AX2550/AX2850 Users Manual
Contents
1. la gt 0 65 16 1mm 0 24 6 0mm T A O T Es 0 120 3 0mm G z 3 8mm 0 120 3 0mm L 5 Yo 0 40 10 2mm 2 e mi 0 35 8 9mm amp _ m T 3 7 6 S L6rmrm e E E s E E PUR CTL 0 3 7 6mm D N Ke E S o 2 47 7 da iS GND 0 2 5 1mm Le 5 5 5 5 GND t 0 2 5 1mm 2 3 S GND T z e S 0 6 10 11mm E S S 8 1 ie 0 35 8 9mm A EET I gt E M2 a S E 0 40 10 2mm E 0 15 5 VMOT 3 8mm row 0 15 3 8mm 1 U Y L S 0 65 16 1mm ar 0 15 3 8mm T Y L 3 42 86 9mm 1 25 31 8mm 3 00 76 2mm t Lat bd FIGURE 17 MDC2250 top view and dimensions MDC2250 Motor Controller Datasheet 112. lRoboteQ 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 com Features List mands received from an RC radio Analog Joystick wireless modem PC via RS232 or USB or microcomputer into high USB RS232 0 5V Analog or Pulse RC radio command voltage and high current output for driving one or two DC modes motors Designed for maximal ease of use it is delivered with e Auto switch between USB RS232 Analog or Pulse based all necessary cables and hardware and is ready to use in min on user defined priority utes e Built in high power power drivers for two brushed DC motors at up to 60A output per channel The controller features a high performance 32 bit microcom E puter 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 e Operates from a single 10V 50V power source feedback inputs limit switches or many other functions e Programmable current limit for each channel up to 2x60A for protecting controller motors wiring and battery Orderable as single channel version up to 120A e Full forward amp reverse control on each channel Four quad rant operation Supports regeneration The controller s two motor channels can eit
3. analog or pulse fre quency feedback MDC2250 Motor Controller Datasheet 1 lRoboteQ Precise speed and position control when Encoder feed back 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 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 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 Ultra efficient 3 mOhm High Efficiency version ON resis tance MOSFETs Stall detection and selectable triggered action if Amps is outside userselected range Short circuit protection with selectable sensitivity levels Overvoltage and Undervoltage protection Orderable Product References Programmable Watchdog for automatic motor shutdown in case of command loss Overtemperature protection Diagnostic LED Open frame or enclosed design with heat conducting bottom plate Efficient heat sinking Operates without a fan in most applications Pow
4. Controller Datasheet 7 lRoboteQ Power Stage Electrical Specifications at 250C ambient TABLE 7 Parameter Measure point Models Min Typ Max Units Battery Leads Voltage Ground to VMot All 0 1 50 Volts Motor Leads Voltage Ground to M1 M1 All 0 1 50 2 Volts M2 M2 Power Control Voltage Ground to Power Con All 0 1 50 Volts trol wire Minimum Operating Voltage VMot or Pwr Ctrl All 9 3 Volts wires Idle Current Consumption VMot or Pwr Ctrl All 50 100 4 150 mA wires ON Resistance VMot to M plus M All 6 mOhm to Ground at 100 power Per channel Max Current per channel for Motor current MDC2250 60 Amps 30s MDC2250S 20 5 Amps Continuous Max Current per Motor current MDC2250 50 5 6 Amps channel MDC2250S 00 5 6 Amps Current Limit range Ch1 or Ch2 Motor MDC2250 0 50 7 60 Amps current MDC2250S 0 100 7 20 5 Amps Stall Detection Amps range Ch1 or Ch2 Motor MDC2250 0 60 7 60 Amps current MDC2250S 0 120 7 120 5 Amps Stall Detection timeout range Ch1 or Ch2 Motor All 65000 8 65000 millisec current onds Short Circuit Detection Between Motor wires MDC2250 40 10 400 10 Amps hreshold 9 or Between Motor MDC2250S 280 800 Amps wire and Ground Short Circuit Detection Between Motor wires All No Protection Permanent damage will result hreshold and VMot Motor Acceleration Deceler
5. N6 Unused 8 RC2 ANA2 DIN2 RCRadio2 Note 1 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 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 RC Ch1 FIGURE 13 Factory default pins assignment RS232 Ground TxOut RxIn Motor Brake Safety Contactor MDC2250 Motor Controller Datasheet Version 1 2 May 3 2012 IRoboteQ Status LED Flashing Patterns Analog command mode is disabled by default 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 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 flash
