RoboteQ Dual Channel Digital Motor Controller AX2550 Datasheet

SDC21xx
2x20A or 1x40A
High Performance
Dual Channel
Brushed DC Motor
Controller with USB
and CAN Interface
Fitting a very compact 70x70mm board, Roboteq’s SDC21xx
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. A version with CAN bus
allows up to 127 controllers to communicate at up to 1Mbit/s
on a single twisted pair.
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 SDC21xx features several Analog,
Pulse and Digital I/Os which can be remapped as command or
feedback inputs, limit switches, or many other functions.
•
•
For mobile robot applications, 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 user programs. The controller can be reprogrammed in the field with the latest features by downloading
new operating software from Roboteq.
•
Built-in programming language for automation and customization
•
•
Operates from a single power source
Applications
• Industrial Automation
• Tracking, Pan & Tilt systems
• Small to mid-size Terrestrial and Underwater Robotic
Vehicles
•
•
•
•
•
USB, RS232, 0-5V Analog, or Pulse (RC radio) command
modes
•
•
Available in version with CAN bus up to 1Mbit/s
•
•
SDC21xx Motor Controller Datasheet
Built-in high-power power drivers for two brushed DC
motors at up to 20A output per channel
Available in single channel version up to 40A
Full forward & reverse control on each channel. Four quadrant operation. Supports regeneration
Programmable current limit for each channel up to 2x20A
or 1x40A for protecting controller, motors, wiring and battery
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
2 general purpose 24V, 1A output for brake release or
accessories
•
Selectable min, max, center and deadband in Pulse and
Analog modes
•
Selectable exponentiation factors for each command
inputs
Telepresence Systems
Animatronics
Input for direct connection to Spektrum digital RC radios
•
Automatic Guided Vehicles
Automated machines
Auto switch between USB, RS232 (12V levels or noninverted TTL levels), CAN, Analog, or Pulse based on userdefined priority
1
•
Trigger action if Analog, Pulse or Encoder capture are
outside user selectable range (soft limit switches)
•
•
Open loop or closed loop speed control operation
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
Optional Mixed control (sum and difference) for tank-like
steering
•
Configurable Data Logging of operating parameters on
RS232 Output for telemetry or analysis
•
•
Built-in Battery Voltage and Temperature sensors
•
•
Power Control header for turning On or Off the controller
from external microcomputer or switch
No consumption by output stage when motors stopped
Regulated 5V output for powering Encoders, RC radio,
RF Modem or microcomputer
•
Separate Programmable acceleration and deceleration
for each motor
•
Separate Programmable maximum forward and reverse
power
•
•
Support for CANopen and two simplified CAN protocols
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Orderable as single channel version up to 40A
Stall detection and selectable triggered action if Amps is
outside user-selected range
Overvoltage and Undervoltage protection
Programmable Watchdog for automatic motor shutdown
in case of command loss
Overtemperature protection
Diagnostic LED
Efficient heat sinking using conduction bottom plate.
Operates without a fan in most applications
Power wiring via terminal strip wires up to AWG12
2.76” (70mm) L, 2.76” W (70mm), 0.78” (20mm) H
-40o to +85o C operating environment
3.5oz (100g)
Easy configuration, tuning and monitory using provided
PC utility
Field upgradeable software for installing latest features
via the internet
Direct connection to multi-channel Spektrum SPM9545
2.4GHz RC satellite receiver
Ultra-efficient 10 mOhm ON resistance MOSFETs
Orderable Product References
TABLE 1.
2
Reference
Number of Channels
Amps/Channel
Volts
CAN
USB
SDC2130
2
20
30
No
Yes
SDC2160
2
20
60
No
Yes
SDC2130S
1
40
30
No
Yes
SDC2160S
1
40
60
No
Yes
SDC2160N
2
20
60
Yes
No
SDC2160SN
1
40
60
Yes
No
SDC21xx Motor Controller Datasheet
Version 1.3. April 05, 2014
Power Wires Identifications and Connection
Important Safety Disclaimer
Dangerous uncontrolled motor runaway condition can occur for a number of reasons, including, but not
limited to: command or feedback wiring failure, configuration error, faulty firmware, errors in user script or
user program, or controller hardware failure.
The user must assume that such failures can occur and must make his/her system safe in all conditions.
Roboteq will not be liable in case of damage or injury as a result of product misuse or failure.
Power Wires Identifications and Connection
Power connections are made through a 6 position screw terminal.
