AX2550/AX2850 Users Manual

MDC2250
2x60A
High Performance
Dual Channel
Forward/Reverse
Brushed DC Motor
Controller with USB
and Encoder Inputs
Roboteq’s MDC2250 controller is designed to convert commands received from an RC radio, Analog Joystick, wireless
modem, PC (via RS232 or USB) or microcomputer into high
voltage and high current output for driving one or two DC
motors. Designed for maximal ease-of-use, it is delivered with
all necessary cables and hardware, and is ready to use in minutes.
Features List
The controller features a high-performance 32-bit microcomputer and quadrature encoder inputs to perform advanced
motion control algorithms in Open Loop or Close Loop (Speed
or Position) modes. The MDC2250 features several Analog,
Pulse and Digital I/Os which can be remapped as command or
feedback inputs, limit switches, or many other functions.
The controller’s two motor channels can either be operated
independently or mixed to set the direction and rotation of a
vehicle by coordinating the motion of each motor.
Numerous safety features are incorporated into the controller
to ensure reliable and safe operation. The controller's operation
can be extensively automated and customized using Basic Language scripts. The controller can be reprogrammed in the field
with the latest features by downloading new operating software from Roboteq.
Applications
•
•
•
•
•
•
•
•
Industrial Automation
Tracking, Pan & Tilt systems
•
USB, RS232, 0-5V Analog, or Pulse (RC radio) command
modes
•
Auto switch between USB, RS232, Analog, or Pulse based
on user-defined priority
•
Built-in high-power power drivers for two brushed DC
motors at up to 60A output per channel
•
Full forward & reverse control on each channel. Four quadrant operation. Supports regeneration
•
•
Operates from a single 10V-50V power source
•
Up to 4 Analog Inputs for use as command and/or feedback
•
Up to 5 Pulse Length, Duty Cycle or Frequency Inputs for
use as command and/or feedback
•
Up to 6 Digital Inputs for use as Deadman Switch, Limit
Switch, Emergency stop or user inputs
•
•
Dual Quadrature Encoder inputs with 32-bit counters
Police and Military Robots
Selectable min, max, center and deadband in Pulse and
Analog modes
•
Selectable exponentiation factors for each command
inputs
•
Trigger action if Analog, Pulse or Encoder capture are outside user selectable range (soft limit switches)
•
•
Open loop or closed loop speed control operation
Flight simulators
Telepresence Systems
Animatronics
MDC2250 Motor Controller Datasheet
2 general purpose 24V, 1A output for brake release or
accessories
•
Terrestrial and Underwater Robotic Vehicles
Automatic Guided Vehicles
Programmable current limit for each channel up to 2x60A
for protecting controller, motors, wiring and battery
Closed loop position control with analog or pulse/frequency feedback
•
Precise speed and position control when Encoder feedback is used
•
PID control loop with separate gains for each channel
1
•
Multi-range PID gains changing on-the-fly according to
motor speed
•
10 to 32kHz user programmable Pulse Width Modulation
(PWM) output.
•
Optional Mixed control (sum and difference) for tank-like
steering
•
•
Overvoltage and Undervoltage protection
•
Configurable Data Logging of operating parameters on
RS232 Output for telemetry or analysis
•
•
Built-in Battery Voltage and Temperature sensors
Optional 12V backup power input for powering safely the
controller if the main motor batteries are discharged
•
Power Control wire for turning On or Off the controller
from external microcomputer or switch
•
•
No consumption by output stage when motors stopped
•
•
Separate Programmable acceleration and deceleration
for each motor
•
•
•
•
•
Separate Programmable maximum forward and reverse
power
•
Regulated 5V output for powering Encoders, RC radio,
RF Modem or microcomputer
•
Ultra-efficient 3 mOhm High-Efficiency version ON resistance MOSFETs
•
•
Orderable as single channel version up to 120A
•
•
•
•
•
Programmable Watchdog for automatic motor shutdown
in case of command loss
Overtemperature protection
Diagnostic LED
Open frame design with heat conducting bottom plate
Efficient heat sinking. Operates without a fan in most
applications
Power wiring 0.25" Faston tabs
5.5” (139.7mm) L, 5.5” W (139.7mm), 1.0” (25mm) H
-40o to +85o C operating environment
0.5 lbs (250g)
Easy configuration, tuning and monitory using provided
PC utility
Field upgradeable software for installing latest features
via the internet
Stall detection and selectable triggered action if Amps is
outside user-selected range
Short circuit protection with selectable sensitivity levels
Orderable Product References
TABLE 1.
