MCP260 Dual Channel Motor Controller Data Sheet MCP260A Dual

MCP260 Dual Channel Motor Controller Data Sheet MCP260A Dual
MCP260 Dual Channel Motor Controller
MCP260A Dual Channel Programmable
Brushed DC Motor Controller
(c) 2016 Ion Motion Control. All Rights Reserved.
Data Sheet
MCP260 Dual Channel Motor Controller
Data Sheet
Feature Overview:
• 60 Amps per channel continuous
for two brushed DC motors
• Up to 7 PWM inputs for control, encoder
feedback or as user script controlled inputs
• 120 Amps in bridged channel mode
for one brushed DC motor
• Up to 10 Digital inputs for limit switches, emergency
stops, homing or as user script controlled inputs
• Dual quadrature encoder inputs with
hardware 32-Bit counters
• 2 General purpose 40V, 3Amp user controlled
outputs for driving relays, brakes or contactors
• Programmable with built-in user scripting language
• User programmable input triggers with
minimum and maximum range settings
• Minimum of 100,000 instructions
per second execution speed
• 128Kb Flash availa for user scripting programs
• 16Kb Ram allocated for user scripting programs
• 1kb Eeprom for storage by user scripting programs
• USB, RS232, TTL, R/C, PWM and
Analog control modes
• Automatic switch control methods with
user defined priority settings
• Mixed Control Inputs
• Regulated 5VDC, 500mA output for
powering external devices such as sensors
or controllers like Arduino, Rasberry Pi
• Up to 80VDC versions available
• Fully enclosed for protection
• Conduction plate and top side heat
mangement for high performance cooling
• 3.3v Compliant outputs for safe interfacing
with controllers such as Rasberry Pi
• Data Logging
• 15v Tolerant inputs for interfacing to
industrial devices such as PLCs
• Diagnostic LEDs for easy in feild diagnostics
• Overvoltage and under voltage protection monitoring
• Field Firmware Updates
• Programmable current limiting
• OpenCAN master or slave support
• Auto tune PID feature for fast encoder motor setup
• I2C Interface for use with sensor such as gyros,
accelerometers, temperature and displays
• PC utility included for fast setup and tunning
• Up to 8 Analog inputs for control, encoder
feedback or as user script controlled inputs
Device Overview
The MCP series motor controller is a high power, high performance rugged motor controller built to withstand the most demanding
applications. It incorperates a built-in scripting language with advance motion control. At the heart is a 32Bit high performance
Cortex M4 processor with DSP and FPU. The user programmable feature allows the MCP to be customized for any application. It can
interface with several communication standards in addition to including several user configurable I/O. The MCP can be used as a
standalone controller with out the need for an additional processor therefore reducing over all design cost and system complexity.
At the heart of the MCP motro controller is a high performance motion control intelligence which achieves high precision control and
optimum motor performance in open or closed loop modes. Close loop mode supports dual quadrature encoders with up to 21 million
PPS. Close loop mode creates absolute control over speed, velocity and direction regardless of loading changes. In addition, a wide
range of sensor inputs including potentiometers and absolute encoders are supported.
Multimode Interface
The MCP supports several types of control input. USB, R/C Pulse, Analog, TTL, RS232 and CAN are supported. Control can be setup
to auto switch from one interface to another. The MCP can be configured as a master or slave in a CAN network. In addition several
user controllable I/O are available for setting up limit switches, sensors, E-stops and more. The MCP includes 2 user controllable
general purpose 40V at 3Amp I/O for controlling brakes, contactors and other high load devices.
Protection
The MCP utilizes high precision temperature, current and voltage sensing to monitor conditions and ensure safe and reliable
operations. The peak operational voltage depending on model can be up to 80VDC. MCP is a regenerative motor controller. During
regeneration, voltages can peak over 80VDC. MCP is designed to handle well over 100VDC voltage spikes and is not rated to its
absolutely maximum operating specifications which provides a safe and reliable operating margin.
Software
IonMotion is a free PC utility configuration tool used to setup, configure and monitor the MCP. The software can be used during run
time to monitor and control several operational parameters. IonMotion is also the interface for customizing the built-in motion control
language.