Battery and Motor Connections
M1+ M1- VMot GND M2+ M2-
P2
50V
Jumper
P4
P3
GND
PwrCtrl
J2
8
P1
J1
USB Connector
15
1
Spektrum
Radio Connector
9
IO Connector
FIGURE 8. Controller layout
SDC21xx Motor Controller Datasheet
3
The diagram below shows how to wire the dual-channel 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
>10A
Resistor
1K, 0.5W
Note 3
M2+
Note 2
VMot
F1
Note 4
Motor 2
SW2
Emergency
Contactor or
Cut-off Switch
M2-
Ground
+
I/O Connector
Main
Battery
Note 5
Do not Connect!
FIGURE 9. Powering the controller. Thick lines identify MANDATORY connections
Important Warning
Carefully follow the wiring instructions provided 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 line are mandatory. The controller must be powered
On/Off using switch SW1on the Power Control Header.
Emergency Switch or Contactor
The battery must be connected in permanence to the controller’s VMot power via an input emergency switch or
contactor SW2 as additional safety measure. The user must be able to deactivate the switch or contactor at any
time, independently of the controller state.
Precautions and Optional Connections
Note 1: Optional backup battery to ensure motor operation with weak or discharged battery.
Note 2: Use precharge 1K Resistor to prevent switch arcing.
Note 3: Insert a high-current diode to ensure a return path to the battery during regeneration in case the fuse is
blown.
Note 4: Optionally ground the VMot wires when the controller is Off if there is any concern that the motors could
be made to spin and generate voltage in excess of 35V.
Note 5: Beware not to create a path from the ground pins on the I/O connector and the battery’s minus terminal.
4
SDC21xx Motor Controller Datasheet
Version 1.3. April 05, 2014
Use of Safety Contactor for Critical Applications
Use of Safety Contactor for Critical Applications
An external safety contactor must be used in any application where damage to property or injury to person can
occur because of uncontrolled motor operation resulting from failure in the controller’s power output stage.
F2
1A
SW1 Main
On/Off Switch 1A
PwrCtrl
Ground
Resistor
1K, 0.5W
Diode
>20A
F1
VMot
Digital Out
to +40V Max
I/O Connector
+
Ground
Main
Battery
FIGURE 10. Contactor wiring diagram
The contactor coil must be connected to a digital output configured to activate when “No MOSFET Failure”. The
controller will automatically deactivate the coil if the output is expected to be off and battery current of 500mA or
more is measured for more than 0.5s. This circuit will not protect against other sources of failure such as those
described in the “Important Safety Disclaimer” on page 3.
Single Channel Wiring
The single channel version of the controller (SDC2130S and SDC2160S) require that the output be parallel and
that the load be wired as shown in the diagram below.
M
M1+ M1-
M2+ M2-
FIGURE 11. SDC2130S and SDC2160S wiring diagram
Important Warning
This wiring is only possible on controllers fitted with the Single Channel version of the firmware. Dual
channel controllers will be damaged if wired as single channel. Verify that the PC utility identifies the controller as SDC2130S or SDC2160S before applying power to the load.
SDC21xx Motor Controller Datasheet
5
Controller Mounting
During motor operation, the controller will generate heat that must be evacuated. The published amps rating can
only be fully achieved if adequate cooling is provided. Mount the controller so that the bottom plate makes contact with a metallic surface (chassis, cabinet) to conduct the heat.
Sensor and Commands Connection
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
1
15
9
RC
Ana
FIGURE 12. Connector pin locations
TABLE 4.
Connector Pin
Power
1
9
Dout
Com
Dinput
Enc
DOUT1
Unused
DOUT2
Unused
2
TxOut
10
RS232Tx
RC5
3
ANA1
DIN5
ENC2A
RxIn
RC4
12
RC3
4
AnaCmd1 (2)
RS232Rx
11
ANA4
RC1
5
Default Config
DIN4
DIN1
ANA3
AnaCmd2 (2)
ENC1A
DIN3
RCRadio1
Unused
GND
13
GND
6
14
TTL TxD/
CANL (1)
TTL Serial TxD/
CANL
TTL RxD/
CANH (1)
TTL Serial RxD/
CANH
5VOut
7
15
8
RC2
ANA2
DIN6
ENC2B
Unused
DIN2
ENC1B
RCRadio2
Note 1: CANH and CANL on SDC2130N and SDC2160N versions
Note 2: Analog command is disabled in factory default configuration.
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 pres-
6
SDC21xx Motor Controller Datasheet
Version 1.3. April 05, 2014
Enabling Analog Commands
ence of a valid command signal in the following order: 1-RS232, 2-RC Pulse, 3-None. 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 Brake
Safety Contactor
15
9
Pot 2
Pot 1
FIGURE 13. Factory default pins assignment
Enabling Analog Commands
For safety reasons, the Analog command mode is disabled by default. To enable the Analog mode, use the PC
utility and set Analog in Command Priority 2 or 3 (leave Serial as priority 1). Note that by default the additional
securities are enabled and will prevent the motor from starting unless the potentiometer is centered, or if the
voltage is below 0.25V or above 4.75V. The drawing shows suggested assignment of Pot 1 to ANA1 and Pot 2 to
ANA4. Use the PC utility to enable and assign analog inputs.
