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RoboteQ AX2850 user manual Important Safety, Beware of Motor Runaway in Improperly Closed Loop

Models: AX2850

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	Important Safety
SECTION 1	Important Safety
	Warnings

Read this Section First

The AX2550 is a high power electronics device. Serious damage, including fire, may occur to the unit, motors, wiring and batteries as a result of its misuse. Please review the User’s Manual for added precautions prior to applying full battery or full load power.

This product is intended for use with rechargeable batteries

Unless special precautions are taken, damage to the controller and/or power supply may occur if operated with a power supply alone. See“Power Regeneration Consid- erations” on page 37 of the Users Manual. Always keep the controller connected to the Battery. Use the Power Control input to turn On/Off.

Do not Connect to a RC Radio with a Battery Attached

Without proper protection, a battery attached to an RC Radio may inject its voltage directly inside the controller’s sensitive electronics. See

Beware of Motor Runaway in Improperly Closed Loop

Wiring or polarity errors between the feedback device and motor in position or closed loop position mode may cause the controller to runaway with no possibility to stop it until power is turned off.

AX2550 Motor Controller User’s Manual

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RoboteQ AX2850 user manual Important Safety, Beware of Motor Runaway in Improperly Closed Loop

Contents

AX2550 AX2850 Dual Channel High Power Digital Motor ControllerAX2550 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 Beware of Motor Runaway in Improperly Closed Loop Important SafetyImportant Safety Warnings AX2550 Locating the Switches, Wires and ConnectorsQuick Start What you will needOptical Encoders Program LED Sensors AX2850 only Display AX2550 Quick StartConnecting to the Batteries and Motors Connecting to the Batteries and MotorsSignal Pin RC Mode RS232 Mode Analog Mode Connecting to the 15-pin ConnectorConnecting the R/C Radio Connecting the R/C RadioButton Operation Powering On the ControllerProg 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= Software version 1.9b Exploring furtherProduct Description AX2550 Motor Controller OverviewTechnical features Low Power Consumption Technical featuresHigh Efficiency Motor Power Outputs Optical Encoder Inputs AX2850 onlyData Logging Capabilities Advanced Safety FeaturesSturdy and Compact Mechanical Design Power Connections Connecting Power and Motors to the ControllerPower Connections Connecting Power and Motors to the Controller Controller PowerMended Off Configuration Controller PowerPowering the Controller from a single Battery Controller Powering SchemesController Powering Schemes Powering the Controller Using a Main and Backup BatteryPowering the AX2550 with a Main and Backup Supply Connecting the MotorsConverting the AX2550 to Single Channel Single Channel OperationMCU Power FusesPower Regeneration Considerations Wire Length LimitsElectrical Noise Reduction Techniques Undervoltage Protection Overvoltage ProtectionUsing the Controller with a Power Supply Using the Controller with a Power SupplyConnecting Power and Motors to the Controller General Operation Input Command ModesBasic Operation Basic OperationOpen Loop, Separate Speed Control Selecting the Motor Control ModesOpen Loop, Mixed Speed Control General OperationClose Loop Position Control Closed Loop Speed ControlSelecting the Motor Control Modes Temperature-Based Current Limitation User Selected Current Limit SettingsSetting Continuous High Amps Battery Current vs. Motor Current Battery Current vs. Motor CurrentTemperature Max Amps Motor Current = Battery Current / PWM ratioOff Regeneration Current LimitingProgrammable Acceleration Programmable AccelerationCommand Control Curves Left / Right Tuning Adjustment Left / Right Tuning AdjustmentExponentiation Parameter Value Selected Curve Parameter Value Speed Adjustment Emergency Stop using External Switch Emergency Shut Down Using Controller SwitchesActivating Brake Release or Separate Motor Excitation Activating Brake Release or Separate Motor ExcitationUsing the Inputs to Activate the Buffered Output Special Use of Accessory Digital InputsInverted Operation Self-Test Mode Self-Test ModeImportant Warning AX2550 Connections Connecting Sensors and Actuators to Input/OutputsAX2550 Connections Connecting Sensors and Actuators to Input/Outputs AX2550’s Inputs and Outputs Signal Type Use ActivatedAX2550’s Inputs and Outputs