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AX2550
AX2850
Dual Channel
High Power
Digital Motor
Controller
User’s Manual
v1.9b, June 1, 2007
visit www.roboteq.com to download the latest revision of this manual
©Copyright 2003-2007 Roboteq, Inc.
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2 AX2550 Motor Controller User’s Manual Version 1.9b. June 1, 2007
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Revision History Revision History Date Version Changes June 1, 2007 1.9b Added Output C active when Motors On Fixed Encoder Limit Switches Protection in case of Encoder failure in Closed Loop Speed Added Short Circuit Protection (with supporting hardware) Added Analog 3 and 4 Inputs (with supporting hardware) Added Operating Mode Change on-the-fly Changeable PWM frequency Selectable polarity for Dead Man Switch Modified Flashing Pattern Separate PID Gains for Ch1 and C2, changeable on-the-fly Mi
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4 AX2550 Motor Controller User’s Manual Version 1.9b. June 1, 2007
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Revision History 3 SECTION 1 Important Safety Warnings 13 This product is intended for use with rechargeable batteries 13 Do not Connect to a RC Radio with a Battery Attached 13 Beware of Motor Runaway in Improperly Closed Loop 13 SECTION 2 AX2550 Quick Start 15 What you will need 15 Locating the Switches, Wires and Connectors 15 Connecting to the Batteries and Motors 17 Connecting to the 15-pin Connector 18 Connecting the R/C Radio 19 Powering On the Controller 20 Button Operation 20 Default Co
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SECTION 5 General Operation 41 Basic Operation 41 Input Command Modes 41 Selecting the Motor Control Modes 42 Open Loop, Separate Speed Control 42 Open Loop, Mixed Speed Control 42 Closed Loop Speed Control 43 Close Loop Position Control 43 User Selected Current Limit Settings 44 Temperature-Based Current Limitation 44 Battery Current vs. Motor Current 45 Regeneration Current Limiting 46 Programmable Acceleration 47 Command Control Curves 48 Left / Right Tuning Adjustment 49 Activating Brake Rel
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SECTION 7 Installing, Connecting and Using the Encoder Module 71 Optical Incremental Encoders Overview 71 Recommended Encoder Types 72 Installing the Encoder Module 73 Connecting the Encoder 75 Cable Length and Noise Considerations 76 Motor - Encoder Polarity Matching 76 Voltage Levels, Thresholds and Limit Switches 76 Wiring Optional Limit Switches 78 Wiring Limit Switches Without Encoders 79 Effect of Limit Switches 79 Using the Encoder Module to Measure Distance 80 Using the Encoder to Measur
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Tachometer or Encoder Mounting 98 Tachometer wiring 98 Speed Sensor and Motor Polarity 99 Adjust Offset and Max Speed 100 Control Loop Description 100 PID tuning in Speed Mode 102 SECTION 10 Normal and Fault Condition LED Messages 103 Use of the LED Display 103 Motor Direction Status 104 Fault Messages 105 No Control 105 Temporary Faults 106 Permanent Faults 106 Self-Test Display 106 SECTION 11 R/C Operation 109 Mode Description 109 Selecting the R/C Input Mode 110 Connector I/O Pin Assignment
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Analog Deadband Adjustment 127 Power-On Safety 128 Under Voltage Safety 128 Data Logging in Analog Mode 128 SECTION 13 Serial (RS-232) Controls and Operation 131 Use and benefits of RS232 131 Connector I/O Pin Assignment (RS232 Mode) 132 Cable configuration 133 Extending the RS232 Cable 133 Communication Settings 134 Establishing Manual Communication with a PC 134 RS232 Communication with the Encoder Module 135 Entering RS232 from R/C or Analog mode 136 Data Logging String in R/C or Analog mode
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Default PID Gains 150 Joystick Min, Max and Center Values 150 Reading & Changing Operating Parameters at Runtime 151 Operating Modes Registers 152 Read/Change PID Values 152 PWM Frequency Register 153 Controller Status Register 153 Controller Identification Register 154 Current Amps Limit Registers 154 RS232 Encoder Command Set 155 Read Encoder Counter 155 Set/Reset Encoder Counters and Destination Registers 155 Read Speed 156 Read Distance 157 Read Speed/Distance 157 Read Encoder Limit Switch S
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SECTION 15 Using the Roborun Configuration Utility 177 System Requirements 177 Downloading and Installing the Utility 177 Connecting the Controller to the PC 178 Roborun Frame, Tab and Menu Descriptions 179 Getting On-Screen Help 180 Loading, Changing Controller Parameters 181 Control Settings 181 Power Settings 182 Analog or R/C Specific Settings 183 Closed Loop Parameters 184 Encoder Setting and Testing 184 Encoder Module Parameters Setting 185 Exercising the Motors 186 Viewing Encoder Data 1
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12 AX2550 Motor Controller User’s Manual Version 1.9b. June 1, 2007
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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
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Important Safety Warnings 14 AX2550 Motor Controller User’s Manual Version 1.9b. June 1, 2007
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SECTION 2 AX2550 Quick Start This section will give you the basic information needed to quickly install, setup and run your AX2550 controller in a minimal configuration. The AX2850 is a version of the AX2550 controller with the addition of Optical Encoder inputs. What you will need For a minimal installation, gather the following components: One AX2550 Controller and its provided cables 12V to 40V high capacity, high current battery One or two brushed DC motors One R/C to DB15 connecto
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AX2550 Quick Start The front side (shown in Figure 1) contains the buttons and display needed to operate and monitor the controller. The 15-pin connector provides the connection to the R/C radio, joy- stick or microcomputer, as well as connections to optional switches and sensors. Program Set Reset Connector to Connector to Receiver/Controls Controller Configu- Operating Status Optical Encoders ration buttons and Program LED and sensors (AX2850 only) Display FIGURE 1. Front Controller Layout A
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Connecting to the Batteries and Motors Connecting to the Batteries and Motors Connection to the batteries and motors is shown in the figure below and is done by con- necting the set of wires coming out from the back of the controller. Motor2 Power switch Optional Diode + Fuse On - Off + - Optional Motor1 Emergency Disconnect 12V to 24V Motor Battery Controller Notes: - The Battery Power connection are doubled in order to provide the maximum current to the controller. If only one motor is used
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AX2550 Quick Start the Controller” on page 29 for more information about batteries and other connection options. Important Warning Do not rely on cutting power to the controller for it to turn off if the Power Control is left floating. If motors are spinning because the robot is pushed are pushed or because of inertia, they will act as generators and will turn the controller, possibly in an unsafe state. ALWAYS ground the Power Control wire to turn the controller Off and keep it Off. Import
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Connecting the R/C Radio Connecting the R/C Radio Connect the R/C adapter cables to the controller on one side and to two or three channels on the R/C receiver on the other side. If present, the third channel is for activating the accessory outputs and is optional. When operating the controller in “Separate” mode, the wire labelled Ch1 controls Motor1, and the wire labelled Ch2 controls Motor2. When operating the controller in “Mixed” mode, Ch1 is used to set the robot’s speed and directio
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AX2550 Quick Start Powering On the Controller Important reminder: There is no On-Off switch on the controller. You must insert a switch on the controller’s power wire as described in section“Connecting to the Batteries and Motors” on page 17. To power the controller, center the joystick and trims on the R/C transmitter. In Analog mode, center the command potentiomenter or joystick.Then turn on the switch that you have placed on the on the Power Control input. If the R/C transmitter and/or re
