MDC22xx Motor Controller Datasheet
Contents
1. TABLE 7 Parameter Measure point Models Min Typ Max Units Battery Leads Voltage Ground to VMot MDC2230 0 1 30 Volts MDC2250 0 1 50 Volts MDC2460 0 1 62 Volts Motor Leads Voltage Ground to M1 M1 MDC2230 0 1 30 2 Volts M2 M2 MDC2250 50 2 Volts MDC2460 62 2 Volts Power Control Voltage Ground to Power Con A 0 1 50 Volts trol wire Minimum Operating Voltage VMot or Pwr Ctrl A 9 3 Volts wires Idle Current Consumption VMot or Pwr Ctrl Al 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 MDC2230 50 60 60 5 Amps 30s MDC2230S 120 5 6 Amps 50S 60S Continuous Max Current per Motor current MDC2230 50 60 100 6 7 Amps channel MDC2230S 100 6 7 Amps 50S 60S Current Limit range Ch1 or Ch2 Motor MDC2230 50 60 10 50 8 60 Amps cunemi MDC2230S 10 100 8 120 6 Amps 50S 60S Stall Detection Amps range Ch1 or Ch2 Motor MDC2230 50 60 10 60 8 60 Amps current MDC2230S 10 120 8 120 6 Amps 50S 60S MDC2xxx Motor Controller Datasheet IRoboteQ TABLE 7 Parameter Measure point Models Min Typ Max Units Stall Detection timeout range Ch1 or Ch2 Motor All 1 65000 9 65000 millisec current onds Short Circuit Detection Between Motor wires MDC2230 50 60 140 11 400 11 Amps threshold 10 or Bet2. lRoboteQ MDC2xxx 2x60A High Performance Dual Channel Forward Reverse Brushed DC Motor Controller with USB CAN and Encoder Inputs Roboteq s MDC2xxx 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 CAN bus interface up to 1Mbit s all necessary cables and hardware and is ready to use in min e Auto switch between USB RS232 CAN Analog or Pulse utes Using CAN bus up to 127 controllers can be networked at based on userdefined priority up to IMbit s on a single twisted pair e Built in high power power drivers for two brushed DC ee motors at up to 60A output per channel The controller features a high performance 32 bit microcom puter and quadrature encoder inputs to perform advanced e Orderable as single channel version up to 120A motion control algorithms in Open Loop or Close Loop Speed e Full forward amp reverse control on each channel Four quad or Position modes The MDC2xxx features several Analog rant operation Supports regeneration Pulse and Digital I Os which can be remapped as command or e Operates from a single power source feedback inputs limit switches or many other functions Program
3. 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 Parameter Measure Point Min Typ Max Units Scripting Flash Memory Internal 8192 Bytes Max Basic Language programs Internal 1000 1500 Lines 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 MDC2xxx Motor Controller Datasheet IRoboteQ Mechanical Specifications TABLE 12 Pa
4. 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 6 Parameter Measure point Model Min Typ Max Units Battery Leads Voltage Ground to VMot MDC2230 35 Volts MDC2250 50 Volts MDC2460 62 Volts Reverse Voltage on Battery Leads Ground to VMot All 1 Volts Power Control Voltage Ground to Pwr Control wire All 50 Volts 8 MDC2xxx Motor Controller Datasheet Version 1 3 April 05 2014 lIRoboteQ Electrical Specifications TABLE 6 Parameter Measure point Model Min Typ Max Units Motor Leads Voltage Ground to M1 M1 M2 M2 MDC2230 30 Volts MDC2250 50 1 Volts MDC2460 62 1 Volts Digital Output Voltage Ground to Output pins All 30 Volts Analog and Digital Inputs Voltage Ground to any signal pin on All 15 Volts 15 pin and encoder connectors RS232 I O pins Voltage External voltage applied to Rx All 15 Volts Tx pins Temperature Board All 40 85 oC Humidity Board All 100 2 Note 2 Non condensing Power Stage Electrical Specifications at 250C ambient Note 1 Maximum regeneration voltage in normal operation Never inject a DC voltage from a battery or other fixed source
5. 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 FIGURE 12 Connector pin locations 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 CANL CAN Low 14 5VOut 7 CANH CAN High 15 DIN6 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
6. If needed use the Roborun PC Utility to change the pin assignments and the command priority order MDC2xxx Motor Controller Datasheet Version 1 3 April 05 2014 lRob oteQ Enabling Analog Commands RC Ch2 RCCh1 RS232 Ground TxOut RxIn Motor Brake Safety Contactor 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 ANAG4 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 u
7. atasheet Version 1 3 April 05 2014 IRoboteQ Single Channel Motor Wiring Single Channel Motor Wiring The single channel version of the controller MDC2230S MDC2250S MDC2460S requires that the output be par allel and that the load be wired as shown in the diagram below LL re ae D AOS A O VMOT M1 GND M2 M2 VMOT FIGURE 10 MDC2230S MDC2250S MDC2460S 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 MDC2230S MDC2250S MDC2460S 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 EnclA Enc1B Enc2A Enc2B GND 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 con tact with a metallic surface chassis cabinet to conduct the heat MDC2xxx Motor Controller Datasheet 5 lIRoboteQ Commands and I O Connections
8. atteries connect a second battery to the Power Control wire terminal via the SW1 switch Note 2 Use precharge 1K 0 5W 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 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 30V MDC2230 50V MDC2250 or 60V MDC2460 Note 5 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 Resistor Digital Out to 40V Max 1 0 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 MDC2xxx Motor Controller D
