Data Sheet
Contents
1. lRoboteQ VSX1850 500A Forward Reverse Separate Excitation DC Motor Controller Roboteq s VSX1850 is a high current controller for Separate Key Features Excitation DC motors The controller is composed of a unidirec tional half bridge capable of up to 500A for the motor s arma R5232 0 5V Analog AG lee RC radiocommand modes ture and a 25A bidirectional power bridge for the motor s e Auto switch between RS232 Analog or Pulse based on excitation field user defined priority e Built in high power driver for Separate Excitation DC The controller accepts commands received from a RC radio motors at up to 500A Analog Joystick wireless modem or microcomputer to coordi Secondary 25A full bridge for Excitation power nate the armature and field bridge power so that the motor will move in a precisely controlled manner in the forward or reversed direction e Full forward amp reverse motor direction control Four quad rant operation Supports regeneration e User programmable curve of Excitation power vs Arma The motor may be operated in open or closed loop speed ture power mode Using low cost position sensors it may also be set to e Compatible with Serial motors Unidirectional control only operate as a heavy duty position servos The controller s opera tion can be extensively automated and customized using Basic Language scripts e Operates from a single 10V 50V power source e Programmable curre2. 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 RC radio RF Modem or microcomputer Separate Programmable acceleration and deceleration rate Separate Programmable maximum forward and reverse power Ultra efficient 0 4 mOhm ON resistance MOSFETs Orderable as dual channel with one unidirectional 500 output and one bidirectional 25A output Stall detection and selectable triggered action if Amps is outside userselected range Short circuit protection with selectable sensitivity levels Orderable Product References 10 to 32kHz user programmable Pulse Width Modulation PWM output Overvoltage and Undervoltage protection Watchdog for automatic motor shutdown in case of command loss Overtemperature protection Diagnostic LED Extruded aluminum heat sinking enclosure for opera tion harsh shock and temperature environment Efficient heat sinking Operates without a fan in most applications Dustproof and weather resistant IP51 NEMA rating Power wiring via heavy duty copper bars 9 228 5mm L 5 5 W 140mm 1 6 40mm H 400 to 850 C operating environment 3 Ibs 1 3509 Easy confi
3. Specifications TABLE 11 Parameter Measure Point Min Tye Max Units wm e e e VSX1850 Motor Controller Datasheet lIRoboteQ P41 Aux 00000000 40 mm o Power Status 4 00 102 mm 5 50 140 mm FIGURE 15 VSX1850 front view and dimensions 1650 42mm 625 400 15 9mm 10 1 D250 D320 6mm 8 13mm FIGURE 16 High Current copper bar connectors 20 2mm 5 50 140 mm 4 00 101 6 mm 7 00 177 8 mm 8 00 203 mm 9 00 228 6 mm inl FIGURE 17 VSX1850 top view and dimensions 10 VSX1850 Motor Controller Datasheet Version 1 2 July 20 2010
4. 1 Sum of all 5VOut outputs VSX1850 Motor Controller Datasheet Version 1 2 July 20 2010 lRoboteQ Electrical Specifications Operating amp Timing Specifications TABLE 8 Parameter Measure Point Min Typ Max Units Command Latency Command to output change 1 0 5 1 ms PWM Frequency Ch1 Ch2 outputs 10 18 1 32 kHz Closed Loop update rate Internal 1000 Hz RS232 baud rate Rx amp Tx pins 115200 Bits s 2 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 9 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 10 Parameter Measure Point Min Typ Max Units Case Temperature Case 40 85 1 oC Thermal Protection range Case 80 90 2 oC Power Dissipation Case 70 Watts Thermal resistance Power MOSFETs to case 0 6 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
