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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 Date Version Changes Revision HistoryRevision 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 Important Safety Beware of Motor Runaway in Improperly Closed Loop Important Safety Warnings Quick Start Locating the Switches, Wires and ConnectorsAX2550 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 Prog and Set button status Function Powering On the ControllerButton Operation Parameter Default Values Letter Default Controller ConfigurationDefault Controller Configuration 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 High Efficiency Motor Power Outputs Technical featuresLow Power Consumption Optical Encoder Inputs AX2850 only Sturdy and Compact Mechanical Design Advanced Safety FeaturesData Logging Capabilities Power Connections Connecting Power and Motors to the ControllerPower 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 Electrical Noise Reduction Techniques Wire Length LimitsPower Regeneration Considerations 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 Basic Operation Input Command ModesGeneral Operation Basic Operation Open Loop, Mixed Speed Control Selecting the Motor Control ModesOpen Loop, Separate Speed Control General Operation Selecting the Motor Control Modes Closed Loop Speed ControlClose Loop Position Control Setting Continuous High Amps User Selected Current Limit SettingsTemperature-Based Current Limitation Temperature Max Amps Battery Current vs. Motor CurrentBattery Current vs. Motor Current Motor Current = Battery Current / PWM ratio Regeneration Current Limiting Off Programmable Acceleration Programmable Acceleration Command Control Curves Exponentiation Parameter Value Selected Curve Left / Right Tuning AdjustmentLeft / Right Tuning Adjustment Parameter Value Speed Adjustment Activating Brake Release or Separate Motor Excitation Emergency Shut Down Using Controller SwitchesEmergency Stop using External Switch Activating Brake Release or Separate Motor Excitation Inverted Operation Special Use of Accessory Digital InputsUsing the Inputs to Activate the Buffered Output Self-Test Mode Self-Test Mode Important 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 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 Analog Inputs Connecting Position Potentiometers to 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 Resistance kOhm Connecting External Thermistor to Analog InputsTemp oC Using the Analog Inputs to Monitor External Voltages Using the Analog Inputs to Monitor External VoltagesConnecting User Devices to Analog Inputs 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 Optical Incremental Encoders Overview Installing Connecting Using Encoder ModuleOptical Incremental Encoders Overview Installing, Connecting and Using the Encoder Mod Recommended Encoder Types Pulse Frequency in Hz = RPM / 60 * PPR Installing the Encoder ModuleInstalling the Encoder Module Position of Encoder Module on Controller’s main board Pin Name Cable Color Connecting the EncoderConnecting the Encoder Motor Encoder Polarity Matching Voltage Levels, Thresholds and Limit SwitchesCable Length and Noise Considerations Voltage Levels, Thresholds and Limit Switches Wiring Optional Limit Switches Wiring Limit Switches Without Encoders Wiring Limit Switches Without EncodersEffect of Limit Switches Motor 1 Fwd Motor 1 Rev Motor Fwd Motor Rev Using the Encoder Module to Measure DistanceUsing the Encoder to Measure Speed 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 Selecting the Position Mode Closed Loop Position ModeMode Description Mode Description Sensor Mounting Closed Loop Position ModePosition Sensor Selection Feedback Potentiometer wiring Feedback Potentiometer wiringFeedback Potentiometer wiring in RC or RS232 Mode 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 Encoder Error Detection and ProtectionAdding Safety Limit Switches SW1 SW2 Control Loop Description Using Current Limiting as ProtectionUsing Current Limiting as Protection PID tuning in Position Mode PID tuning in Position Mode Closed Loop Position Mode Closed Loop Speed Mode Selecting the Speed Mode Closed Loop Speed Mode Using Optical Encoder for Speed Feedback AX2850 onlyTachometer wiring 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 Use of the LED Display Normal Fault Condition LED MessagesUse of the LED Display Possible Display Motor Comment Normal and Fault Condition LED MessagesMotor Direction Status No Control Fault MessagesFault Messages Rapidly Flashing Self-Test Display Temporary FaultsPermanent Faults = Software version 1.9b Self-Test Display 108 C radio control mode C Operation Pin Input or Number Output Signal Description Selecting the R/C Input ModeConnector I/O Pin Assignment R/C Mode Operation Input Circuit Description Input Circuit DescriptionSupplied Cable 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 Analog Control and Operation Connector I/O Pin Assignment Analog ModePin Input or Number Signal Output Description Connecting to a Voltage Source Connecting