(c) 2016 Ion Motion Control. All Rights Reserved.
2
MCP260 Dual Channel Motor Controller
Hardware Overview:
Data Sheet
G
B
E
A
TOP VIEW
D
F
H
C
FRONT VIEW
H
A
SIDE VIEW
B
Label
C
Function
A
DB15 Female Connector.
B
USB Port.
C
Logic Battery Connector.
D
Main Battery Input.
E
Motor Channel 1
F
Motor Channel 2.
G
Status LEDs.
H
Encoder Connector.
(c) 2016 Ion Motion Control. All Rights Reserved.
3
MCP260 Dual Channel Motor Controller
Data Sheet
Interface
The MCP260 utilizes a DB15 female connector, Molex 6 pin connector and a 2 pin JST connector. The following tables list the pins and
their available functions. All digital input pins are 15V tolerant. Digital output pins are low side driving with up to 3Amp at 40VDC.
The CAN interface and RS232 pins are duplexed. When a duplex function is used the other is set to a high Z state. R/C pulse input,
Analog, TTL and PWM can be generated from any microcontroller such as a Arduino or Rasberry Pi. The R/C Pulse in pins can be
driven by any standard R/C radio receiver. There are several user configurable options depending on the device used to control the
MCP. To configure MCP, installation of the IonMotion App is required and the MCP connected to an available USB port.
Pin
PWR
DIN
DOUT
1
DOUT1
9
DOUT2
2
GND
10
GND
3
+5V
ANALOG
PULSE
ENCODER
UART TTL
UART RS232
CAN
I2C
11
TX1
SCL
4
RX1
SDA
12
RX0
CANL
5
TX0
CANH
13
DIN1
AN1
P1
6
DIN2
AN2
P2
HALL3
TX3
14
DIN3
AN3
7
DIN4
AN4
15
DIN5
TX2
8
DIN6
RX2
RX3
P4
Notes:
1.
2.
3.
4.
5.
Digital input pins are 15V tolerant.
Digital output pins can drive up to 3Amp at 40V. DOUT are low side driving pins.
Analog pins are 0V to 5.1V range.
I2C pins are 5V tolerant inputs with 3.3V compliant output.
Pulse inputs have a resolution of 12ns.
(c) 2016 Ion Motion Control. All Rights Reserved.
4
MCP260 Dual Channel Motor Controller
Data Sheet
Encoders
The MCP260A supports dual quadrature encoders with up to 40 million pulses per second. In addition, a wide range of sensor inputs
including potentiometers and absolute encoders are supported. The encoder pins are not exclusive to supporting encoders and have
several functions available. The encoder inputs were put on a separate connector for wiring convenience.
Mating Connector Part
Number: 794617-6
Pin
PWR
1
+5V
2
GND
DIN
DOUT
2
4
6
1
3
5
ANALOG
PULSE
ENCODER
3
DIN7
AN7
P7
PID1A / HALL1
4
DIN8
AN8
P8
PID2A
5
DIN9
AN9
P9
PID1B / HALL2
6
DIN10
AN10
P10
PID2B
UART TTL
UART RS232
CAN
I2C
Notes:
1.
2.
3.
4.
5.
Digital input pins are 15V tolerant.
Digital output pins can drive up to 3Amp at 40V. DOUT are low side driving pins.
Analog pins are 0V to 5.1V range.
I2C pins are 5V tolerant inputs with 3.3V compliant output.
Pulse inputs have a resolution of 12ns.
(c) 2016 Ion Motion Control. All Rights Reserved.
5
MCP260 Dual Channel Motor Controller
Data Sheet
Logic Battery
The MCP supports an optional logic battery. Under heavy loads the main power can dip potentially causing brown outs. The separate
logic battery will alleviate this problem. In addition a logic battery should be utilized to avoid uncontrolled behavior when the main
battery power becomes low. The logic battery maximum input voltage is 12VDC with a minimum input voltage of 6VDC. The mAh
of the battery should be determined based on the loading conditions. The BEC is supplied by the logic battery when it is attached.