2
Reference
Number of Channels
Amps/Channel
Volts
Cooling
MDC2250
2
60
50V
Conduction Plate
MDC2250S
1
240
50V
Conduction Plate
MDC2250 Motor Controller Datasheet
Version 1.1. July 7, 2011
Power Wires Identifications and Connection
Power Wires Identifications and Connection
The diagram below shows how to wire the controller and how to turn power On and Off.
F2
1A
SW1 Main
On/Off Switch 1A
PwrCtrl
Note 1
M1+
Ground
Motor 1
Backup
Battery
M1Diode
>20A
Resistor
1K, 0.5W
Note 3
VMot
VMot
F1
Note 4
+
M2+
Note 2
-
Motor 2
SW2
Emergency
Cut-off Switch
M2-
Ground
Ground
I/O Connector
Main
Battery
Note 5
Do not Connect!
FIGURE 8. Powering the controller. Thick lines identify MANDATORY connections
Important Warning
Carefully follow the wiring Instructions provided in the Read Me First sheet that comes with the controller, or in the Power Connection section of the User Manual. The information on this datasheet is only a
summary.
Mandatory Connections
It is imperative that the controller is connected as shown in the above diagram in order to ensure a safe and trouble-free operation. All connections shown as thick black lines are mandatory. The controller must be powered On/
Off using switch SW1on the Power Control Header. Use a suitable high-current fuse F1 as a safety measure to
prevent damage to the wiring in case of major controller malfunction.
The battery must be connected in permanence to the controller’s VMot power via an input emergency switch
SW2 as additional safety measure.
Precautions and Optional Connections
Note1: Backup battery to ensure motor operation with weak or discharged batteries, connect a second battery to
the Power Control wire/terminal via the SW1 switch.
Note2: Use precharge 1K, 0.5W Resistor to prevent switch arcing.
Note3: Insert a high-current diode to ensure a return path to the battery during regeneration in case the fuse is
blown.
Note4: Optionally ground the VMot tabs when the controller is Off if there is any concern that the motors could
be made to spin and generate voltage in excess of 50V.
Note5: Beware not to create a path from the ground pins on the I/O connector and the battery minus terminal.
MDC2250 Motor Controller Datasheet
3
Single Channel Wiring
The single channel version of the controller (MDC2250S) requires that the output be parallel and that the load be
wired as shown in the diagram below.
M
VMOT
M1-
M1+
GND
M2- M2+
VMOT
FIGURE 9. MDC2250S wiring diagram
Important Warning
This wiring is only possible on controllers fitted with the Single Channel version of the controller logic. Dual channel controllers will be damaged if wired as single channel. Verify that the PC utility identifies the controller as
MDC2250S before applying power to the load.
Encoder Wiring
The encoder connector is a 6-pin Molex Microfit 3.0, model 43645. Pin assignment is in the table below.
6
1
6
1
FIGURE 10. Encoder connector
TABLE 4.
Pin Number
1
2
3
4
5
6
Signal
5Vout
Enc1A
Enc1B
Enc2A
Enc2B
GND
Commands and I/O Connections
Connection to RC Radio, Microcomputer, Joystick and other low current sensors and actuators is done via the 15
connector located in front of the board. The functions of many pins vary depending on user configuration. Pin
assignment is found in the table below.
8
15
1
9
FIGURE 11. Connector pin locations
4
MDC2250 Motor Controller Datasheet
Version 1.1. July 7, 2011
Commands and I/O Connections
TABLE 5.
Connector Pin
Power
1
9
Dout
Com
RC
Ana
Dinput
DOUT1
Unused
DOUT2
Unused
2
TxOut
10
RS232Tx
RC5
3
ANA1
DIN5
RxIn
11
ANA4
RC1
12
AnaCmd1
RS232Rx
RC4
4
5
Default Config
RC3
ANA3
DIN4
AnaCmd2
DIN1
RCRadio1
DIN3
Unused
GND
13
GND
14
5VOut
6
7
SCLI
Reserved
SDAI
Reserved
15
8
RC2
ANA2
DIN6
Unused
DIN2
RCRadio2
Default I/O Configuration
The controller can be configured so that practically any Digital, Analog and RC pin can be used for any purpose.
The controller’s factory default configuration provides an assignment that is suitable for most applications. The
figure below shows how to wire the controller to two analog potentiometers, an RC radio, and the RS232 port. It
also shows how to connect the two outputs to motor brake solenoids. You may omit any connection that is not
required in your application. The controller automatically arbitrates the command priorities depending on the presence of a valid command signal in the following order: 1-RS232, 2-RC Pulse, 3-Analog. If needed, use the Roborun+ PC Utility to change the pin assignments and the command priority order.