5. guration tuning and monitory using provided PC utility Field upgradeable software for installing latest features via the internet Reference Number of Channels Amps Channel Volts VSX1850 1 Sepex 500A 50V VSX1850 D 1 Unidirectional 1 Bidi 500A 25A 50V rectional VSX1850 Motor Controller Datasheet Version 1 2 July 20 2010 lRoboteQ Power Wires Identifications and Connection Power Wires Identifications and Connection Power connections are made by means of copper bars located at the back of the controller for the high current output to the motor armature Pwr Mot Vbat Ctrl top FIGURE 8 Rear Controller Layout The connection to motor field is done using Fast On tabs located on the controller s front Important Warning Because of the extremely high current on the copper bars it is imperative that the connection between the wires and the copper bars be perfect A poor connection will cause potentially damaging heat to be generated at the point of contact between the wire lug and the copper bar P1 oo0000000 oo000000 Power Status m a Communication and 1 O Connector FIGURE 9 Front Controller Layout Power and Status LEDs Power Connectors to Motor Field The diagram below shows how to wire the controller and how to turn power On and Off VSX1850 Motor C
6. ions Absolute Maximum Values The values in the table below should never be exceeded Permanent damage to the controller may result TABLE 5 Parameter Measure point Min Typ Max Units Battery Leads Voltage Ground to VBat 55 Volts Reverse Voltage on Battery Ground to VBat 1 Volts Leads Power Control Voltage Ground to Pwr Control wire 65 Volts Motor Leads Voltage Ground to Mot 55 1 Volts Digital Output Voltage Ground to DOut1 2 30 Volts Analog and Digital Inputs Volt Ground to any signal pin on DSub15 15 Volts age connectors RS232 I O pins Voltage External voltage applied to Rx Tx pins 15 Volts Case Temperature Case 40 85 oC Humidity Case 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 Power Stage Electrical Specifications at 250C ambient TABLE 6 Parameter Measure point Min Typ Max Units Battery Input Voltage Ground to VBat 0 1 50 Volts Motor Output Voltage Ground to Mot F or F 0 1 50 2 Volts Power Control Voltage Ground to Power Control wire 0 1 65 Volts Minimum Operating Voltage VBat or Pwr Ctrl wires 9 3 Volts Over Voltage protection range Ground to VBat 5 50 4 55 Volts Under Voltage protection range Ground to VBat 0 5 4 55 Volts Idle Current Consumption VBat or Pwr Ctrl wires 50 100 5 150 mA Ar
7. mature ON Resistance Mot to Ground at 100 power 0 4 mOhm Field ON Resistance F to F at 100 power 6 mOhm Max Current per channel for Mot to Mot Armature 500 Amps 60s F to F Field 25 Amps Continuous Max Current per Mot to Mot Armature 250 6 Amps channel F to F Field 20 Amps Current Limit range Motor current 50 350 7 500 Amps Stall Detection Amps range Motor current 50 350 7 500 Amps Stall Detection timeout range Motor current 1 65000 8 65000 millisec onds VSX1850 Motor Controller Datasheet IRoboteQ TABLE 6 Parameter Measure point Min Typ Max Units Short Circuit Detection thresh Between Mot and Ground 5000 10000 Amps old 9 10 Between F and F Between F or 280 800 10 Amps F and Ground Short Circuit Detection thresh old Motor Acceleration Decelera Motor output 100 500 11 65000 millisec tion range onds Between Mot F or F and VBat No Protection Permanent damage will result 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 VBat or Power Control wire Note 4 Factory default value Adjustable in 0 1V increments Note 5 Current consumption is lower when higher voltage is applied to the c
8. nt limit up to 500A for protecting con troller motor wiring and battery The controller can be configured monitored and tuned in real e Upto 4 Analog Inputs for use as command and or feed time using a Roboteq s free PC utility The controller can also be back reprogrammed in the field with the latest features by down e Up to 5 Pulse Length Duty Cycle or Frequency Inputs for loading new operating software from Roboteq use as command and or feedback e Up to 6 Digital Inputs for use as Deadman Switch Limit Switch Emergency stop or as user inputs e Two general purpose 24V 1 5A output for brake release or Applications e Electric Vehicles e Terrestrial and Underwater Robotic Vehicles accessories e Automatic Guided Vehicles e Custom scripting in Basic language Execution speed e Police and Military Robots 50 000 lines per second e Hazardous Material Handling Robots e Selectable min max center and deadband in Pulse and e Telepresence Systems Analog modes Animatronics e Selectable exponentiation factors on command input e Trigger action at user programmable Analog or Pulse input e Industrial Controls levels soft limit switches e Hydraulic Pumps control e Open loop or closed loop speed control operation e Closed loop position control with analog or pulse fre quency feedback VSX1850 Motor Controller Datasheet 1 lRoboteQ PID control loop Configurable Data Logging of operating parameters on
