SyRen 50 User's Guide
Contents
1. UimensionEngineering SyRen 50 User s Guide February 2011 Single Channel 50A continuous 100A peak Brushed motor controller Basic Information Input voltage 6 30V nominal 33 6V absolute max Output Current Up to 50A continuous Peak loads may be up to 100A for a few seconds These ratings are for input voltages up to 30V in still air without any additional heatsinking Recommended power sources are e 5 to 24 cells NIMH or NiCd e 2s to 8s lithium ion or lithium polymer SyRen motor drivers have a lithium battery mode to prevent cell damage due to over discharge of lithium battery packs e 6v to 30v lead acid e 6v to 30v power supply when in parallel with a suitable battery Dimensions e Size 3 0 x 3 5 x 1 3 76 5mm x 89mm x 33mm e Weight 176g 6 20z Features Synchronous regenerative drive Going one step farther than just regenerative braking a SyRen motor driver will return power to the battery any time a deceleration or motor reversal is commanded This can lead to dramatic improvements in run time for systems that stop or reverse often like a placement robot or a vehicle driving on hilly terrain This drive scheme also saves power by returning the inductive energy stored in the motor windings to the battery each switching cycle instead of burning it as heat in the motor windings This makes part throttle operation very efficient Ultra sonic switching frequency SyRen 50 features a PWM fre2. the SyRen will drive the motor backwards The signal on S2 can be either an analog signal forward reverse select on S2 or a digital signal This is useful for oscillating loads that go back and forth at a preset speed as well as vehicles with a reverse selector switch Lt 5 B eg Option 4 Max Speed Single Direction This option is set by flipping switch 5 OFF or down and flipping switch 6 ON or up Max Speed Mode allows you to connect another potentiometer to S2 and set the max speed If you set this potentiometer to 50 the potentiometer on S1 will scale between 0 and 50 over the entire length of its travel This mode is very useful if a IE 5 amp a Max Speed Mode Single Direction you are for example running off of 24V and want to limit the top speed somewhere around 14V Option 5 Max Speed Bi directional This option is set by flipping switched 5 and 6 OFF or down Max Speed Mode allows you to connect another potentiometer to S2 and set the max speed This potentiometer will set the maximum speed of both directions This is very useful for limiting the top speed without having to lower the input voltage Option 6 Analog motor reverse Switch 6 reverses the direction of the motor driver in all analog operating modes except Diff Drive Mix in which case it is the right left select switch This is sometimes better than physically reversing the motor connect
3. R C input mode takes one or two standard R C channels and uses those to set the speed and direction of the motor R C mode can be set up as a single input driver for robots and vehicles that have steering wheels as well as a 2 input mode for differential drive steering This combines the ease of use of a dual motor driver with the flexibility of a single motor driver There is an optional timeout setting When timeout is enabled the motor driver will shut down on loss of signal This is for safety and to prevent the robot from running away should it encounter interference and should be used if a radio is being used to control the driver If timeout is disabled the motor driver will continue to drive at the commanded speed until another command is given This makes the SyRen easy to interface to a Basic Stamp or other low speed microcontrollers Mode 3 Simplified serial Simplified serial mode uses TTL level RS 232 serial data to set the speed and direction of the motor This is used to interface the SyRen to a PC or microcontroller If using a PC a level converter such as a MAX232 chip must be used The baud rate is set via DIP switches Commands are single byte with O representing full reverse and 255 representing full forward There is also a Slave Select mode which allows the use of multiple motors from a single microcontroller serial port Mode 4 Packetized serial Packetized serial mode uses TTL level RS 232 serial data to set the speed a
4. Sending the bauding character during this time period may cause undesirable results When using Packetized Serial mode please allow a two second delay between applying power and sending the bauding character to the drivers Address Byte Configuration Address bytes are set by switches 4 5 and 6 Addresses start at 128 and go to 135 The switch settings for the addresses are shown in the chart below Address 134 Address 135 Commands The command byte is the second byte of the packet There are four possible commands in packetized serial mode Each is followed by one byte of data 0 Drive forward decimal 0 binary 0b00000000 hex 0h00 This is used to command the SyRen 10 and 20 to drive forward Valid data is 0 127 for off to full forward drive If a command of 0 is given the SyRen will go into power save mode after approximately 4 seconds 1 Drive backwards decimal 1 binary 0b00000001 hex 0h01 This is used to command the SyRen 10 and 20 to drive forward Valid data is 0 127 for off to full reverse drive If a command of 0 1s given the SyRen will go into power save mode after approximately 4 seconds 2 Min voltage decimal 3 binary 0b00000011 hex 0h03 This is used to set a custom minimum voltage for the battery feeding the SyRen 50 If the battery voltage drops below this value the output will shut down This value is cleared at startup so much be set each run The value is sent in 2 volt increments with a command