6. V Output Current 5V pins on Hall Connector and DSub15 200 1 mA Digital Output Voltage Ground to Output pins 40 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 05 1 4 1 75 Amps Input Impedances AIN DIN Input to Ground 53 kOhm Digital Input O Level Ground to Input pins 1 1 Volts Digital Input 1 Level Ground to Input pins 15 Volts Analog Input Range Ground to Input pins 5 1 Volts Analog Input Precision Ground to Input pins 0 5 Analog Input Resolution Ground to Input pins mV Pulse durations Pulse inputs 20000 10 us Pulse repeat rate Pulse inputs 50 250 Z Pulse Capture Resolution Pulse inputs 1 us Frequency Capture Pulse inputs 100 10000 Z Encoder count Internal 2 147 2 15 1049 Counts Encoder frequency Encoder input pins 250 kHz Note 1 Sum of all 5VOut outputs Operating amp Timing Specifications TABLE 9 Parameter Measure Point Min Typ Max Units Command Latency Command to output change 0 5 1 ms PWM Frequency Ch1 Ch2 outputs 10 18 1 20 kHz Closed Loop update rate Internal 1000 Hz USB Rate USB pins 12 MBits s RS232 baud rate Rx amp Tx pins 115200 2 Bits s RS232 Watchdog timeout Rx pin 1 3 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 10 amaer Measure Point min typ Max Un
7. a Ch1 or Ch2 All 100 500 11 65000 millisec tion range onds 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 Current consumption is lower when higher voltage is applied to the controller s VMot or PwrCtrl wires Note 5 Current is sum of both synchronized channels Current must be balanced between channel to obtain max current Note 6 Estimate Limited by case temperature Current may be higher with better cooling Note 7 Factory default value Adjustable in 0 2A increments Note 8 Factory default value Time in ms that Stall current must be exceeded for detection Note 9 Controller will stop until restarted in case of short circuit detection Note 10 Sensitivity selectable by software Note 11 Factory default value Time in ms for power to go from 0 to 100 8 MDC2250 Motor Controller Datasheet Version 1 2 May 3 2012 lRoboteQ Electrical Specifications Command I O and Sensor Signals Specifications TABLE 8 Parameter Measure point Min Typ Max Units Main 5V Output Voltage Ground to 5V pins on 4 6 4 75 4 9 Volts 5
8. er wiring 0 25 Faston tabs 5 5 139 7mm L 5 5 W 139 7mm 1 0 25mm H 400 to 850 C operating environment 0 5 Ibs 250g Easy configuration tuning and monitory using provided PC utility Field upgradeable software for installing latest features via the internet TABLE 1 Reference Number of Channels Amps Channel Volts Cooling Cover MDC2250 2 60 50 Conduction Plate No MDC2250S 1 120 50 Conduction Plate No MDC2250C 2 60 50 Conduction Plate Yes MDC2250CS 1 120 50 Conduction Plate Yes MDC2250 Motor Controller Datasheet Version 1 2 May 3 2012 IRoboteQ 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 The diagram below shows how to wire the controller and how to turn power On and Off F2 SW1 Main 1A On Off Switch 1A Motor 1 Resistor 1K 0 5W Motor 2 Emergency Contactor or Cut off Switch Ground Ground 1 0 Co
9. her be operated independently or mixed to set the direction and rotation of a vehicle by coordinating the motion of each motor e Built in programming language for automation and custom ization e Up to 4 Analog Inputs for use as command and or feed Numerous safety features are incorporated into the controller back to ensure reliable and safe operation The controller s operation e Up to 5 Pulse Width Duty Cycle or Frequency Inputs for can be extensively automated and customized using Basic Lan use as command and or feedback guage scripts The controller can be reprogrammed in the field e Up to 6 Digital Inputs for use as Deadman Switch Limit with the latest features by downloading new operating soft Switch Emergency stop or user inputs ware Irom Roboted e Dual Quadrature Encoder inputs with 32 bit counters Applications e 2 general purpose 40V 1A output for brake release or C accessories e Industrial Automation e Selectable min max center and deadband in Pulse and e Tracking Pan amp Tilt systems Analog modes gt JerfestiaLand Unagrwater ROBOTIC Venicles e Selectable exponentiation factors for each command e Automatic Guided Vehicles inputs e Police and Military Robots e Tigger action if Analog Pulse or Encoder capture are out e Flight simulators side user selectable range soft limit switches e Telepresence Systems e Open loop or closed loop speed control operation s Animatronics e Closed loop position control with
