUsing the Analog Inputs to Monitor External Voltages NTCConnecting User Devices to Analog Inputs Connecting User Devices to Analog InputsMeasured volts = controller reading + 128 * 0.255 Internal Heatsink Temperature Sensors Internal Voltage Monitoring SensorsTemperature Conversion C Source Code Temperature Conversion C Source CodeConnecting Sensors and Actuators to Input/Outputs Normal Fault Condition LED Messages Use of the LED DisplayUse of the LED Display Normal and Fault Condition LED Messages Motor Direction StatusPossible Display Motor Comment Fault Messages Fault MessagesNo Control Self-Test Display Emergency StopMode Description Mode DescriptionOperation Selecting the R/C Input Mode Typical WiringOperation Connector I/O Pin Assignment R/C Mode Connector I/O Pin Assignment R/C ModePin Input or Number Signal Output Description Input Circuit Description Supplied Cable Description Supplied Cable DescriptionCabling 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-IsolationPowering the Radio from the controller Partial opto-isolation with Channel 3 electrical diagramPowering the Radio from the controller Wiring for powering R/C radio from controllerOperating the Controller in R/C mode Joystick position vs. pulse duration default valuesReception Watchdog Transmitter/Receiver Quality ConsiderationsReception Watchdog Joystick Deadband Programming Left/Right Tuning Adjustment Command Control CurvesJoystick Calibration Automatic Joystick Calibration Activating the Accessory Outputs Activating the Accessory OutputsData Logging in R/C Mode Using Channel 3 to activate accessory outputsData Logging in R/C Mode Operation Serial RS-232 Controls Operation Use and benefits of RS232Use and benefits of RS232 Connector I/O Pin Assignment RS232 Mode Must be wired to pin 13 or pinMust be wired to pin Serial RS-232 Controls and OperationCable configuration Cable configurationExtending the RS232 Cable Communication Settings Bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even ParityEstablishing Manual Communication with a PC Entering RS232 from R/C or Analog mode Data Logging String in R/C or Analog modeEstablishing Manual Communication with a PC Roboteq v1.7 02/01/05 sRS232 Commands Set RS232 Mode if defaultSet Motor Command Value Set Accessory Outputs Query Power Applied to MotorsRS232 Commands Set B7F A3FQuery Amps Consumed by Motors Query Analog InputsQuery Heatsink Temperatures Query Battery VoltagesRS232 Commands Set Query Digital InputsRead and Modify Controller Settings Read parameterModify parameter Optical Encoder Commands Commands Acknowledge and Error MessagesReset Controller Apply Parameter ChangesCommand Acknowledgement Command ErrorRS-232 Watchdog Watchdog time-outRS232 Accessible Parameter Table RS232 Accessible Parameter TablePID Automatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC ModeAnalog and R/C Modes Data Logging String Format Data Logging Cables Data Logging CablesDecimal to Hexadecimal Conversion Table Dec HexDecimal to Hexadecimal Conversion Table 106 Analog Control and Operation Connector I/O Pin Assignment Analog Mode Analog Control and OperationUnused Connecting to a Voltage Source Connecting a PotentiometerConnecting to a Voltage Source Selecting the Potentiometer Value = U/R = 5V / 1000 Ohms = 0.005A = 5mAAnalog Deadband Adjustment Analog Deadband AdjustmentPower-On Safety Under Voltage SafetyData Logging in Analog Mode Data Logging in Analog Mode Modified Analog cable with RS232 output data logging for PC114 Closed Loop Position Mode Selecting the Position ModeClosed Loop Position Mode Position Sensor SelectionSensor Mounting Potentiometer wiring Using Optical Encoders in Position ModePotentiometer wiring Sensor and Motor PolarityImportant Safety Warning Adding Safety Limit Switches Safety limit switches interrupting power to motorsUsing Current Limiting as Protection Control Loop DescriptionControl Loop Description