5. in analog mode it is important to have the signal wires to the motor driver connected before applying power to the device Otherwise the motor may start unexpectedly Battery Terminals B and B The battery or power supply is connected to terminals B and B B connects to the negative side of the battery usually black B connects to the positive side of the battery usually red or yellow Often it is convenient to connect the battery through a connector instead of directly to the motor driver This The battery connects to terminals B and B makes it easy to unplug the battery for charging and prevents plugging in the battery backwards Warning Be very careful to wire and plug in the battery and connector correctly Connecting the battery backwards will destroy the SyRen and will void the warranty Power terminals OV and 5V The OV and 5V connections are used to power and interface to low power control circuits The 5V connection is a 5v power output This is useful for supplying power to low current devices such as a potentiometer or a radio receiver The 5v terminal is capable of supplying 100 milliamps if the source battery The 5V terminal can be used to power small is 12 6v or less If the source battery is greater loads like a potentiometer or a radio receiver than 12 6 volts the 5v terminal is capable of The OV signal must be connected to the ground supplying 10 milliamps If more power is of the de
6. is simple enough to use for your first project Sabertooth software compatibility The SyRen 50 is compatible with the Sabertooth software available for Windows This software suite can be used to control the SyRen50 from a PC using a packet serial interface Hooking up the SyRen motor driver All connections to the SyRen are done with screw terminals This makes it easy to set up and reconfigure your project If you ve never used screw terminal connections before here is a quick overview bs Step 1 Strip the wire which you are using Step 2 With a small screwdriver turn the top approximately 4 The wires may be 14 screw counter clockwise until it stops gently gauge to 30 gauge Step 4 Turn the top screw clockwise until Step 3 Insert the stripped portion of the wire you encounter resistance then tighten the into the opening in the screw terminal screw firmly Pull on the wire gently to ensure that it is secured Motor Terminals M1 and M2 The motor is connected to terminals M1 and M2 as shown below If the motor runs in the opposite way that you want you may reverse the motor wires to reverse rotation Signal Input Terminals SI and S2 The input signals that control the SyRen are connected to terminals S1 and S2 S1 is the primary input and must always be connected S2 is the secondary input and may or may not be connected depending on which operating mode and options you have selected If you are running
7. 5v loads we recommend a ParkBEC or a receiver battery pack as shown in figure 5 2 If using a receiver pack do not connect power to the 5V line of the SyRen because the maximum voltage it can tolerate is 6V z Mi i F P Figure 5 1 R C connection Figure 5 2 R C with a ParkBEC There are two operating modes for R C These are selected with switch 5 Option 1 Standard R C mode A standard R C pulse is fed into S1 A 1500us pulse is zero speed a 1000 us pulse is full reverse and a 2000 us pulse is full forward Because different transmitter manufacturers use different default pulse widths if it seems like you are not getting full power it may be necessary to increase the transmitter s ATV to 120 Option 2 R C Auto Calibrate Mode R C Auto Calibrate mode is used to interface to R C systems that do not use 1500us as their center point Examples are pistol style transmitters with a 70 30 throttle and airplane style throttles where a single direction control is desired In R C auto calibrate mode the position the control stick is when the driver is powered up is taken as the neutral point During operation the driver will detect the minimum and maximum control inputs and use those to set the control range If the driver is initialized with the control stick at either extreme the driver will operate in single direction mode Switch 6 R C Failsafe Timeout In all the R C modes if switch 6 is set to the UP pos