10. ing at a 2 seconds interval The flashing pattern provides operating or exception status information BREE dic Waiting for Command BEEREEEEEEEREEEERM RS232 USB Mode BERBER EREEEEEREEE C Pulse Mode BEEEEREEREEEREEEEEB Analog Mode FIGURE 14 Normal Operation Flashing Patterns BEEEEEEEEEEEEEEM Short Detected BEER Overheat SH HSR Under or Over Voltage BERBER Power Stage Off FIGURE 15 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 Battery Leads Voltage Ground to VMot 50 Volts Reverse Voltage on Battery Leads Ground to VMot 1 Volts Power Control Voltage Ground to Pwr Control wire 50 Volts Motor Leads Voltage Ground to M1 M1 M2 M2 50 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 15 Volts encoder connectors RS232 I O pins Voltage External voltage applied to Rx Tx pins 15 Volts Temperature Board 40 85 oC Humidity Board 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 MDC2250 Motor
11. ite Max Basic Language programs Internal 1000 1500 Lines MDC2250 Motor Controller Datasheet lRoboteQ TABLE 10 Parameter Measure Point Min Typ Max Units E 5 EES Integer Variables Internal 1024 Words 1 Boolean Variables Internal 1024 Symbols Execution Speed Internal 50 000 100 000 Lines s Note 1 32 bit words Thermal Specifications TABLE 11 Parameter Measure Point Model Min Typ Max Units Board Temperature Heatsink plate All 40 85 1 oC Thermal Protection range Heatsink plate All 80 90 2 oC Power Dissipation Case All 30 Watts Thermal resistance Power MOSFETs to heatsink 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 Mechanical Specifications TABLE 12 Parameter Measure Point Min Typ Max Units Weight Board 250 0 5 g Ibs Power Connectors width Terminal tab 0 25 Inches S 0 25 o57 im 1 CR ep T L 6 3 mm 0 7 178mm a A LHI pees 0 3 4 7 6 mm 0 16 4 0mm Ae ee FIGURE 16 MDC2250 front view and dimensions 0 325 8 3 mm MDC2250 Motor Controller Datasheet Version 1 2 May 3 2012 IRo b oteQ Electrical Specifications 5 50 139 7mm 5 25 133 4mm
12. nnector 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 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 trou ble 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 MDC2250 Motor Controller Datasheet lRoboteQ 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 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 blo
13. ring 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 FIGURE 11 Encoder connector TABLE 4 Pin Number 1 2 3 4 5 6 Signal 5Vout Enc A 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 1 Warts 15 9 FIGURE 12 Connector pin locations MDC2250 Motor Controller Datasheet lRoboteQ TABLE 5 Connector Pin Power Dout Com RC Ana Dinput Default Config 1 DOUT1 Motor Brake 9 DOUT2 Safety Contactor 2 TxOut RS232Tx 10 RC5 ANA1 DIN5 AnaCmd1 1 3 RxlIn RS232Rx 11 RC4 ANA4 DIN4 AnaCmd2 1 4 RC1 DIN1 RCRadio1 12 RC3 ANAS DIN3 Unused 5 GND 13 GND 6 SCLI Reserved 14 5VOut 7 SDAI Reserved 15 DI
14. wn 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 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 SW1 Main 1A On Off Switch 1A PwrCtrl Ground Digital Out UO Connector Ground FIGURE 9 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 1A 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 4 MDC2250 Motor Controller Datasheet Version 1 2 May 3 2012 lRoboteQ Single Channel Motor Wiring Single Channel Motor 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 Li UU U Uy LI VMOT M1 MT GND M2 M2 VMOT FIGURE 10 MDC2250S wi
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