Any additional electronics attached to the MCP and powered from the MCP will need to be accounted for when determining the logic
battery size.
Logic Battery Wiring
The MCP comes with a small 2pin JST connector for the logic battery. The MCP is shipped with a wired pig tail mating connector. The
mating connector can also be sourced from DigiKey 455-1165-ND. The 2 pins are ground and power as shown below.
GND-
(c) 2016 Ion Motion Control. All Rights Reserved.
PWR+
6
MCP260 Dual Channel Motor Controller
Data Sheet
Important Notices
The following information is required for safe and reliable operation. It is up to the user to ensure the following criteria is met.
Several external factors can influence how the MCP operates. Following basic safety procedures can prevent dangerous situations.
Warnings
The following guidelines should be followed when using the MCP or damage will occur. There are several factors that will affect the
operation of the MCP.
1. Battery wire should be no longer than 20 inches in length.
2. Motor wire should be no longer than 20 inches in length.
3. DO NOT overload the BEC. Logic power is drawn from the same source and brownouts can occur.
4. DO NOT reverse the battery polarity. Damage will result.
5. ALWAYS Incorporate an emergency main battery cut off switch.
6. Cut off should always be on the positive (+) of power to prevent ground loops.
7. Power diode, fuse and pre charge resistor should be added to all power switch circuits.
8. DO NOT get the MCP wet and avoid high moisture environments without proper moisture control.
Mounting
The MCP will generate heat. The controller should be mounted to a metal surface that will conduct the heat away from the MCP
during operation. The maximum amperage ratings can only be achieved and maintained with adequate heat dissipation.
Emergency Stop
MCP should be wired using an external contactor or relay to ultimately control the main power input. A second power source should
be used to power the logic section in situations where the main power will be under heavy load. Voltage level drops can occur from
constant full load or full speed direction changes and can potential cause logic brown outs.
USB
The MCP USB port can be used for configuration and debugging. The USB protocol is not meant for electrically noisy environments.
The USB port can potentially drop out during operation and may not recover without unplugging and plugging in the MCP. In high
electrical noise environment RS232 should be used.
CAN Bus
The MCP can interface to a CAN bus using CANOpen protocol. The MCP supports the DS402 profile for motion control devices. The
MCP can be a master or slave devices on the bus. CAN is available when the MCP is plugged into the USB. The MCP can be used as a
master interface to control other MCPs over the a CAN bus.
I2C
The I2C buss can be used to communicate to any compatible I2C device. The I2C device can be controlled by a user program. The
MCP can be easily interfaced to devices such as Gyro and Accelerometers for standalone applications.
Firmware Updates
From time to time new firmware updates will be available to add new features or resolve an issue. It is recommended to update to
the latest firmware during development. Firmware updates are handled by the IonMotion App. IonMotion is free to download from
Ionmc.com. Once IonMotion is installed, connect MCP to your computer running Windows 7 or newer. Once IonMotion is launched it
will detect your MCP and attempt to download the latest firmware from our website, then update the detected MCP.
(c) 2016 Ion Motion Control. All Rights Reserved.
7
MCP260 Dual Channel Motor Controller
Data Sheet
Wiring Basics
The MCP must be wired correctly to ensure safe and reliable operation. The diagram below illustrates a basic configurations for
wiring. An external main power cut off solution should be incorporated for safety. Power generation will occur if the motors are
moved when the system is off. Use a high current diode to create a return path to ground when the unit is switched off. Add a pre
charge resistor to avoid high inrush currents. Pre charge resistor should be 1K, 2Watt for 80VDC models. A lower resistance can be
used with lower voltages to decrease the pre-charge time.
Wiring Closed Loop Mode
The MCP supports a wide range of sensors for closed loop function. Absolute and quadrature encoders are supported along with
potentiometers and hall effect sensor.
The below illustration shows the basic wiring required for closed loop mode using quadrature encoders. Quadrature encoders are
directional. The internal MCP counter to increment in one direction and decrement in the opposite direction. When wiring encoders it
is important they are wired to match the direction of the motor. If the encoder is wired in reverse it can cause a run away condition.
