RoboteQ AX2550/2850 guide

Connecting Sensors and Actuators to Input/Outputs

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AX2500/2850 Motor Controller User’s Manual

Version 1.7. February 1, 2005

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RoboteQ AX2550/2850 user manual Connecting Sensors and Actuators to Input/Outputs

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 Connecting the R/C Radio Using the Power Control WirePower Control input connected to Action Powering On the Controller Powering On the Controller Button Operation Prog and Set button status Function Default Controller Configuration Checking and Changing ConfigurationsDefault Controller Configuration 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 Technical features Low Power ConsumptionHigh Efficiency Motor Power Outputs Optical Encoder Inputs AX2850 only Data Logging Capabilities Advanced Safety FeaturesSturdy and Compact Mechanical Design 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 Overvoltage Protection Using the Controller with a Power SupplyUndervoltage Protection Using the Controller with a Power Supply Connecting Power and Motors to the Controller Input Command Modes General OperationBasic Operation Basic Operation Selecting the Motor Control Modes Open Loop, Separate Speed ControlOpen Loop, Mixed Speed Control General Operation Close Loop Position Control Closed Loop Speed ControlSelecting the Motor Control Modes Setting Continuous High Amps Current Limit SettingsContinuous and Extended Current Limitation Temperature-Based Current Limitation Temperature-Based Current LimitationSetting Continuous High Amps Extended Safe Amps Regeneration Current Limiting Surge Current ProtectionProgrammable Acceleration Programmable Acceleration Command Control Curves Exponentiation curves Left / Right Tuning Adjustment Left / Right Tuning AdjustmentExponentiation Parameter Value Selected Curve Emergency Shut Down Using Controller Switches Parameter Value Speed Adjustment Emergency Stop using External Switch Emergency Stop using External SwitchInverted Operation Self-Test Mode Special Use of Accessory Digital InputsUsing the Inputs to Activate the Buffered Output 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 Connecting External Thermistor to Analog Inputs Connecting External Thermistor to Analog InputsTemp oC Resistance kOhm Using the Analog Inputs to Monitor External Voltages NTC Connecting User Devices to Analog Inputs Connecting User Devices to Analog InputsMeasured volts = controller reading + 128 * 0.255 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 Motor Direction Status Normal and Fault Condition LED MessagesPossible Display Motor Comment Fault Messages Fault MessagesNo Control Self-Test Display Emergency Stop Mode Description Mode DescriptionOperation Typical Wiring Selecting the R/C Input ModeOperation 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 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 Transmitter/Receiver Quality Considerations Reception WatchdogReception Watchdog Joystick Deadband Programming Command Control Curves Left/Right Tuning AdjustmentJoystick Calibration 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 Connector I/O Pin Assignment RS232 Mode Must be wired to pin 13 or pinMust be wired to pin Serial RS-232 Controls and Operation Cable configuration Cable configurationExtending the RS232 Cable Bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Communication SettingsEstablishing 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 s RS232 Mode if default RS232 Commands SetSet Motor Command Value Set Accessory Outputs Query Power Applied to MotorsRS232 Commands Set B7F A3F Query Amps Consumed by Motors Query Analog Inputs Query Heatsink Temperatures Query Battery VoltagesRS232 Commands Set Query Digital Inputs Read parameter Read and Modify Controller SettingsModify parameter Optical Encoder Commands Commands Acknowledge and Error MessagesReset Controller Apply Parameter Changes Command Acknowledgement Command ErrorRS-232 Watchdog 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 Analog Control and Operation Connector I/O Pin Assignment Analog ModeUnused Connecting a Potentiometer Connecting to a Voltage SourceConnecting to a Voltage Source Selecting the Potentiometer Value = U/R = 5V / 1000 Ohms = 0.005A = 5mA Analog Deadband Adjustment Analog Deadband Adjustment Under Voltage Safety Power-On SafetyData Logging in Analog Mode Data Logging in Analog Mode Modified Analog cable with RS232 output data logging for PC 114 Closed Loop Position Mode Selecting the Position Mode Position Sensor Selection Closed Loop Position ModeSensor Mounting Potentiometer wiring Using Optical Encoders in Position ModePotentiometer wiring 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 Using Optical Encoder for Speed Feedback AX2850 only Tachometer wiringClosed Loop Speed Mode 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 Installing 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 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 RS232 Encoder Command Set Read Encoder Counter?q or Q n ?Q0 Set/Reset Encoder Counters and Destination Registers RS232 Encoder Command SetRead Speed Or !Q n Read Distance Read Encoder Limit Switch StatusRead Speed/Distance Read / Modify Encoder Module Registers and Parameters Switch Value?w or ?W Address Parameter Description Size Access Controller replies, value is Register Description Encoder Hardware ID code Switch Status Speed or Distance 1 orCounter Read/Write Mailbox Counter 1 Counter Read Data Format Speed 1Time Base 1 Encoder Threshold Encoder Testing and Setting Using the PC Utility FFFFFF15 Encoder Module Parameters Setting Encoder Testing and Setting Using the PC Utility Exercising the Motors Updating the Encoder SoftwareViewing Encoder Data Programming using built-in Switches and Display Configuring Controller using SwitchesProgramming Methods Entering Programming Mode Configuring the Controller using the Switches Changing parameters Restoring factory defaultsSpecial Case of Joystick Calibration Exiting the Parameter Setting Mode Programmable Parameters List Order Letter Description Possible Values default Pages Programmable Parameters List 158 Downloading and Installing the Utility Using the Roborun Configuration UtilitySystem Requirements Connecting the Controller to the PC Using the Roborun Configuration Utility Roborun Frame, Tab and Menu Descriptions Roborun Frame, Tab and Menu Descriptions Parameter Selection and Setting, and Special Functions File and Program Management CommandsGetting On-Screen Help Loading, Changing Controller Parameters Controls Settings Power Settings Left/Right AdjustAcceleration Setting Effect of Digital Inputs Deadband Analog or R/C Specific SettingsJoystick Timing Viewing the Parameters Summary Closed Loop Parameters Running the Motors Optical Encoder OperationOptical Encoder Operation Run/Stop Button Motor Power settingMeasurement Real-Time Strip Chart Recorder Input Status and Output SettingRunning the Motors Transmit and Receive Data Logging Data to Disk Connecting a Joystick Parameter Header Data type/range Measured Parameter Viewing and Logging Data in Analog and R/C Modes Operating the AX2500/2850 over a Wired or Wireless LANLoading and Saving Profiles to Disk 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 Mounting Considerations Mechanical SpecificationsThermal Considerations Wire Dimensions WeightWire Dimensions Wire Gauge Outside Diameter Color Length 180