to a Voltage SourceConnecting a Potentiometer Selecting the Potentiometer Value = U/R = 5V / 1000 Ohms = 0.005A = 5mA Analog Deadband Adjustment Analog Deadband Adjustment Data Logging in Analog Mode Power-On SafetyUnder Voltage Safety Data Logging in Analog Mode Modified Analog cable with RS232 output data logging for PC 130 Use and benefits of RS232 Serial RS-232 Controls OperationUse and benefits of RS232 Connector I/O Pin Assignment RS232 Mode Serial RS-232 Controls and Operation Extending the RS232 Cable Cable configurationCable configuration Establishing Manual Communication with a PC Communication SettingsBits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Roboteq v1.9b 06/01/07 s RS232 Communication with the Encoder ModuleEstablishing Manual Communication with a PC Entering RS232 from R/C or Analog mode Data Logging String in R/C or Analog mode Commands Acknowledge and Error Messages RS-232 Watchdog Controller Commands and QueriesCommand Type Description Controller Commands and Queries Set Motor Command ValueSet Accessory Output Query Analog Inputs Query Power Applied to MotorsQuery Amps from Battery to each Motor Channel Syntax ?r or ?R Query Heatsink TemperaturesQuery Battery Voltages ?m or ?M Reset Controller Query Digital Inputs Apply Parameter Changes Accessing & Changing Configuration Parameter in FlashAccessing & Changing Configuration Parameter in Flash Read parameter Flash Configuration Parameters List Location Description Active after Address Access Read/Write Effective After Reset Input Control ModeMotor Control Mode Value Mode See pages Amps Limit Bit Definition See pages Input Switches Function Acceleration Exponentiation on Channel 1 and Channel Address Channel Access Read/Write Effective InstantlyRC Joystick or Analog Deadband Left/Right Adjust Default Encoder Time Base 1 Joystick Min, Max and Center Values Default Encoder Distance DividerDefault PID Gains Reading & Changing Operating Parameters at Runtime Location Function Bit Function Operating Modes RegistersRead/Change PID Values Address 82 P1 83 I1 84 D1 85 P2 PWM Frequency Register Controller Status Register Bit Model or Function Controller Identification RegisterCurrent Amps Limit Registers Read Encoder Counter RS232 Encoder Command SetSet/Reset Encoder Counters and Destination Registers Read Speed Or !Q n Read Speed/Distance Read Encoder Limit Switch StatusRead Distance DD= parameter value Switch ValueRead / Modify Encoder Module Registers and Parameters Address Parameter Description Size Access Encoder Hardware ID code Switch StatusRegister Description Speed or Distance 1 or Destination Register 1 Counter Read/Write MailboxCounter 1 Register Description Time Base 1 Distance 1Speed 1 Encoder Threshold Decimal Bit Hex Controller Output Counter Read Data FormatCounter Read Data Format 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 Dec Hex Decimal to Hexadecimal Conversion TableDecimal to Hexadecimal Conversion Table UDec Hex AX2550 Motor Controller User’s Manual 169 170 Programming Methods Configuring Controller using SwitchesProgramming using built-in Switches and Display Entering Programming Mode Configuring the Controller using the Switches Special Case of Joystick Calibration Restoring factory defaultsChanging parameters Exiting the Parameter Setting Mode Programmable Parameters List See Order Letter Description Possible Values default PagesProgrammable Parameters List 176 System Requirements Using the Roborun Configuration UtilityDownloading and Installing the Utility Connecting the Controller to the PC Using the Roborun Configuration Utility Roborun Frame, Tab and Menu Descriptions Roborun Frame, Tab and Menu Descriptions View Controller Connector Pinout Parameter Selection and Setting and Special FunctionsFile and Program Management Commands Getting On-Screen Help Loading, Changing Controller Parameters Control SettingsMotor Control Mode Loading, Changing Controller Parameters Power Settings Acceleration Setting Analog or R/C Specific SettingsLoading, Changing Controller Parameters Left/Right Adjust Deadband Encoder Setting and Testing Closed Loop Parameters Encoder Module Parameters Setting Encoder Setting and Testing Viewing Encoder Data Running the MotorsExercising the Motors Run/Stop Button Motor Power settingRunning the Motors Measurement Transmit and Receive Data Real-Time Strip Chart RecorderInput Status and Output Setting Logging Data to Disk Connecting a Joystick Parameter Header Data type/range Measured Parameter Command Entry Using the ConsoleUsing the Console Terminal Screen Loading and Saving Profiles to Disk Send Reset StringViewing and Logging Data in Analog and R/C Modes 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 Creating Customized Object FilesUpdating the Encoder Software Objectmaker creates controller firmware with custom defaults Mechanical Dimensions Mechanical SpecificationsMechanical Dimensions Mechanical Specifications Mounting Considerations Thermal Considerations Wire DimensionsWire Gauge Outside Diameter Color Length Attaching the Controller Directly to a Chassis Weight