8. ce The baud rate is set to 9600 baud from the factory To change the baud rate see the list of serial commands later in this section Packet Overview The packet format for the SyRen 50 consists of an address byte a command byte a data byte and a seven bit checksum Address bytes have value greater than 128 and all subsequent bytes have values 127 or lower This allows multiple types of devices to share the same serial line An example packet and pseudo code to generate it are shown in Figures 7 1 and 7 2 Void DriveForward char address char speed Packet Address 130 Putc address Command 0 Putc Q Data 64 Putc speed Checksum 66 Putc address 0 speed amp ObOI111111 Figure 7 1 Example 50 forward Figure 7 2 Pseudocode to generate 7 1 Baud Rate Selection Packetized Serial operates with an 8N1 protocol 8 data bytes no parity bits and one stop bit The baud rate is automatically calculated by the first character sent This character must be 170 binary 10101010 and must be sent before any serial communications are done It is not possible to change the baud rate once the bauding character has been sent The valid baud rates are 2400 9600 19200 and 38400 baud Until the bauding character is sent the driver will accept no commands and the green status light will stay lit Please note that the SyRen 50 may take up to a second to start up after power 1s applied depending on the power source being used
9. e system will continue to draw some power even with the motor shut down it is important to unplug the battery from the SyRen promptly once the cutoff 1s reached when using lithium batteries If the SyRen is being run from NiCd NiMH or alkaline batteries or from a power supply switch 3 should be in the up position User adjustable current limit The blue potentiometer on the board sets the current limit The SyRen 50 can handle up to a 100A limit There are many circumstance where you may need 50A but do not want to let the system draw more than 60A or 70A Some motors may have a rated stall current of 60A You can set the SyRen 50 s adjustable current limit to 50A and never put your motor in harm s way with a dangerous stall Current limit potentiometer This option can be used to limit acceleration and starts with too much torque It will basically act as an on demand ramp that will only activate when you ve reached the set limit In some situations long wire runs will prevent higher amount of current to be drawn due to heat This option can reduce the amount of current being drawn and thusly reduce heat through the wire If you have an application where a vehicle could run into a wall or an automatic door could pin someone or something the adjustable current limit could be set to detect this and greatly reduce output to the motors Mode 1 Analog Input Analog input mode is selected by setting switches and 2 to the UP
10. h 5v when the serial command is sent then the driver will change to the new speed If the signal on S2 is not high when the command is sent then command will be ignored Pseudo code demonstrating this is shown below After sending the signal allow about 50 us before commanding the Slave Select line to a logic LOW to allow time for processing A hookup diagram and example pseudo code are shown in Figures 6 2 and 6 3 set controller 1 s speed Output_High S2 pin on controller 1 1 A A O M USART_TX controller 1 speed 0 to 255 Delay_us 50 A ei Output_Low S2 pin on controller 1 Microcontroller set controller 2 s speed Output_High S2 pin on controller 2 USART_TX controller 2 speed 0 to 255 Delay_us 50 Output_Low S2 pin on controller 2 Figure 6 2 Hookup for Slave Select Figure 6 3 Pseudocode for Slave Select Mode 4 Packetized Serial Mode Packetized Serial uses TTL level multi byte serial commands to set the motor speed and direction Packetized serial is a one direction only interface The transmit line from the host is connected to S1 The host s receive line is not connected to the SyRen 50 Because of this multiple SyRens can be connected to the same serial transmitter If using a true RS 232 device like a PC s serial port it is necessary to use a level converter to shift the 10V to 10V rs 232 levels to the Ov Sv TTL Packetized serial uses an address byte to select the target devi
11. hich may not correspond to the center stick position depending on trim settings This may cause the motors to move slowly even when the transmitter stick is centered If you encounter this either consult your receiver manual to reprogram the startup position or adjust your transmitter trims until the motors stop moving As a last resort you can enter R C microcontroller mode which will disable SyRen s autocalibration Mode 3 Simplified Serial Mode Simplified serial uses TTL level single byte serial commands to set the motor speed and direction This makes it easy to interface to microcontrollers and PCs without having to implement a packet based communications protocol Simplified serial is a one direction only interface The transmit line from the host is connected to S1 The host s receive line is not connected to the SyRen Because of this multiple drivers can be connected to the same serial transmitter If using a true RS 232 device like a PC s serial port it is necessary to use a level converter to shift the 10V to 10V rs 232 levels to the Ov Sv TTL levels the SyRen is expecting This is usually done with a Max232 type chip If using a TTL serial device like a microcontroller the TX line of the microcontroller may be connected directly to S1 Baud Rate Selection Simplified Serial operates with an 8N1 protocol 8 data bytes no parity bits and one stop bit The baud rate is selected by switches 4 and 5 from the following 4 op