RC Ch2
2
RC Ch1
RS232
Ground
TxOut
RxIn
1
8
1
Motor 1
Motor 2
15
9
Pot 2
Pot 1
FIGURE 12. Factory default pins assignment
MDC2250 Motor Controller Datasheet
5
Status LED Flashing Patterns
After the controller is powered on, the Power LED will turn on, indicating that the controller is On. The Status LED
will be flashing at a 2 seconds interval. The flashing pattern provides operating or exception status information.
Idle - Waiting for Command
RS232/USB Mode
RC Pulse Mode
Analog Mode
FIGURE 13. Normal Operation Flashing Patterns
Short Detected
Overheat
Under or Over Voltage
Power Stage Off
FIGURE 14. Exception or Fault Flashing Patterns
Additional status information may be obtained by monitoring the controller with the PC utility.
Electrical Specifications
Absolute Maximum Values
The values in the table below should never be exceeded, permanent damage to the controller may result.
TABLE 6.
Parameter
Measure point
Min
Typ
Max
Units
55
Volts
Battery Leads Voltage
Ground to VBat
Reverse Voltage on Battery Leads
Ground to VBat
Power Control Voltage
Ground to Pwr Control wire
65
Volts
Motor Leads Voltage
Ground to M1+, M1-, M2+, M2-
55(1)
Volts
Digital Output Voltage
Ground to Output pins
30
Volts
Analog and Digital Inputs Voltage
Ground to any signal pin on 15-pin and
encoder connectors
15
Volts
RS232 I/O pins Voltage
External voltage applied to Rx/Tx pins
15
Volts
Temperature
Board
Humidity
Board
-1
-40
Volts
85
oC
100 (2)
%
Note 1: Maximum regeneration voltage in normal operation. Never inject a DC voltage from a battery or other fixed source
Note 2: Non-condensing
6
MDC2250 Motor Controller Datasheet
Version 1.1. July 7, 2011
Electrical Specifications
Power Stage Electrical Specifications (at 25oC ambient)
TABLE 7.
Parameter
Measure point
Models
Min
Max
Units
Battery Leads Voltage
Ground to VBat
All
0 (1)
55
Volts
Motor Leads Voltage
Ground to M1+, M1-,
M2+, M2-
All
0 (1)
55 (2)
Volts
Power Control Voltage
Ground to Power Control wire
All
0 (1)
65
Volts
Minimum Operating Voltage
VBat or Pwr Ctrl wires
All
9 (3)
Over Voltage protection range
Ground to VBat
All
5
50 (4)
55
Volts
Under Voltage protection range
Ground to VBat
All
0
5 (4)
55
Volts
Idle Current Consumption
VBat or Pwr Ctrl wires
All
50
100 (5)
150
mA
ON Resistance
VBat to M+, plus Mto Ground at 100%
power. Per channel
All
Max Current per channel for
30s
Motor current
Continuous Max Current per
channel
Motor current
Current Limit range
Ch1 or Ch2 Motor
current
MDC2250
10
50(8)
60
Amps
MDC2250S
10
100 (8)
120 (6)
Amps
Ch1 or Ch2 Motor
current
MDC2250
10
60(8)
60
Amps
MDC2250S
10
120 (8)
120 (6)
Amps
Stall Detection timeout range
Ch1 or Ch2 Motor
current
All
1
65000 (9)
65000
milliseconds
Short Circuit Detection
threshold (10)
Between Motor wires
or Between Motor
wire and Ground
MDC2250
140 (11)
400 (11)
Amps
MDC2250S
280
800
Amps
Short Circuit Detection
threshold
Between Motor wires
and VBat
All
No Protection. Permanent damage will result
Motor Acceleration/Deceleration range
Ch1 or Ch2
All
100
Stall Detection Amps range
Typ
Volts
6
mOhm
MDC2250
60
Amps
MDC2250S
120 (6)
Amps
MDC2250
50 (6)(7)
Amps
MDC2250S
100 (6)(7)
Amps
500 (12)
65000
milliseconds
Note 1: Negative voltage will cause a large surge current. Protection fuse needed if battery polarity inversion is possible
Note 2: Maximum regeneration voltage in normal operation. Never inject a DC voltage from a battery or other fixed source
Note 3: Minimum voltage must be present on VBat or Power Control wire
Note 4: Factory default value. Adjustable in 0.1V increments
Note 5: Current consumption is lower when higher voltage is applied to the controller’s VBat or PwrCtrl wires
Note 6: Current is sum of both synchronized channels. Current must be balanced between channel to obtain max current.
Note 7: Estimate. Limited by case temperature. Current may be higher with better cooling
Note 8: Factory default value. Adjustable in 0.5A increments
Note 9: Factory default value. Time in ms that Stall current must be exceeded for detection
Note 10: Controller will stop until restarted in case of short circuit detection
Note 11: Sensitivity selectable by software
Note 12: Factory default value. Time in ms for power to go from 0 to 100%
MDC2250 Motor Controller Datasheet
7
Command, I/O and Sensor Signals Specifications
TABLE 8.