PID tuning in Position Mode Closed Loop Speed Mode Selecting the Speed ModeUsing Optical Encoder for Speed Feedback AX2850 only Tachometer wiringClosed Loop Speed Mode Tachometer or Encoder MountingSpeed Sensor and Motor Polarity Speed Sensor and Motor PolarityAdjust Offset and Max Speed AX2500/2850 Motor Controller User’s Manual 127 PID tuning in Speed Mode PID algorithm used in Speed modePID tuning in Speed Mode 130 Installing Connecting Using Encoder Module Optical Incremental Encoders OverviewOptical Incremental Encoders Overview Installing, Connecting and Using the Encoder Mod Recommended Encoder TypesInstalling the Encoder Module Installing the Encoder ModulePulse Frequency in Hz = RPM / 60 * PPR Position of Encoder Module on Controller’s main board Connecting the Encoder Connecting the EncoderPin Name Cable Color Voltage Levels, Thresholds and Limit Switches Motor Encoder Polarity MatchingWiring Optional Limit Switches Wiring Optional Limit SwitchesUsing the Encoder Module to Measure Distance Using the Encoder to Measure Speed Using the Encoder to Measure SpeedUsing the Encoder to Track Position Distance = Destination Counter value / DividerRS232 Communication with the Encoder Module RS232 Encoder Command Set Read Encoder Counter?q or Q n ?Q0Set/Reset Encoder Counters and Destination Registers RS232 Encoder Command SetRead Speed Or !Q nRead Encoder Limit Switch Status Read DistanceRead Speed/Distance Switch Value Read / Modify Encoder Module Registers and Parameters?w or ?W Address Parameter Description Size Access Controller replies, value isRegister Description Encoder Hardware ID codeSwitch Status Speed or Distance 1 orCounter Read/Write Mailbox Counter 1Counter Read Data Format Speed 1Time Base 1 Encoder ThresholdEncoder Testing and Setting Using the PC Utility FFFFFF15Encoder Module Parameters Setting Encoder Testing and Setting Using the PC UtilityUpdating the Encoder Software Exercising the MotorsViewing Encoder Data Configuring Controller using Switches Programming using built-in Switches and DisplayProgramming Methods Entering Programming Mode Configuring the Controller using the SwitchesRestoring factory defaults Changing parametersSpecial Case of Joystick Calibration Exiting the Parameter Setting Mode Programmable Parameters ListOrder Letter Description Possible Values default Pages Programmable Parameters List158 Using the Roborun Configuration Utility Downloading and Installing the UtilitySystem Requirements Connecting the Controller to the PC Using the Roborun Configuration UtilityRoborun Frame, Tab and Menu Descriptions Roborun Frame, Tab and Menu DescriptionsParameter Selection and Setting, and Special Functions File and Program Management CommandsGetting On-Screen Help Loading, Changing Controller ParametersControls Settings Power Settings Left/Right AdjustAcceleration Setting Effect of Digital InputsAnalog or R/C Specific Settings DeadbandJoystick Timing Viewing the Parameters Summary Closed Loop ParametersOptical Encoder Operation Running the MotorsOptical Encoder Operation Motor Power setting Run/Stop ButtonMeasurement Real-Time Strip Chart Recorder Input Status and Output SettingRunning the Motors Transmit and Receive DataLogging Data to Disk Connecting a Joystick Parameter Header Data type/range Measured ParameterOperating the AX2500/2850 over a Wired or Wireless LAN Viewing and Logging Data in Analog and R/C ModesLoading and Saving Profiles to Disk Operating the AX2500/2850 over a Wired or Wireless LAN Roboserver screenshot when idleUpdating the Controller’s Software Creating Customized Object FilesObjectmaker creates controller firmware with custom defaults Creating Customized Object Files176 Mechanical Specifications Mechanical DimensionsMechanical Dimensions Mechanical Specifications Mounting ConsiderationsThermal Considerations Wire Dimensions WeightWire Dimensions Wire Gauge Outside Diameter Color Length180