Wiring Diagrams
The MCP has several different configurations depending on the type of input or output being used. See the MCP manual for additional
diagrams examples.
UART TX
RX0
UART RX
TX0
5VDC
+5V
GROUND
GROUND
M1A
Motor 1
R1
MCU
M1B
Optional Encoders
Encoder 1
A
B
GND
+5V
B+
D1
EN1 A
EN1 B
Ground
GROUND
5VDC
F1
M2B
Encoder 2
A
B
GND
+5V
EN2 A
EN2 B
Motor 2
GROUND
-
+
5VDC
M2A
ROBOCLAW
(c) 2016 Ion Motion Control. All Rights Reserved.
Battery
8
MCP260 Dual Channel Motor Controller
Data Sheet
Bridged Channel Mode
The MCPs dual channels can be bridge to run as one channel effectively doubling its current capability for one motor. Damage will
result if the MCP is not set to single channel mode before wiring. Download and install IonMotion PC utility. Connect the MCP to the
computer using an available USB port. Run IonMotion and in general settings check the option to bridge channels. When operating
in bridged channel mode the total peak current output is 120 amps. Peak current is directly affected by heat build up. If adequate
cooling is maintained, peak currents can be sustained indefinitely.
Bridged Channel Wiring
When bridged channel mode is active the internal driver scheme for the output stage is modified. The output leads must be wired
correctly or damage will result. The motor output wire M1A is bridged to M1B to create one side. Then M2A is bridged to M2B to form
the other side.
MOTOR
(c) 2016 Ion Motion Control. All Rights Reserved.
9
MCP260 Dual Channel Motor Controller
Data Sheet
Status and Error LEDs
The MCP has three LEDs. Two status LEDs named STAT1 and STAT2 and an error LED named ERR. When MCP is first powered up all 3
LEDs should flash briefly to indicate all LEDs are functional. The LEDs will behave differently depending on the mode. During normal
operation the status 1 LED will remain on continuously or blink when data is received in RC Mode or Serial Modes. The status 2 LED
will light when either drive stage is active.
STAT1
STAT2
ERR
Error and Warning States
When an error occurs both motor channel outputs will be disabled and the MCP will stop any further actions until the unit is reset, or
in the case of non-latching E-Stops, the error state is cleared. When warnings occur both motor channel outputs will be controlled
automatically depending on the warning condition(s).
Condition
Type
LED Status
Description
E-Stop
Error
All three LEDs lit.
Motors are stopped by braking.
Over 85c Temperature
Warning
Error LED lit while condition is
active.
Motor current limit is recalculated
based on temperature.
Over 100c Temperature
Error
Error LED blinks once with short
delay. Other LEDs off.
Motors freewheel while condition
exist.
Over Current
Warning
Error LED lit while condition is
active.
Motor power is automatically
limited.
Logic Battery High
Error
Error LED blinking three times.
Motors freewheel until MCP is
reset.
Logic Battery Low
Error
Error LED blinking four times.
Motors freewheel until MCP is
reset.
Main Battery High
Error
Error LED blinking five times.
Motors are stopped by braking
until MCP is reset.
Main Battery High
Warning
Error LED lit while condition is
active.
Motors are stopped by braking
while condition exist.
Main Battery Low
Warning
Error LED lit while condition is
active.
Motors freewheel while condition
exist.
M1 or M2 Home
Warning
Error LED lit while condition is
active.
Motor is stopped and encoder is
reset to 0
(c) 2016 Ion Motion Control. All Rights Reserved.
10
MCP260 Dual Channel Motor Controller
Data Sheet
Firmware Update LED State
If all three LEDs begin to cycle on and off after powering on, the MCP has successfully been set to install new firmware. Use
IonMotion on a Windows PC to install the new firmware to clear this state.
Automatic Battery Detection on Startup
If the automatic battery detection mode is enabled the Stat2 LED will blink to indicate the detected battery type. Each blink indicates
the number of LIPO cells detected. If automatic detection is used the number of cells detected should be confirmed on power up
before running the unit.
Undercharged or overcharged batteries can cause invalid auto detection.