12. ions but accomplishes the same thing Analog One direction reverse Note on using filtered PWM in Analog Mode E 8 5 5 5 O O O i 2 9 Figure 4 1 Fast filtering Figure 4 2 Very smooth filtering If you are using a filtered PWM signal from a microcontroller to generate the analog voltage an R C filter with component values 10k ohms and at least luf is recommended as shown in Figure 4 1 This will provide a fast response to changes in duty cycle and is suitable for PWM rates of 20 kHz Using a larger value filter capacitor such as 47uf Figure 4 2 will result in smoother motor operation and greater efficiency However the transient response will be slower This extra capacitance is strongly recommended when using slower PWM frequencies as low as 1kHz Tweaking the value of the capacitor to suit your individual needs is safe way to optimize your robot s performance Mode 2 R C Input R C input mode is used with a standard hobby Radio control transmitter and receiver or a microcontroller using the same protocol R C mode is selected by setting switch 1 to the DOWN position and switch 2 to the UP position If running from a receiver it is necessary to obtain one or more servo pigtails and hook them up according to figure 5 1 If there are only motor drivers being used it is acceptable to power the receiver directly from a SyRen as shown If the system also has to power servos or other
13. ition then Timeout Failsafe mode is active This will bring the motor to a stop if the servo signal is interrupted Once several valid control signals are sent the motor will restart This is useful to prevent to robot driving away if it R C Failsafe Timeout Disabled encounters interference drives out of range or if the transmitter is inadvertently de activated Many robot competitions require this feature If switch 6 is set in the DOWN position then Timeout Failsafe mode is de activated This means that the SyRen will continue to drive the motor according to the last command until another command is given If the control link is possible unreliable like a radio then this can be dangerous due to the robot not stopping However it is extremely convenient if you are controlling the SyRen from a microcontroller In this case commanding the controller can be done with as little as three lines of code Output_High Pin connected to S1 Delay 1000us to 2000us Output_Low Pin connected to S1 This makes it easy to use R C mode without having to set up a repeating pulse stream This is most advantageous on controllers like Basic Stamps which don t have the ability to perform background tasks A note on certain microprocessor receivers Some receivers such as the Spektrum AR6000 will output servo pulses before a valid transmitter signal is present This will cause the SyRen to autocalibrate to the receiver s startup position w
14. m Example of Packetized Serial The following is an example function for commanding a pair of SyRen 10s or 20s using Packetized Serial Mode Figure 7 3 shows an example hookup and Figure 7 4 shows an example function Void DriveForward char address char speed UNN ae i E Putc address a a a a 44 Putc Q Putc speed Putc address 0 speed amp ObO1I111111 Microcontroller alls all MiB B M2 a Figure 7 3 Packetized serial hookup Figure 7 4 Packetized Serial Function Example So in this function if address is 130 command is O for driving forward speed is 64 the checksum should calculate as follows 130 0 64 194 194 in binary is Ob1 1000010 Ob1 1000010 amp Ob01111111 0b01000010 Once all the data is sent this will result in the SyRen with address 130 driving forward at roughly half throttle The SyRen s 7 bit design is done this way to allow different products that don t use the same protocol to live on the same bus Emergency Stop In Packetized Serial mode the S2 input is configured as an active low emergency stop It 1s pulled high internally so if this feature isn t needed it can be ignored If an emergency stop is desired all the S2 inputs can be tied together Pulling the S2 input of one or more SyRen 50s low will cause the driver to shut down This should be tied to an emergency stop button if used in a device that could endanger humans