CAN Bus Operation
The controller can interface to a standard CAN Bus network, using 3 possible protocols: Standard CANOpen, and
two simplified proprietary schemes (MiniCAN and RawCAN). Please refer to the User Manual for details. USB and
CAN cannot operate at the same time. The controller starts up with CAN available, but CAN will be disabled as
soon as the controller is plugged into USB. To re-enable CAN, disconnect USB and restart the controller.
USB communication
Use USB only for configuration, monitoring and troubleshooting. USB is not a reliable communication method
when used in a electrically noisy environments and communication will not always recover after it is lost without
unplugging and replugging the connector, or restarting the controller. Always prefer RS232 communication when
interfacing to a computer.
Spektrum Satellite Receiver Connection
3-pin plug is provided for direct connection to a Spektrum SP9545 miniature receiver.
SDC21xx Motor Controller Datasheet
7
Status LED Flashing Patterns
After the controller is powered on, the Power LED will tun 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 14. Normal Operation Flashing Patterns
Short Detected
Overheat
Under or Over Voltage
Power Stage Off
FIGURE 15. Exception or Fault Flashing Patterns
Additional status information may be obtained by monitoring the controller with the PC utility.
Self-Test and Reset Default Configuration
It is possible to verify that the controller is functioning by activating a self-test that will in turn ramp the motor(s)
up to full forward power and down to full reverse power. Then it toggles each digital output. To activate self-test,
turn off the controller, short RS232 Rx and Tx pins together (Pins 2 and 3 of I/O connector), and turn the controller
on again. The process will repeat until power is turned off and the RS232 is no longer shorted. Activating the selftest also resets the controller settings to factory defaults.
Note: RS232 cannot be connected to PC as this will prevent the controller from entering the self-test mode.
Electrical Specifications
Absolute Maximum Values
The values in the table below should never be exceeded. Permanent damage to the controller may result.
TABLE 5.
Parameter
Measure point
Models
Min
Battery Leads Voltage
Ground to VMot
SDC2130
Max
Units
10
40
Volts
SDC2160
10
62
Volts
-1
Reverse Voltage on Battery Leads
Ground to VMot
All
Motor Leads Voltage
Ground to M1+, M1-,
M2+, M2-
SDC2130
35
Volts
SDC2160
62
Volts
Ground to Output pins
All
40
Volts
Digital Output Voltage
8
Typ
SDC21xx Motor Controller Datasheet
Volts
Version 1.3. April 05, 2014
Electrical Specifications
TABLE 5.
Parameter
Measure point
Models
Analog and Digital Inputs
Voltage
Ground to any signal pin
on 25 & 9-pin connectors
RS232 I/O pins Voltage
External voltage applied
to Rx/Tx pins
Board Temperature
Board
Humidity
Board
Min
Typ
Max
Units
All
15
Volts
All
15
Volts
85
oC
100 (2)
%
-40
Note 1: Maximum regeneration voltage in normal operation. Never inject a DC voltage from a battery or other fixed source
Note 2: Non-condensing
Power Stage Electrical Specifications (at 25oC ambient)
TABLE 6.
Parameter
Measure point
Models
Min
Battery Leads Voltage
Ground to VMot
SDC2130(S)
Motor Leads Voltage
Ground to M1+, M1-,
M2+, M2-
Over Voltage protection
range
Ground to VMot
Under Voltage protection
range
Ground to VMot
Idle Current Consumption
Max
Units
10 (1)
35
Volts
SDC2160(S)
10 (1)
62
Volts
SDC2130(S)
0 (1)
35(2)
Volts
SDC2160(S)
0 (1)
62(2)
Volts
SDC2130(S)
5
30 (4)
35
Volts
SDC2160(S)
5
60 (4)
62(2)
Volts
SDC2130(S)
0
5 (4)
35
Volts
SDC2160(S)
0
5 (4)
62
Volts
VMot or Pwr Ctrl wires
All
50
75 (5)
100
mA
ON Resistance (Excluding
wire resistance)
VMot to M+, plus M- to
Ground at 100% power.