Parameter
Measure point
Min
Typ
Main 5V Output Voltage
Ground to 5V pins on
4,6
4,75
4,9
Volts
5V Output Current
5V pins on Hall Connector and DSub15
200 (1)
mA
Digital Output Voltage
Ground to Output pins
30
Volts
Digital Output Current
Output pins, sink current
1
Amps
Output On resistance
Output pin to ground
0,75
1,5
Ohm
Output Short circuit threshold
Output pin
1,4
1,75
Amps
Input Impedances
AIN/DIN Input to Ground
Digital Input 0 Level
Ground to Input pins
-1
1
Volts
Digital Input 1 Level
Ground to Input pins
3
15
Volts
Analog Input Range
Ground to Input pins
0
5,1
Volts
Analog Input Precision
Ground to Input pins
0,5
%
Analog Input Resolution
Ground to Input pins
1
mV
Pulse durations
Pulse inputs
20000
10
us
Pulse repeat rate
Pulse inputs
50
250
Hz
Pulse Capture Resolution
Pulse inputs
Frequency Capture
Pulse inputs
100
Encoder count
Internal
-2.147
Encoder frequency
Encoder input pins
1,05
Max
Units
53
kOhm
1
us
10000
Hz
2,15
10^9 Counts
250
kHz
Note 1: Sum of all 5VOut outputs
Operating & Timing Specifications
TABLE 9.
Parameter
Measure Point
Min
Typ
Max
Command Latency
Command to output change
1
0,5
1
ms
PWM Frequency
Ch1, Ch2 outputs
10
18 (1)
32
kHz
Closed Loop update rate
Internal
USB Rate
USB pins
RS232 baud rate
Rx & Tx pins
RS232 Watchdog timeout
Rx pin
1000
Hz
12
115200 (2)
1 (3)
Units
MBits/s
Bits/s
65000
ms
Note 1: May be adjusted with configuration program
Note 2: 115200, 8-bit, no parity, 1 stop bit, no flow control
Note 3: May be disabled with value 0
8
MDC2250 Motor Controller Datasheet
Version 1.1. July 7, 2011
Electrical Specifications
Scripting
TABLE 10.
Parameter
Measure Point
Scripting Flash Memory
Internal
Max Basic Language programs
Internal
Integer Variables
Internal
Boolean Variables
Internal
Execution Speed
Internal
Min
Typ
Max
8192
Bytes
1000
50 000
Units
1500
Lines
1024
Words (1)
1024
Symbols
100 000
Lines/s
Note 1: 32-bit words
Thermal Specifications
TABLE 11.
Parameter
Measure Point
Model
Min
Board Temperature
Heatsink
All
Thermal Protection range
Heatsink
All
Power Dissipation
Case
All
Thermal resistance
Power MOSFETs to heatsink
All
Typ
Max
Units
-40
85 (1)
oC
80
90 (2)
oC
30
Watts
2
oC/W
Max
Units
Note 1: Thermal protection will protect the controller power
Note 2: Max allowed power out starts lowering at minimum of range, down to 0 at max of range
Mechanical Specifications
TABLE 12.
Parameter
Measure Point
Min
Typ
Weight
Board
250 (0.5)
g (lbs)
Power Connectors width
Terminal tab
0,25
Inches
0.25"
(6.3 mm)
0.57"
0.7" (17.8mm)
0.3"
(14.5mm)
(7.6 mm)
0.16" (4.0mm)
0.325" (8.3 mm)
FIGURE 15. MDC2250 front view and dimensions
MDC2250 Motor Controller Datasheet
9
5.50" (139.7mm)
5.25" (133.4mm)
0.120" (3.0mm)
0.15"
(3.8mm)
0.120" (3.0mm)
0.40" (10.2mm)
0.3" (7.6mm)
2.32" (59.0mm)
2.0" (5.08mm)
4.20" (106.7mm)
0.3" (7.6mm)
0.2" (5.1mm)
0.2" (5.1mm)
0.6" (10.11mm)
1.09"
0.35" (8.9mm)
0.15"
(3.8mm)
5.00" (127.0mm)
5.50" (139 .7mm)
0.35" (8.9mm)
2.75" (69.9mm)
0.24" (6.0mm)
0.65" (16.1mm)
0.40" (10.2mm)
0.15" (3.8mm)
(3.8mm)
0.15" (3.8mm)
0.65" (16.1mm)
3.42" (86.9mm)
1.25" (31.8mm)
3.00" (76.2mm)
FIGURE 16. MDC2250 top view and dimensions
10
MDC2250 Motor Controller Datasheet
Version 1.1. July 7, 2011