15. nd direction of the motor There is a short packet format consisting of an address byte a command byte a data byte and a 7 bit checksum SyRen 50 is set to 9600 baud from the factory To change this please navigate to the Packet serial section in this document and locate the commands page Address bytes are set via dip switches Up to 8 SyRen motor drivers may be ganged together on a single serial line This makes packetized serial the preferred method to interface multiple SyRens to a PC or laptop Lithium cutoff Switch 3 of the DIP switch block selects lithium cutoff If Switch 3 is in the down position as shown the SyRen will automatically detect the number of series lithium cells at startup and set a cutoff voltage of 3 0 volts per cell The number of detected cells is flashed out on the Status LED Lithi Cutoff enabled If the number of cells detected is too low your battery is in cdc a severely discharged state and must be charged before operation Failure to do so may cause damage to the battery pack When 3 0V per cell is reached the SyRen will shut down preventing damage to the battery pack This is necessary because a lithium battery pack discharged below 3 0v per cell will lose capacity and batteries discharged below 2 0v per cell may not recharge ever Lithium cutoff mode may also be useful to increase the number of battery cycles you can get when running from a lead acid battery in non critical applications Because th
16. of zero corresponding to 6v which is the minimum Valid data is from O to 120 The function for converting volts to command data is Value desired volts 6 x 5 3 Max voltage decimal 4 binary 0b00000100 hex 0h04 This is used to set a custom maximum voltage If you are using a power supply that cannot sink current such as an ATX supply the input voltage will rise when the driver is regenerating slowing down the motor Many ATX type supplies will shut down if the output voltage on the 12v supply rises beyond 16v If the driver detects an input voltage above the set limit it will put the motor into a hard brake until the voltage drops below the set point again This is inefficient because the energy 1s heating the motor instead of recharging a battery but may be necessary The driver comes preset for a maximum voltage of 30V The range for a custom maximum voltage is Ov 25v The formula for setting a custom maximum voltage is Value Desired Volts 5 12 If you are using any sort of battery then this is not a problem and the max voltage should be left at the startup default Checksum To prevent data corruption each packet is terminated with a checksum If the checksum is not correct the data packet will not be acted upon The checksum is calculated as follows Checksum address byte command byte data byte The checksum should be added with all unsigned 8 bit integers and then ANDed with the mask Ob0O1111111 in an 8 bit syste
17. position Switch 3 should be either up or down depending on the battery type being used Inputs S1 and S2 are configured as analog inputs The output impedance of the signals fed into the inputs should be less than 10k ohms for best results If you are using a potentiometer to generate the input signals a 1k 5k or 10k linear taper pot is recommended Remember to connect OV to the ground of your control circuit There are 6 operating options for analog input These are selected with switches 4 and 5 Option 1 Analog Bi direction A signal of 2 5 volts corresponds to the motor being stopped Ov corresponds to full power reverse and 5v corresponds to full power forward mode This is useful for direct bi directional control of motors There is one input which is connected to S1 Option 2 Analog One direction A signal of Ov corresponds to the motor being fully stopped 5v corresponds to full power forward The motor acts single direction only and cannot be commanded to reverse This is useful for fans pumps propellers and other single direction only loads There is one input which is connected to S1 Option 3 Analog One direction with forward reverse select on S2 A signal on S1 of Ov corresponds to the motor being fully stopped 5v corresponds to full power A second signal is fed to S2 If the signal on S2 is greater than 2 5 volts the SyRen will drive the motor forward If the signal on S2 is l less than 2 5 volts
18. quency of 32kHz which is well above the maximum frequency of human hearing Unlike some other motor drivers there is no annoying whine when the motor is on even at low power levels Thermal and overcurrent protection SyRen 50 features dual temperature sensors and overcurrent sensing It will protect itself from failure due to overheating overloading and short circuits Easy mounting and setup SyRen has screw terminals for all inputs and outputs There are four mounting holes which accept 4 40 screws Mounting hardware is included All operating modes and options are set with DIP switches there are no jumpers to struggle with or lose No soldering is required Compact Size SyRen utilizes surface mount construction to provide the most power from a compact package Its small size and light weight mean you have more space for cargo batteries or can make your robot smaller and more nimble than the competition Carefree reversing Unlike some other motor drivers there is no need for the SyRen to stop before being commanded to reverse You can go from full forward immediately to full reverse or vice versa Braking and acceleration are proportional to the amount of reversal commanded so gentle or rapid reversing is possible Many operating modes With analog R C and serial input modes as well as dozens of operating options the SyRen has the flexibility to be used over and over even as your projects grow more sophisticated Yet it
