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RoboteQ AX2850 user manual AX2550 Motor Controller User’s Manual

Models: AX2850

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AX2550 Motor Controller User’s Manual

Version 1.9b. June 1, 2007

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RoboteQ AX2850 user manual AX2550 Motor Controller User’s Manual

Contents

Dual Channel High Power Digital Motor Controller AX2550 AX2850 AX2550 Motor Controller User’s Manual Revision History Revision HistoryDate Version Changes AX2550 Motor Controller User’s Manual Section Section Installing, Connecting and Using the Encoder Module 100 127 152 177 AX2550 Motor Controller User’s Manual Important Safety Beware of Motor Runaway in Improperly Closed Loop Important Safety Warnings Locating the Switches, Wires and Connectors AX2550Quick Start What you will need AX2550 Quick Start Optical Encoders Program LED Sensors AX2850 only Display Connecting to the Batteries and Motors Connecting to the Batteries and Motors Connecting to the 15-pin Connector Signal Pin RC Mode RS232 Mode Analog Mode Connecting the R/C Radio Connecting the R/C Radio Powering On the Controller Button OperationProg and Set button status Function Default Controller Configuration Default Controller ConfigurationParameter 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 = Software version 1.9b AX2550 Motor Controller Overview Product Description Technical features Technical features Low Power ConsumptionHigh Efficiency Motor Power Outputs Optical Encoder Inputs AX2850 only Advanced Safety Features Data Logging CapabilitiesSturdy and Compact Mechanical Design Connecting Power and Motors to the Controller Power ConnectionsPower Connections Controller Power Connecting Power and Motors to the Controller Controller Power Mended Off Configuration Controller Powering Schemes Powering the Controller from a single Battery Powering the Controller Using a Main and Backup Battery Controller Powering Schemes Connecting the Motors Powering the AX2550 with a Main and Backup Supply Single Channel Operation Converting the AX2550 to Single Channel Power Fuses MCU Wire Length Limits Power Regeneration ConsiderationsElectrical Noise Reduction Techniques Overvoltage Protection Undervoltage Protection Using the Controller with a Power Supply 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 Closed Loop Speed Control Close Loop Position ControlSelecting the Motor Control Modes User Selected Current Limit Settings Temperature-Based Current LimitationSetting Continuous High Amps Battery Current vs. Motor Current Battery Current vs. Motor CurrentTemperature Max Amps Motor Current = Battery Current / PWM ratio Regeneration Current Limiting Off Programmable Acceleration Programmable Acceleration Command Control Curves Left / Right Tuning Adjustment Left / Right Tuning AdjustmentExponentiation Parameter Value Selected Curve Parameter Value Speed Adjustment Emergency Shut Down Using Controller Switches Emergency Stop using External SwitchActivating Brake Release or Separate Motor Excitation Activating Brake Release or Separate Motor Excitation Special Use of Accessory Digital Inputs Using the Inputs to Activate the Buffered OutputInverted Operation Self-Test Mode Self-Test Mode Important Warning Connecting Sensors and Actuators to Input/Outputs AX2550 ConnectionsAX2550 Connections Connecting Sensors and Actuators to Input/Outputs Signal Type Use Activated AX2550’s Inputs and OutputsAX2550’s Inputs and Outputs Pin1 List and Pin Assignment Connecting devices to Output C Connecting devices to Output C Connecting Switches or Devices to Input E Connecting Switches or Devices to Input F 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 Analog InputsAnalog Inputs Connecting Tachometer to Analog Inputs Ana Ana2 Operating Mode Pin Connecting Tachometer to Analog Inputs Operating Mode Ana 1 p11 Ana2 p10 Ana 3 p12 Ana 4 p8 Connecting External Thermistor to Analog Inputs Temp oCResistance kOhm Using the Analog Inputs to Monitor External Voltages Connecting User Devices to Analog InputsUsing the Analog Inputs to Monitor External Voltages Measured 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 Installing Connecting Using Encoder Module Optical Incremental Encoders OverviewOptical 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 Cable Length and Noise ConsiderationsMotor Encoder Polarity Matching Voltage Levels, Thresholds and Limit Switches Wiring Optional Limit Switches Wiring Limit Switches Without Encoders Effect of Limit SwitchesWiring Limit Switches Without Encoders Motor 1 Fwd Motor 1 Rev Using the Encoder Module to Measure Distance Using the Encoder to Measure SpeedMotor Fwd Motor Rev Using the Encoder to Track Position Using the Encoder to Track Position RS232 Communication with the Encoder Module Distance = Destination Counter value / Divider Encoder Testing and Setting Using the PC Utility Encoder Testing and Setting Using the PC Utility Installing, Connecting and Using the Encoder Mod Closed Loop Position Mode Mode DescriptionSelecting the Position Mode Mode Description Closed Loop Position Mode Position Sensor SelectionSensor Mounting Feedback Potentiometer wiring Feedback Potentiometer wiring in RC or RS232 ModeFeedback Potentiometer wiring Feedback Potentiometer wiring in Analog Mode Pot wiring for RS232 or RC Command and Analog Feedback Analog Feedback on Single Channel Controllers Analog Feedback on Single Channel Controllers Using Optical Encoders in Position Mode Sensor and Motor Polarity Encoder Error Detection and Protection Adding Safety Limit SwitchesEncoder Error Detection and Protection SW1 SW2 Using Current Limiting as Protection Using Current Limiting as ProtectionControl Loop Description PID tuning in Position Mode PID tuning in Position Mode Closed Loop 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 PID algorithm used in Speed mode Control Loop Description PID tuning in Speed Mode 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 Rapidly Flashing