AX2550 AX2850
Dual Channel High Power Digital Motor Controller
AX2550 Motor Controller User’s Manual
Date Version Changes
Revision History
Revision History
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 Safety
Important Safety Warnings
AX2550
Locating the Switches, Wires and Connectors
Quick Start
What you will need
Optical Encoders Program LED Sensors AX2850 only Display
AX2550 Quick Start
Connecting to the Batteries and Motors
Connecting to the Batteries and Motors
Signal Pin RC Mode RS232 Mode Analog Mode
Connecting to the 15-pin Connector
Connecting the R/C Radio
Connecting the R/C Radio
Prog and Set button status Function
Powering On the Controller
Button Operation
Parameter Default Values Letter
Default Controller Configuration
Default Controller Configuration
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 further
Product Description
AX2550 Motor Controller Overview
Technical features
Low Power Consumption
Technical features
High Efficiency Motor Power Outputs
Optical Encoder Inputs AX2850 only
Sturdy and Compact Mechanical Design
Advanced Safety Features
Data Logging Capabilities
Power Connections
Connecting Power and Motors to the Controller
Power Connections
Connecting Power and Motors to the Controller
Controller Power
Mended Off Configuration
Controller Power
Powering the Controller from a single Battery
Controller Powering Schemes
Controller Powering Schemes
Powering the Controller Using a Main and Backup Battery
Powering the AX2550 with a Main and Backup Supply
Connecting the Motors
Converting the AX2550 to Single Channel
Single Channel Operation
MCU
Power Fuses
Electrical Noise Reduction Techniques
Wire Length Limits
Power Regeneration Considerations
Undervoltage Protection
Overvoltage Protection
Using the Controller with a Power Supply
Using the Controller with a Power Supply
Connecting Power and Motors to the Controller
General Operation
Input Command Modes
Basic Operation
Basic Operation
Open Loop, Separate Speed Control
Selecting the Motor Control Modes
Open Loop, Mixed Speed Control
General Operation
Selecting the Motor Control Modes
Closed Loop Speed Control
Close Loop Position Control
Setting Continuous High Amps
User Selected Current Limit Settings
Temperature-Based Current Limitation
Battery Current vs. Motor Current
Battery Current vs. Motor Current
Temperature Max Amps
Motor Current = Battery Current / PWM ratio
Off
Regeneration Current Limiting
Programmable Acceleration
Programmable Acceleration
Command Control Curves
Exponentiation Parameter Value Selected Curve
Left / Right Tuning Adjustment
Left / Right Tuning Adjustment
Parameter Value Speed Adjustment
Emergency Stop using External Switch
Emergency Shut Down Using Controller Switches
Activating Brake Release or Separate Motor Excitation
Activating Brake Release or Separate Motor Excitation
Inverted Operation
Special Use of Accessory Digital Inputs
Using the Inputs to Activate the Buffered Output
Self-Test Mode
Self-Test Mode
Important Warning
AX2550 Connections
Connecting Sensors and Actuators to Input/Outputs
AX2550 Connections
Connecting Sensors and Actuators to Input/Outputs
AX2550’s Inputs and Outputs
Signal Type Use Activated
AX2550’s Inputs and Outputs
List and Pin Assignment
Pin1
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
Show how to wire the switch to this input
Connecting Switches or Devices to EStop/Invert Input
Analog Inputs
Connecting Position Potentiometers to Analog Inputs
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 Tachometer to Analog Inputs
Resistance kOhm
Connecting External Thermistor to Analog Inputs
Temp oC
Connecting User Devices to Analog Inputs
Using the Analog Inputs to Monitor External Voltages
Using the Analog Inputs to Monitor External Voltages
Measured volts = controller reading + 128 * 0.255
Internal Voltage Monitoring Sensors
Internal Heatsink Temperature Sensors
Temperature Conversion C Source Code
Temperature Conversion C Source Code
Connecting Sensors and Actuators to Input/Outputs
Optical Incremental Encoders Overview
Installing Connecting Using Encoder Module
Optical Incremental Encoders Overview
Recommended Encoder Types
Installing, Connecting and Using the Encoder Mod
Pulse Frequency in Hz = RPM / 60 * PPR
Installing the Encoder Module
Installing the Encoder Module
