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