19. tions 19200 Baud 38400 Baud What baud rate to use is dependent on what your host can provide and the update speed necessary 9600 baud or 19200 baud are recommended as the best starting points If communication is unreliable decrease the baud rate If communications are reliable you may increase the baud rate The maximum update speed on the SyRen 50 is approximately 2000 commands per second Sending characters faster than this will not cause problems but it will not increase the responsiveness of the controller either The baud rate may be changed with power on by changing the DIP switch settings There is no need to reset or cycle power after a baud rate change There are 2 operating options for Simplified Serial These are selected by the position of Switch 6 Option 1 Standard Simplified Serial Mode Serial data is sent to input S1 The baud rate is selected with switches 4 and 5 Commands are sent as single bytes Sending a value of 0 will cause the motor to drive full forward and sending a value of 255 will cause the motor to drive reverse A value of 127 will cause the motor to stop Option 2 Simplified Serial with Slave Select This mode is used when it is desirable to have multiple SyRen 50s running from the same serial transmitter but you do not wish to use packetized serial A digital signal Ov or 5v is fed to the S2 input This is controlled by the host microcontroller If the signal on S2 is logic hig
20. vice generating the input signal needed we recommend using a Park BEC or SW050 to supply the needed 5V power to the rest of the robot The OV connection is the signal ground for the SyRen In order to receive input signals correctly it must be connected to the ground of the device sending the signals OV is internally connected to B Using the OV and 5v connections to power a radio receiver in R C mode and potentiometer in analog mode is shown in Figures 2 1 and 2 2 If you are using multiple SyRens running from the same radio receiver only one should have the 5v line connected Figure 2 1 Analog input using a potentiometer powered from terminal 5V Figure 2 2 R C input using a receiver powered from terminal 5V Status and Error LEDs The SyRen 50 has two indicator LEDs The green LED marked status is used to communicate various information A about the current state Its operation depends on the i operating mode For example 1f a lithium battery pack is selected the status LED blinks the number of cells detected Unless you are in lithium mode the status LED will usually remain on The Error LED illuminates if the SyRen has detected a problem It will light if the driver has shut down due to a depleted battery or due to overheating If you are using a NiCd or NiMH battery and commanding an acceleration causes the motor to jerk and the Error LED to flash on and off the battery is depleted Mounting your SyRen The S
21. yRen is supplied with four mounting holes These can be used to attach it to your robot The centers of the mounting holes form a X x X rectangle The holes are 125 inches in diameter The proper size screw is a 4 40 round head machine or wood screw Four 1 long machine screws and nuts are included Figure 2 3 Mounted to a wood frame using standoffs If your robot or device is constructed from insulating materials such as wood or plastic it is advisable to use the four included plastic standoffs to allow air to circulate This is Shown in Figure 2 3 If your robot or device is constructed from metal it is usually better to attach the SyRen directly to the frame without standoffs This will allow your frame to act as a heat sink and will cause the SyRen to run cooler This is Figure 2 4 Mounted directly to a shown in Figure 2 4 metal frame Operating Modes Overview Mode 1 Analog Input Analog input mode takes one or two analog inputs and uses those to set the speed and direction of the motor The valid input range is Ov to 5v This makes the SyRen easy to control using a potentiometer the PWM output of a microcontroller with an R C filter or an analog circuit Major uses include joystick or foot pedal controlled vehicles speed and direction control for pumps and machines and analog feedback loops There is also a Diff Drive mixing mode which takes two analog inputs for tank style steering Mode 2 R C Input
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