Motion Control Language
The MCP motor controller can be customized using a built in programming language. The programming language is modeled
after BASIC. The MCP motor controller can operate in standalone mode without additional external control. Several user I/O and
operational parameters are directly accessible from user programs. The MCP includes IonMotion which is a free PC utility to create
and download user programs to the motor controller.
Programming Specifications
Characteristic
Model
Min
Typ
Max
Rating
User Program Memory
All
128
KBytes
User Variable Memory
All
16
KBytes
User Program Execution Speed
All
100,000
Lines/s
Analog to Digital Resolution
All
12
Bits
System Clock Resolution
All
32
Bits
Microsecond Clock Resolution
All
32
Bits
Millisecond Clock Resolution
All
32
Bits
Uart Buffer
All
256
Bytes
256
Levels
Subroutine Nesting
(c) 2016 Ion Motion Control. All Rights Reserved.
11
MCP260 Dual Channel Motor Controller
Data Sheet
Mechanical Specifications
Characteristic
Weight
Model
Min
MCP230
Typ
12 (340)
Max
Rating
Oz (g)
Mechanical Dimensions
1.34” (34.3mm)
4.3 (109.2mm)
4.5 (114.3mm)
4.2” (106.6mm)
(c) 2016 Ion Motion Control. All Rights Reserved.
12
MCP260 Dual Channel Motor Controller
Data Sheet
MCP260 Specifications
Characteristic
Min
Logic Battery
6
Main Battery
10
Typ
12
Max
Rating
34
VDC
60
VDC
Maximum External Current Draw (BEC)
300
mA
Motor Current Per Channel
60
A
120
A
Motor Current Bridged Channel Mode
Logic Circuit Current Draw
90mA
mA
Input Impedance
1.2
KΩ
I2C Input Impedance
100
Ω
I2C Input
3.3
5
VDC
DIN Input
0
15
VDC
DIN Input Low
-0.3
0.5
VDC
DIN Input High
1.5
15
VDC
3
A
3.3
VDC
15
VDC
5.1
VDC
DOUT
I/O Output Voltage
0
Analog Input Voltage
Analog Useful Range
0
Analog Resolution
1.44
mV
Pulse In Resolution
12
ns
Encoder Counters
32
Bits
Encoder Frequency
21
Mhz
RS232 Baud Rate
921,600
Bits/s
RS232 Time Out
10
ms
User Program Memory
128
KBytes
User Variable Memory
16
KBytes
User Program Execution Speed
Temperature Range
100,000
-40
40
Lines/s
+100
°C
Notes:
1.Current is limited by maximum temperature. Starting at 85°C, the current limit is reduced on a slope with a maximum temperature of
100°C, which will reduce the current to 0 amps.
2.RS232 format is 8Bit, No Parity and 1 Stop bit.
(c) 2016 Ion Motion Control. All Rights Reserved.
13
MCP260 Dual Channel Motor Controller
Data Sheet
Warranty
Ion Motion Control warranties its products against defects in material and workmanship for a period of 1 year. If a defect is
discovered, Ion Motion Control will, at our discretion, repair, replace, or refund the purchase price of the product in question. Contact
us at sales@ionmc.com. No returns will be accepted without the proper authorization.
Copyrights and Trademarks
Copyright© 2015 by Ion Motion Control, Inc. All rights reserved. All referenced trademarks mentioned are registered trademarks of
their respective holders.
Disclaimer
Ion Motion Control cannot be held responsible for any incidental or consequential damages resulting from use of products
manufactured or sold by Ion Motion Control or its distributors. No products from Ion Motion Control should be used in any medical
devices and/or medical situations. No product should be used in a life support situation.
Contacts
Email: sales@ionmc.com
Tech support: support@ionmc.com
Web: http://www.ionmc.com
Discussion List
A web based discussion board is maintained at http://www.ionmc.com
Technical Support
Technical support is available by sending an email to support@ionmc.com, by opening a support ticket on the Ion Motion Control
website or by calling 800-535-9161 during normal operating hours. All email will be answered within 48 hours.
(c) 2016 Ion Motion Control. All Rights Reserved.
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