9. cations 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 5V 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 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 mV Pulse durations Pulse inputs 20000 10 us Pulse repeat rate Pulse inputs 50 250 Hz Pulse Capture Resolution Pulse inputs 1 us Frequency Capture Pulse inputs 100 10000 Hz MDC2xxx Motor Controller Datasheet Version 1 3 April 05 2014 lIRoboteQ Electrical Specifications TABLE 8 Parameter Measure point Min Typ Max Units 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
10. mable current limit for each channel up to 2x60A for protecting controller motors wiring and batter The controller s two motor channels can either be operated p 9 9 Y independently or mixed to set the direction and rotation of a e Built in programming language for automation and custom vehicle by coordinating the motion of each motor 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 with the latest features by downloading new operating soft ware from Roboteq e Up to 6 Digital Inputs for use as Deadman Switch Limit Switch Emergency stop or user inputs e Dual Quadrature Encoder inputs with 32 bit counters Applications e 2 general purpose 40V 1A output for brake release or e Industrial Automation accessories e Tracking Pan amp Tilt systems e Selectable min max center and deadband in Pulse and i Analog modes e Terrestrial and Underwater Robotic Vehicles 9 i e Selectable exponentiation factors for each command e Automatic Guided Vehicles p inputs pans ang Military Robots e Trigger action if Analog Pulse or Encoder capture are out e Flight simulators side u
11. otor 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 Power 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 MDC2230 2 60 30 Conduction Plate MDC2230S 1 120 30 Conduction Plate MDC2250 2 60 50 Conduction Plate MDC2250S 1 120 50 Conduction Plate MDC2460 2 60 60 Conduction Plate MDC2460S 1 120 60 Conduction Plate MDC2xxx Motor Controller Datasheet Version 1 3 April 05 2014 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 Wi
12. rameter Measure Point Min Typ Max Units Weight Board 250 0 5 g Ibs Power Connectors width Terminal tab 0 25 Inches 0 1 2 5 mm 0 98 0 25 25mm 0 57 FOA hl E ig de 4 6 3 mm 0 7 178mm 14 5mm 0 3 7 6 mm 0 16 4 0mm lt 0 325 8 3 mm FIGURE 16 MDC2xxx side view and dimensions 5 50 139 7mm 2 5 25 133 4mm ree iein 0 24 6 0mm A A O li 7 0 15 Q 0 120 3 0mm BI el z 3 8mm 0 120 3 0mm r T aontoami 5 7 ON m 0 35 8 9mm X 2 mis 0 3 76mm E E V7 th N E gt PWR CTL 0 3 7 6mm a S Ss gasen J amp GND 0 2 5 1mm 4 rl or 2 i b b R 5 wy a 0 2 5 1mm w v e E e i E y 0 6 10 11mm o 8 y w a 0 35 8 9mm N A q 3E y gt 0 40 10 2mm 0 15 3 se VMOT 3 8mm O 4 0 15 3 8mm Y Y A A gt 1 0 65 16 1mm as 0 15 3 8mm 1 25 31 8mm jt gt t 3 42 86 9mm ft 3 00 76 2mm FIGURE 17 MDC2xxx top view and dimensions 12 MDC2xxx Motor Controller Datasheet Version 1 3 April 05 2014
13. res 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 PwrCtrl Ground Motor 1 Resistor Motor 2 Emergency Contactor or Cut off Switch 1 0 Connector 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 MDC2xxx 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 Note 1 Backup battery to ensure motor operation with weak or discharged b
14. sed 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 MDC2xxx Motor Controller Datasheet 1 lIRoboteQ 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 FIGURE 14 Normal Operation Flashing Patterns Idle Waiting for Command RS232 USB Mode RC Pulse Mode Analog Mode FIGURE 15 Exception or Fault Flashing Patterns Short Detected Overheat Under or Over Voltage Power Stage Off 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 self test also resets the controller settings
15. ser selectable range soft limit switches e Telepresence Systems e Open loop or closed loop speed control operation e Animatronics MDC2xxx Motor Controller Datasheet 1 lRoboteQ Closed loop position control with analog or pulse fre quency feedback 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 Support for CANopen and two simplified CAN protocols Ultra efficient 3 mOhm High Efficiency version ON resis tance MOSFETs Orderable Product References Stall detection and selectable triggered action if Amps is outside userselected range Short circuit protection with selectable sensitivity levels Overvoltage and Undervoltage protection Programmable Watchdog for automatic m
16. ween Motor MDC2230S 280 800 Amps wire and Ground 50S 60S Short Circuit Detection Between Motor wires All No Protection Permanent damage will result threshold and VMot Motor Acceleration Decelera Ch1 or Ch2 All 100 500 12 65000 millisec tion range onds cooling condition Note 11 Sensitivity selectable by software Note 8 Factory default value Adjustable in 0 2A increments Note 3 Minimum voltage must be present on VMot or Power Control wire Note 7 Estimate Limited by case temperature Current may be higher with better cooling Note 10 Controller will stop until restarted in case of short circuit detection Note 12 Factory default value Time in ms for power to go from 0 to 100 Note 4 Current consumption is lower when higher voltage is applied to the controller s VMot or PwrCtrl wires Note 9 Factory default value Time in ms that Stall current must be exceeded for detection 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 5 Max value is determined by current limit setting Duration is estimated and is dependent on ambient temperature Note 6 Current is sum of both synchronized channels Current must be balanced between channel to obtain max current Command I O and Sensor Signals Specifi
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