Per channel
SDC2130/60
20
mOhm
SDC2130S/60S
10
mOhm
Max Current per channel
for 30s
Ch1 or Ch2 Motor
current
SDC2130/60
20
Amps
SDC2130S/60S
40
Amps
Continuous Max Current
per channel
Ch1 or Ch2 Motor
current
SDC2130/60
15 (7)
Amps
SDC2130S/60S
30 (7)
Amps
Current Limit range
Ch1 or Ch2 Motor
current
SDC2130/60
1
15 (8)
20
Amps
SDC2130S/60S
1
30 (8)
40
Amps
Stall Detection Amps
range
Ch1 or Ch2 Motor
current
SDC2130/60
1
15 (8)
20
Amps
SDC2130S/60S
1
30 (8)
40
Amps
Stall Detection timeout
range
Ch1 or Ch2 Motor current
All
1
500 (9)
65000
milliseconds
Motor Acceleration/Deceleration range
Ch1 or Ch2
All
100
500 (10)
65000
milliseconds
SDC21xx Motor Controller Datasheet
Typ
9
TABLE 6.
Parameter
Measure point
Models
Min
Typ
Max
Units
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 VMot 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 VMot or PwrCtrl wires
Note 6: Max value is determined by current limit setting. Duration is estimated and is dependent on ambient temperature
cooling condition
Note 7: Estimate. Limited by heatsink temperature. Current may be higher with better cooling
Note 8: Factory default value. Adjustable in 0.1A increments
Note 9: Factory default value. Time in ms that Stall current must be exceeded for detection
Note 10: Factory default value. Time in ms for power to go from 0 to 100%
Important Warning:
Beware that regenerative braking can create high voltage at the controller's power inputs. Use the controller only with batteries. See user manual for special precautions when using a power supply.
Command, I/O and Sensor Signals Specifications
TABLE 7.
Parameter
Measure point
Min
Typ
Max
Units
Main 5V Output Voltage
Ground to 5V pins on
4.6
4.75
4.9
Volts
5V Output Current
5V pins on RJ45 and DSub15
100
mA
Digital Output Voltage
Ground to Output pins
30
Volts
Digital Output Current
Output pins, sink current
Output On resistance
Output pin to ground
Output Short circuit threshold
Output pin
Input Impedances
AIN/DIN Input to Ground
1.05
1
Amps
0.75
1.5
Ohm
1.4
1.75
Amps
53
kOhm
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
Analog Input Resolution
Ground to Input pins
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
10000
Hz
Encoder count
Internal
-2.147
2.147
10^9 Counts
Encoder frequency
Encoder input pins
30000 or
1M(1)
Counts/s
0.5
%
1
mV
1
us
Note1: Dual Channel controller max at 30Kcounts/s. Single channel version max at 1Mcounts/s
10
SDC21xx Motor Controller Datasheet
Version 1.3. April 05, 2014
Electrical Specifications
Operating & Timing Specifications
TABLE 8.
Parameter
Measure Point
Min
Typ
Max
Units
Command Latency
Command to output change
1
0.5
1
ms
PWM Frequency
Ch1, Ch2 outputs
10
18 (1)
20
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)
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
Scripting
TABLE 9.
Parameter
Measure Point
Scripting Flash Memory
Internal
Max Basic Language programs
Internal
Min
Typ
Max
8192
1000
Units
Bytes
1500
Lines
Integer Variables
Internal
1024
Words (1)
Boolean Variables
Internal
1024
Symbols
Execution Speed
Internal
100 000
Lines/s
50 000
Note 1: 32-bit words
Thermal Specifications
TABLE 10.
Parameter
Measure Point
Model
Min
Max
Units
Board Temperature
PCB
All
-40
Typ
85 (1)
oC
Thermal Protection range
PCB
All
70
80 (2)
oC
Thermal resistance
Power MOSFETs to
heats sink
All
2
oC/W
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
The SDC21xx uses a conduction plate at the bottom of the board for heat extraction. For best results, attach firmly
with thermal compound paste against a metallic chassis so that heat transfers to the conduction plate to the chassis. If no metallic surface is available, mount the controller on spacers so that forced or natural air flow can go over
the plate surface to remove heat.
SDC21xx Motor Controller Datasheet
11
Mechanical Specifications
TABLE 11.
Measure Point
Weight
Board
Power Wire Gauge
Terminal strip
Min
Typ
Max
Units
12
AWG
100 (3.5)
g (oz.)
0.64"
16.26mm
0.16"
4.1mm
0.75"
19mm
Parameter
2.76"
70mm
1.18"
30mm
1.54"
39.1mm
0.519"
13.2mm
2.45"
62.2mm
2.76"
70mm
1.645"
41.78mm
0.58"
14.73mm
FIGURE 16. SDC21xx front view and dimensions
2.45"
62.2mm
FIGURE 17. SDC21xx top view and dimensions
12
SDC21xx Motor Controller Datasheet
Version 1.3. April 05, 2014