Position of Encoder Module on Controller’s main board
Pin Name Cable Color
Connecting the Encoder
Connecting the Encoder
Motor Encoder Polarity Matching
Voltage Levels, Thresholds and Limit Switches
Cable Length and Noise Considerations
Voltage Levels, Thresholds and Limit Switches
Wiring Optional Limit Switches
Effect of Limit Switches
Wiring Limit Switches Without Encoders
Wiring Limit Switches Without Encoders
Motor 1 Fwd Motor 1 Rev
Motor Fwd Motor Rev
Using the Encoder Module to Measure Distance
Using the Encoder to Measure Speed
Using the Encoder to Track Position
Using the Encoder to Track Position
Distance = Destination Counter value / Divider
RS232 Communication with the Encoder Module
Encoder Testing and Setting Using the PC Utility
Encoder Testing and Setting Using the PC Utility
Installing, Connecting and Using the Encoder Mod
Mode Description
Closed Loop Position Mode
Selecting the Position Mode
Mode Description
Sensor Mounting
Closed Loop Position Mode
Position Sensor Selection
Feedback Potentiometer wiring
Feedback Potentiometer wiring
Feedback Potentiometer wiring in RC or RS232 Mode
Pot wiring for RS232 or RC Command and Analog Feedback
Feedback Potentiometer wiring in Analog Mode
Analog Feedback on Single Channel Controllers
Analog Feedback on Single Channel Controllers
Sensor and Motor Polarity
Using Optical Encoders in Position Mode
Encoder Error Detection and Protection
Encoder Error Detection and Protection
Adding Safety Limit Switches
SW1 SW2
Control Loop Description
Using Current Limiting as Protection
Using Current Limiting as Protection
PID tuning in Position Mode
PID tuning in Position Mode
Closed Loop Position Mode
Selecting the Speed Mode
Closed Loop Speed Mode
Tachometer wiring
Using Optical Encoder for Speed Feedback AX2850 only
Closed Loop Speed Mode
Tachometer or Encoder Mounting
Speed Sensor and Motor Polarity
Speed Sensor and Motor Polarity
Adjust Offset and Max Speed
Control Loop Description
PID algorithm used in Speed mode
PID tuning in Speed Mode
Use of the LED Display
Normal Fault Condition LED Messages
Use of the LED Display
Possible Display Motor Comment
Normal and Fault Condition LED Messages
Motor Direction Status
Fault Messages
Fault Messages
No Control
Rapidly Flashing
Self-Test Display
Temporary Faults
Permanent Faults
Self-Test Display
= Software version 1.9b
108
C Operation
C radio control mode
Connector I/O Pin Assignment R/C Mode
Selecting the R/C Input Mode
Pin Input or Number Output Signal Description
Operation
Input Circuit Description
Input Circuit Description
Supplied Cable Description
RC Cable wiring diagram
Powering the Radio from the controller
Wiring for powering R/C radio from controller
Powering the Radio from the controller
Operating the Controller in R/C mode
Connecting to a Separately Powered Radio
Reception Watchdog
Reception Watchdog
Transmitter/Receiver Quality Considerations
Important Notice about PCM Radios
Joystick Deadband Programming
Joystick Deadband Programming
Joystick Calibration
Left/Right Tuning Adjustment
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
Analog Control and Operation
Connector I/O Pin Assignment Analog Mode
Pin Input or Number Signal Output Description
Connecting to a Voltage Source
Connecting to a Voltage Source
Connecting a Potentiometer
= U/R = 5V / 1000 Ohms = 0.005A = 5mA
Selecting the Potentiometer Value
Analog Deadband Adjustment
Analog Deadband Adjustment
Data Logging in Analog Mode
Power-On Safety
Under Voltage Safety
Modified Analog cable with RS232 output data logging for PC
Data Logging in Analog Mode
130
Use and benefits of RS232
Serial RS-232 Controls Operation
Use and benefits of RS232
Serial RS-232 Controls and Operation
Connector I/O Pin Assignment RS232 Mode
Extending the RS232 Cable
Cable configuration
Cable configuration
Establishing Manual Communication with a PC
Communication Settings
Bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity
Roboteq v1.9b 06/01/07 s
RS232 Communication with the Encoder Module
Establishing Manual Communication with a PC
Data Logging String in R/C or Analog mode
Entering RS232 from R/C or Analog mode
Commands Acknowledge and Error Messages
RS-232 Watchdog
Controller Commands and Queries
Command Type Description
Controller Commands and Queries
