Data Sheet

ManualsBrandsRoboteQ ManualsSerial DC ControllersHDC2460 60V 2x80A Brushed DC Motor Controller

HDC24xx Motor Controller Datasheet 1

HDC24xx

2x150A

High Performance

Dual Channel

Brushed DC Motor

Controller with USB,

Encoder Inputs

and CAN Interface

Roboteq’s HDC24xx controller is designed to convert com-

mands received from a 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. Designed for maximal ease-of-use, it is delivered with

all necessary cables and hardware and is ready to use in min-

utes. Using CAN bus, up to 127 controllers can be networked at

up to 1Mbit/s on a single twisted pair.

The controller features a high-performance 32-bit microcom-

puter and quadrature encoder inputs to perform advanced

motion control algorithms in Open Loop or Close Loop (Speed

or Position) modes. The HDC24xx features a high number of

Analog, Pulse and Digital I/Os which can be remapped as com-

mand or feedback inputs, limit switches, or many other func-

tions. The controller’s two motor channels can either be

operated independently or mixed to set the direction and rota-

tion 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 Lan-

guage scripts. The controller can be reprogrammed in the field

with the latest features by downloading new operating soft-

ware from Roboteq.

Applications

• Industrial Automation

• Tracking, Pan & Tilt systems

• Terrestrial and Underwater Robotic Vehicles

• Automatic Guided Vehicles

• Police and Military Robots

• Flight simulators

• Telepresence Systems

• Animatronics

Features List

• USB, RS232, 0-5V Analog, or Pulse (RC radio) command

modes

• Available in version with CAN bus up to 1Mbit/s

• Auto switch between USB, RS232, CAN, Analog, or Pulse

based on user-defined priority

• Built-in high-power power drivers for two brushed DC

motors at up to 150A output per channel

• Full forward & reverse control on each channel. Four quad-

rant operation. Supports regeneration

• Built-in programming language for automation and custom-

ization

• Operates from a single power source

• Programmable current limit for each channel up to 2x150A

for protecting controller, motors, wiring and battery.

• Up to 11 Analog Inputs for use as command and/or feed-

back

• Up to 4 Pulse Length, Duty Cycle or Frequency Inputs for

use as command and/or feedback

• Up to 21 Digital Inputs for use as Deadman Switch, Limit

Switch, Emergency stop or user inputs

• Dual Quadrature Encoder inputs with 32-bit counters

• 8 general purpose 24V, 1A output for brake release or

accessories

• Custom scripting in Basic language. Execution speed

50,000+ lines per second

• Selectable min, max, center and deadband in Pulse and

Analog modes

• Selectable exponentiation factors for each command

inputs

• Trigger action if Analog, Pulse or Encoder capture are out-

side user selectable range (soft limit switches)

• Open loop or closed loop speed control operation

Summary of content (14 pages)

PAGE 1
HDC24xx 2x150A High Performance Dual Channel Brushed DC Motor Controller with USB, Encoder Inputs and CAN Interface Roboteq’s HDC24xx controller is designed to convert commands received from a 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. Designed for maximal ease-of-use, it is delivered with all necessary cables and hardware and is ready to use in minutes.
PAGE 2
• 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 Multi-range PID gains changing on-the-fly according to motor speed • 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 po
PAGE 3
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.
PAGE 4
The diagram below shows how to wire the controller and how to turn power On and Off. F2 1A SW1 Main On/Off Switch 1A PwrCtrl/Yellow Note 1 White/M1+ Ground/Black Motor 1 Backup Battery Green/M1Diode >20A Resistor 1K, 0.5W Note 3 VMot/Red VMot/Red F1 Note 4 + White/M2+ Note 2 Motor 2 SW2 Emergency Contactor or Cut-off Switch Green/M2- Ground/Black Ground/Black - Earth Tab Note 5 I/O Connector Main Battery Note 6 Do not Connect! FIGURE 2. Powering the controller.
PAGE 5
Use of Safety Contactor for Critical Applications the controller. Some controllers already out in the field will not apply, but all recent purchases made from Roboteq as of 10/2/15 will have this change in effect 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.
PAGE 6
Sensor and Commands Connection Connection to RC Radio, Microcomputer, Joystick and other low current sensors and actuators is done via the 25 and 9 pin connectors located in front of the connector. The functions of many pins vary depending on controller model and user configuration. Pin assignment is found in the table below. USB connect, Power and Status LEDs Auxiliary Connector (Reserved) USB Connector Communication and I/O Connectors FIGURE 4. Front Controller Layout 14 25 1 13 FIGURE 5.
PAGE 7
Sensor and Commands Connection TABLE 4. Connector Pin Power Dout Com Pulse Ana Dinput ANA7 DIN7 ANA8 DIN8 ENC2B Unused 11 ANA9 DIN9 ENC2A Unused ANA10 DIN10 ENC1B Unused 12 ANA11 DIN11 ENC1A Unused 10 23 24 25 Enc Default Config Unused 5VOut 13 GND Note 1: Analog command is disabled in factory default configuration. 9 5 6 1 FIGURE 6. Secondary Connector pin locations TABLE 5.
PAGE 8
RC Ch1 RC Ch2 1 Pot 1 2 14 1 Pot 2 25 13 RS232 TxOut RxIn Ground Contactor Motor Brake 2 Motor Brake 1 FIGURE 7. 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).
PAGE 9
Status LED Flashing Patterns 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 8. Normal Operation Flashing Patterns Short Detected Overheat Under or Over Voltage Power Stage Off FIGURE 9.
PAGE 10
TABLE 6. Parameter Measure point Models Min Typ Max Units 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 7.
PAGE 11
Electrical Specifications TABLE 7. Parameter Measure point Models Min Typ Max Units Stall Detection timeout range Ch1 or Ch2 Motor current All 1 65000 (10) 65000 milliseconds Short Circuit Detection threshold (11) Between Motor wires or Between Motor wire and Ground HDC2450/60/72 550 (12) 1600 (12) Amps HDC2450S/72S 1100 3000 (7) Amps Short Circuit Detection threshold Between Motor wires and VMot All No Protection.
PAGE 12
TABLE 8. Parameter Measure point Pulse Capture Resolution Pulse inputs Min Typ Max Frequency Capture Pulse inputs 100 10000 Hz Encoder count Internal -2.147 2.15 10^9 Counts Encoder frequency Encoder input pins 1 MHz Max Units 1 Units us Note 1: Sum of all 5VOut outputs Note 2: Total average current on all outputs not to exceed 4.5A Operating & Timing Specifications TABLE 9. Parameter Measure Point Min Typ Command Latency Command to output change 1 0.
PAGE 13
Electrical Specifications TABLE 11. Parameter Measure Point Model Min Typ Max Units 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 Case 1.0 (2.0) kg (lbs) Wire Length Case 17 (43) inches (mm) Power Wire Gauge Wire 8 AWG Power Wire Diameter Outside diameter 0.26 (6.6) inches (mm) 1.
PAGE 14
3.00" (76.2 mm) 3.60" (91.4 mm) 4.00" (101.6 mm) 5.50" (140 mm) 0.25" (6.3 mm) 7.00" (177.8 mm) 8.00" (203 mm) 9.00" (228.6 mm) FIGURE 11. HDC24xx top view and dimensions 14 HDC24xx Motor Controller Datasheet Version 1.5.