9. ons The figure below shows how to wire the controller to an analog potentiometers an RC radio and the RS232 port It also shows how to connect the one of the Digital outputs to a motor brake solenoid You may omit any connec tion that is not required in your application The controller automatically arbitrates the command priorities depend ing on the presence of a valid command signal in the following order 1 RS232 2 RC Pulse 3 Analog If needed use the Roborun PC Utility to change the pin assignments and the command priority order VSX1850 Motor Controller Datasheet lRoboteQ e 9000g0 FIGURE 12 Factory default pins assignment RS232 Ground TxOut RxIn 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 FIGURE 13 Normal Operation Flashing Patterns Idle Waiting for Command RS232 USB Mode RC Pulse Mode Analog Mode BOLOOOODOEOoooooo FIGURE 14 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 6 VSX1850 Motor Controller Datasheet Version 1 2 July 20 2010 lRoboteQ Electrical Specifications Electrical Specificat
10. ontroller Datasheet lRoboteQ Diode Resistor gt 20A 1K 0 5W PwrCtrl Yellow SW1 Main On Off Switch 1A VBat Mot Ground Earth Tab 1 0 Connector Do not Connect FIGURE 10 Powering the controller Thick lines identify MANDATORY connections Important Warning Carefully follow the wiring Instructions provided in the Read Me First sheet that comes with the control ler or 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 line are mandatory The controller must be powered On Off using switch SW1on the Power Control tab Use a suitable high current fuse F1 as a safety measure to prevent damage to the wiring in case of major controller malfunction The battery must be connected in permanence to the controller s VBat and Ground copper bars via a high power emergency switch SW2 as additional safety measure Precautions and Optional Connections Note1 To ensure motor operation with weak or discharged batteries connect a second battery to the Power Con trol tab 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 f
11. ontroller s VBat or PwrCtrl wires Note 6 Estimate Limited by case temperature Current may be higher with better cooling Note 7 Factory default value Adjustable 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 Command I O and Sensor Signals Specifications TABLE 7 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 RJ45 and DSub15 200 1 mA Digital Output Voltage Ground to Output pins 30 Volts Output On resistance Output pin to ground 0 25 0 5 Ohm Output Short circuit threshold Output pin 1 7 3 5 Amps Digital Output Current Output pins sink current 1 5 Amps Input Impedances except AIN DIN Input to Ground 53 kOhm DIN11 19 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 1 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 Note
12. use is blown Note4 Connect the controller s earth tab to a wire connected to the Earth while the charger is plugged in the AC main or if the controller is powered by an AC power supply 4 VSX1850 Motor Controller Datasheet Version 1 2 July 20 2010 lRoboteQ Commands and I O Connection Note5 Beware not to create a path from the ground pins on the I O connector and the battery minus terminal Commands and I O Connection Connection to RC Radio Microcomputer Joystick and other low current sensors and actuators is done via the 15 pin connector located in front of the controller The functions of some pins vary depending on controller model and user configuration Pin assignment is found in the table below KO oo0oo0o00000 O oo0o00000 FIGURE 11 Connector pin locations TABLE 4 Connector Pin Power Dout Com RC Ana Dinput Default Config 1 DOUT1 Brake release 9 DOUT2 Unused 2 TxOut RS232Tx 0 RC5 ANA1 DIN5 AnaCmd1 3 RxlIn RS232Rx 11 RC4 ANA4 DIN4 Unused 4 RC1 DIN1 RCRadio1 2 RC3 ANA3 DIN3 Unused 5 GND 13 GND 6 SCLI Reserved 4 5VOut 7 SDAI Reserved 5 DING Unused 8 RC2 ANA2 DIN2 Unused Default I O Configuration The controller can be configured so that practically any Digital Analog and Pulse pin can be used for any purpose The controller s factory default configuration provides an assignment that is suitable for most applicati
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