List and Pin Assignment Pin1Connecting devices to Output C Connecting devices to Output CConnecting Switches or Devices to Input E Connecting Switches or Devices to Input F Connecting Switches or Devices to Input FShow how to wire the switch to this input Connecting Switches or Devices to EStop/Invert InputAnalog Inputs Connecting Position Potentiometers to Analog InputsAnalog Inputs Ana Ana2 Operating Mode Pin Connecting Tachometer to Analog InputsOperating Mode Ana 1 p11 Ana2 p10 Ana 3 p12 Ana 4 p8 Connecting Tachometer to Analog InputsTemp oC Connecting External Thermistor to Analog InputsResistance kOhm Connecting User Devices to Analog Inputs Using the Analog Inputs to Monitor External VoltagesUsing the Analog Inputs to Monitor External Voltages Measured volts = controller reading + 128 * 0.255Internal Voltage Monitoring Sensors Internal Heatsink Temperature SensorsTemperature Conversion C Source Code Temperature Conversion C Source CodeConnecting Sensors and Actuators to Input/Outputs Optical Incremental Encoders Overview Installing Connecting Using Encoder ModuleOptical Incremental Encoders Overview Recommended Encoder Types Installing, Connecting and Using the Encoder ModInstalling 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 Cable Length and Noise Considerations Voltage Levels, Thresholds and Limit SwitchesMotor Encoder Polarity Matching Voltage Levels, Thresholds and Limit Switches Wiring Optional Limit Switches Effect of Limit Switches Wiring Limit Switches Without EncodersWiring Limit Switches Without Encoders Motor 1 Fwd Motor 1 RevUsing the Encoder to Measure Speed Using the Encoder Module to Measure DistanceMotor Fwd Motor Rev Using the Encoder to Track Position Using the Encoder to Track PositionDistance = Destination Counter value / Divider RS232 Communication with the Encoder ModuleEncoder Testing and Setting Using the PC Utility Encoder Testing and Setting Using the PC UtilityInstalling, Connecting and Using the Encoder Mod Mode Description Closed Loop Position ModeSelecting the Position Mode Mode DescriptionPosition Sensor Selection Closed Loop Position ModeSensor Mounting Feedback Potentiometer wiring in RC or RS232 Mode Feedback Potentiometer wiringFeedback Potentiometer wiring Pot wiring for RS232 or RC Command and Analog Feedback Feedback Potentiometer wiring in Analog ModeAnalog Feedback on Single Channel Controllers Analog Feedback on Single Channel ControllersSensor and Motor Polarity Using Optical Encoders in Position ModeAdding Safety Limit Switches Encoder Error Detection and ProtectionEncoder 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 Selecting the Speed Mode Closed Loop Speed ModeTachometer wiring Using Optical Encoder for Speed Feedback AX2850 onlyClosed Loop Speed Mode Tachometer or Encoder MountingSpeed Sensor and Motor Polarity Speed Sensor and Motor PolarityAdjust Offset and Max Speed Control Loop Description PID algorithm used in Speed modePID tuning in Speed Mode 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 Rapidly FlashingPermanent Faults Temporary FaultsSelf-Test Display Self-Test Display = Software version 1.9b108 C Operation C radio control modeConnector I/O Pin Assignment R/C Mode Selecting the R/C Input ModePin Input or Number Output Signal Description OperationSupplied Cable Description Input Circuit DescriptionInput Circuit Description RC Cable wiring diagram Powering the Radio from the controllerWiring for powering R/C radio from controller Powering the Radio from the controllerOperating the Controller in R/C mode Connecting to a Separately Powered RadioReception Watchdog Reception WatchdogTransmitter/Receiver Quality Considerations Important Notice about PCM RadiosJoystick Deadband Programming Joystick Deadband ProgrammingJoystick Calibration Left/Right Tuning AdjustmentAutomatic Joystick Calibration Automatic Joystick CalibrationActivating the Accessory Outputs Data Logging in R/C Mode Data Logging in R/C Mode122 Analog Control and Operation Pin Input or Number Signal Output Description Connector I/O Pin Assignment Analog ModeAnalog Control and Operation Connecting a Potentiometer Connecting to a Voltage SourceConnecting to a Voltage Source = U/R = 5V / 1000 Ohms = 0.005A = 5mA Selecting the Potentiometer ValueAnalog Deadband Adjustment Analog Deadband AdjustmentUnder Voltage Safety Power-On SafetyData Logging in Analog Mode Modified Analog cable with RS232 output data logging for PC Data Logging in Analog Mode130 Use and benefits of RS232 Serial RS-232 Controls OperationUse and benefits of RS232 Serial RS-232 Controls and Operation Connector I/O Pin Assignment