Temporary Faults Permanent FaultsSelf-Test Display = Software version 1.9b Self-Test Display 108 C radio control mode C Operation Selecting the R/C Input Mode Connector I/O Pin Assignment R/C ModePin Input or Number Output Signal Description Operation Input Circuit Description Supplied Cable DescriptionInput Circuit Description Powering the Radio from the controller RC Cable wiring diagram Powering the Radio from the controller Wiring for powering R/C radio from controller Connecting to a Separately Powered Radio Operating the Controller in R/C mode Reception Watchdog Reception Watchdog Important Notice about PCM Radios Transmitter/Receiver Quality Considerations Joystick Deadband Programming Joystick Deadband Programming Left/Right Tuning Adjustment Joystick Calibration Automatic Joystick Calibration Automatic Joystick Calibration Activating the Accessory Outputs Data Logging in R/C Mode Data Logging in R/C Mode 122 Analog Control and Operation Connector I/O Pin Assignment Analog Mode Pin Input or Number Signal Output DescriptionAnalog Control and Operation Connecting to a Voltage Source Connecting a PotentiometerConnecting to a Voltage Source Selecting the Potentiometer Value = U/R = 5V / 1000 Ohms = 0.005A = 5mA Analog Deadband Adjustment Analog Deadband Adjustment Power-On Safety Under Voltage SafetyData Logging in Analog Mode Data Logging in Analog Mode Modified Analog cable with RS232 output data logging for PC 130 Serial RS-232 Controls Operation Use and benefits of RS232Use and benefits of RS232 Connector I/O Pin Assignment RS232 Mode Serial RS-232 Controls and Operation Cable 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 RS232 Communication with the Encoder Module Establishing Manual Communication with a PCRoboteq v1.9b 06/01/07 s Entering RS232 from R/C or Analog mode Data Logging String in R/C or Analog mode Commands Acknowledge and Error Messages Controller Commands and Queries Command Type DescriptionRS-232 Watchdog Set Motor Command Value Set Accessory OutputController Commands and Queries Query Power Applied to Motors Query Amps from Battery to each Motor ChannelQuery Analog Inputs Syntax Query Heatsink Temperatures Query Battery Voltages?r or ?R ?m or ?M Reset Controller Query Digital Inputs Accessing & Changing Configuration Parameter in Flash Accessing & Changing Configuration Parameter in FlashApply Parameter Changes Read parameter Flash Configuration Parameters List Location Description Active after Input Control Mode Motor Control ModeAddress Access Read/Write Effective After Reset Value Mode See pages Amps Limit Bit Definition See pages Input Switches Function Acceleration Address Channel Access Read/Write Effective Instantly RC Joystick or Analog DeadbandExponentiation on Channel 1 and Channel Left/Right Adjust Default Encoder Time Base 1 Default Encoder Distance Divider Default PID GainsJoystick Min, Max and Center Values Reading & Changing Operating Parameters at Runtime Location Function Operating Modes Registers Read/Change PID ValuesBit Function Address 82 P1 83 I1 84 D1 85 P2 PWM Frequency Register Controller Status Register Controller Identification Register Current Amps Limit RegistersBit Model or Function RS232 Encoder Command Set Set/Reset Encoder Counters and Destination RegistersRead Encoder Counter Read Speed Or !Q n Read Encoder Limit Switch Status Read DistanceRead Speed/Distance Switch Value Read / Modify Encoder Module Registers and ParametersDD= parameter value Address Parameter Description Size Access Switch Status Register DescriptionEncoder Hardware ID code Speed or Distance 1 or Counter Read/Write Mailbox Counter 1Destination Register 1 Register Description Distance 1 Speed 1Time Base 1 Encoder Threshold Counter Read Data Format Counter Read Data FormatDecimal Bit Hex Controller Output 164 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 Decimal to Hexadecimal Conversion Table Decimal to Hexadecimal Conversion TableDec Hex UDec Hex AX2550 Motor Controller User’s Manual 169 170 Configuring Controller using Switches Programming using built-in Switches and DisplayProgramming Methods Entering Programming Mode Configuring the Controller using the Switches Restoring factory defaults Changing parametersSpecial Case of Joystick Calibration Exiting the Parameter Setting Mode Programmable Parameters List Order Letter Description Possible Values default Pages Programmable Parameters ListSee 176 Using the Roborun Configuration Utility Downloading and Installing the 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 CommandsView Controller Connector Pinout Getting On-Screen Help Control Settings Motor Control ModeLoading, Changing Controller Parameters Loading, Changing Controller Parameters Power Settings Analog or R/C Specific Settings Loading, Changing Controller Parameters Left/Right AdjustAcceleration Setting Deadband Encoder Setting and Testing Closed Loop Parameters Encoder Module Parameters Setting Encoder Setting and Testing Running the Motors Exercising the MotorsViewing Encoder Data Motor Power setting Running the MotorsRun/Stop Button Measurement Real-Time Strip Chart Recorder Input Status and Output SettingTransmit and Receive Data Logging Data to Disk Connecting a Joystick Parameter Header Data type/range Measured Parameter Using the Console Using the ConsoleCommand Entry Terminal Screen Send Reset String Viewing and Logging Data in Analog and R/C ModesLoading and Saving Profiles to Disk Keep Watchdog Alive Operating the AX2550 over a Wired or Wireless LAN Operating the AX2550 over a Wired or Wireless LAN Roboserver screenshot when idle Updating the Controller’s Software Creating Customized Object Files Updating the Encoder SoftwareCreating Customized Object Files Objectmaker creates controller firmware with custom defaults Mechanical Specifications Mechanical DimensionsMechanical Dimensions Mechanical Specifications Mounting Considerations Wire Dimensions Wire Gauge Outside Diameter Color LengthThermal Considerations Attaching the Controller Directly to a Chassis Weight