Set Motor Command Value
Set Accessory Output
Query Amps from Battery to each Motor Channel
Query Power Applied to Motors
Query Analog Inputs
Syntax
Query Battery Voltages
Query Heatsink Temperatures
?r or ?R
?m or ?M
Query Digital Inputs
Reset Controller
Accessing & Changing Configuration Parameter in Flash
Accessing & Changing Configuration Parameter in Flash
Apply Parameter Changes
Read parameter
Location Description Active after
Flash Configuration Parameters List
Motor Control Mode
Input Control Mode
Address Access Read/Write Effective After Reset
Value Mode See pages
Bit Definition See pages
Amps Limit
Acceleration
Input Switches Function
Exponentiation on Channel 1 and Channel
Address Channel Access Read/Write Effective Instantly
RC Joystick or Analog Deadband
Default Encoder Time Base 1
Left/Right Adjust
Joystick Min, Max and Center Values
Default Encoder Distance Divider
Default PID Gains
Location Function
Reading & Changing Operating Parameters at Runtime
Read/Change PID Values
Operating Modes Registers
Bit Function
Address 82 P1 83 I1 84 D1 85 P2
Controller Status Register
PWM Frequency Register
Bit Model or Function
Controller Identification Register
Current Amps Limit Registers
Read Encoder Counter
RS232 Encoder Command Set
Set/Reset Encoder Counters and Destination Registers
Or !Q n
Read Speed
Read Speed/Distance
Read Encoder Limit Switch Status
Read Distance
DD= parameter value
Switch Value
Read / Modify Encoder Module Registers and Parameters
Address Parameter Description Size Access
Register Description
Switch Status
Encoder Hardware ID code
Speed or Distance 1 or
Counter 1
Counter Read/Write Mailbox
Destination Register 1
Register Description
Speed 1
Distance 1
Time Base 1
Encoder Threshold
Decimal Bit Hex Controller Output
Counter Read Data Format
Counter Read Data Format
164
Automatic Switching from RS232 to RC Mode
Automatic Switching from RS232 to RC Mode
Data Logging Cables
Analog and R/C Modes Data Logging String Format
Dec Hex
Decimal to Hexadecimal Conversion Table
Decimal to Hexadecimal Conversion Table
UDec Hex
AX2550 Motor Controller User’s Manual 169
170
Programming Methods
Configuring Controller using Switches
Programming using built-in Switches and Display
Configuring the Controller using the Switches
Entering Programming Mode
Special Case of Joystick Calibration
Restoring factory defaults
Changing parameters
Programmable Parameters List
Exiting the Parameter Setting Mode
See
Order Letter Description Possible Values default Pages
Programmable Parameters List
176
System Requirements
Using the Roborun Configuration Utility
Downloading and Installing the Utility
Using the Roborun Configuration Utility
Connecting the Controller to the PC
Roborun Frame, Tab and Menu Descriptions
Roborun Frame, Tab and Menu Descriptions
File and Program Management Commands
Parameter Selection and Setting and Special Functions
View Controller Connector Pinout
Getting On-Screen Help
Motor Control Mode
Control Settings
Loading, Changing Controller Parameters
Loading, Changing Controller Parameters
Power Settings
Loading, Changing Controller Parameters Left/Right Adjust
Analog or R/C Specific Settings
Acceleration Setting
Deadband
Closed Loop Parameters
Encoder Setting and Testing
Encoder Setting and Testing
Encoder Module Parameters Setting
Viewing Encoder Data
Running the Motors
Exercising the Motors
Running the Motors
Motor Power setting
Run/Stop Button
Measurement
Transmit and Receive Data
Real-Time Strip Chart Recorder
Input Status and Output Setting
Logging Data to Disk
Parameter Header Data type/range Measured Parameter
Connecting a Joystick
Using the Console
Using the Console
Command Entry
Terminal Screen
Viewing and Logging Data in Analog and R/C Modes
Send Reset String
Loading 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
Updating the Controller’s Software
Roboserver screenshot when idle
Creating Customized Object Files
Creating Customized Object Files
Updating the Encoder Software
Objectmaker creates controller firmware with custom defaults
Mechanical Dimensions
Mechanical Specifications
Mechanical Dimensions
Mounting Considerations
Mechanical Specifications
Wire Gauge Outside Diameter Color Length
Wire Dimensions
Thermal Considerations
Attaching the Controller Directly to a Chassis
Weight