RS232 ModeCable 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 Establishing Manual Communication with a PC RS232 Communication with the Encoder ModuleRoboteq v1.9b 06/01/07 s Data Logging String in R/C or Analog mode Entering RS232 from R/C or Analog modeCommands Acknowledge and Error Messages Command Type Description Controller Commands and QueriesRS-232 Watchdog Set Accessory Output Set Motor Command ValueController Commands and Queries Query Amps from Battery to each Motor Channel Query Power Applied to MotorsQuery Analog Inputs SyntaxQuery Battery Voltages Query Heatsink Temperatures?r or ?R ?m or ?MQuery Digital Inputs Reset ControllerAccessing & Changing Configuration Parameter in Flash Accessing & Changing Configuration Parameter in FlashApply Parameter Changes Read parameterLocation Description Active after Flash Configuration Parameters ListMotor Control Mode Input Control ModeAddress Access Read/Write Effective After Reset Value Mode See pagesBit Definition See pages Amps LimitAcceleration Input Switches FunctionRC Joystick or Analog Deadband Address Channel Access Read/Write Effective InstantlyExponentiation on Channel 1 and Channel Default Encoder Time Base 1 Left/Right AdjustDefault PID Gains Default Encoder Distance DividerJoystick Min, Max and Center Values Location Function Reading & Changing Operating Parameters at RuntimeRead/Change PID Values Operating Modes RegistersBit Function Address 82 P1 83 I1 84 D1 85 P2Controller Status Register PWM Frequency RegisterCurrent Amps Limit Registers Controller Identification RegisterBit Model or Function Set/Reset Encoder Counters and Destination Registers RS232 Encoder Command SetRead Encoder Counter Or !Q n Read SpeedRead Distance Read Encoder Limit Switch StatusRead Speed/Distance Read / Modify Encoder Module Registers and Parameters Switch ValueDD= parameter value Address Parameter Description Size Access Register Description Switch StatusEncoder Hardware ID code Speed or Distance 1 orCounter 1 Counter Read/Write MailboxDestination Register 1 Register DescriptionSpeed 1 Distance 1Time Base 1 Encoder ThresholdCounter 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 ModeData Logging Cables Analog and R/C Modes Data Logging String FormatDecimal to Hexadecimal Conversion Table Decimal to Hexadecimal Conversion TableDec Hex UDec Hex AX2550 Motor Controller User’s Manual 169 170 Programming using built-in Switches and Display Configuring Controller using SwitchesProgramming Methods Configuring the Controller using the Switches Entering Programming ModeChanging parameters Restoring factory defaultsSpecial Case of Joystick Calibration Programmable Parameters List Exiting the Parameter Setting ModeProgrammable Parameters List Order Letter Description Possible Values default PagesSee 176 Downloading and Installing the Utility Using the Roborun Configuration UtilitySystem Requirements Using the Roborun Configuration Utility Connecting the Controller to the PCRoborun Frame, Tab and Menu Descriptions Roborun Frame, Tab and Menu DescriptionsFile and Program Management Commands Parameter Selection and Setting and Special FunctionsView Controller Connector Pinout Getting On-Screen HelpMotor Control Mode Control SettingsLoading, Changing Controller Parameters Loading, Changing Controller ParametersPower Settings Loading, Changing Controller Parameters Left/Right Adjust Analog or R/C Specific SettingsAcceleration Setting DeadbandClosed Loop Parameters Encoder Setting and TestingEncoder Setting and Testing Encoder Module Parameters SettingExercising the Motors Running the MotorsViewing Encoder Data Running the Motors Motor Power settingRun/Stop Button MeasurementInput Status and Output Setting Real-Time Strip Chart RecorderTransmit and Receive Data Logging Data to Disk Parameter Header Data type/range Measured Parameter Connecting a JoystickUsing the Console Using the ConsoleCommand Entry Terminal ScreenViewing and Logging Data in Analog and R/C Modes Send Reset StringLoading and Saving Profiles to Disk Keep Watchdog AliveOperating the AX2550 over a Wired or Wireless LAN Operating the AX2550 over a Wired or Wireless LANUpdating the Controller’s Software Roboserver screenshot when idleUpdating the Encoder Software Creating Customized Object FilesCreating Customized Object Files Objectmaker creates controller firmware with custom defaults Mechanical Dimensions Mechanical SpecificationsMechanical Dimensions Mounting Considerations Mechanical SpecificationsWire Gauge Outside Diameter Color Length Wire DimensionsThermal Considerations Attaching the Controller Directly to a ChassisWeight