RoboteQ HDC2450 Datasheet

HDC2450 Motor Controller Datasheet 1

HDC2450

2x150A
High Performance
Dual Channel
Forward/Reverse
Brushed DC Motor
Controller with USB
and Encoder Inputs

Roboteq’s HDC2450 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.

The controller features a high-performance 32-bit microcom­puter and quadrature encoder inputs to perform advanced
motion control algorithms in Open Loop or Close Loop (Speed
or Position) modes. The HDC2450 features a high number of
Analog, Pulse and Digital I/Os which can be remapped as com­mand or feedback inputs, limit switches, or many other func­tions. The controller’s two motor channels can either be
operated independently or mixed to set the direction and rota­tion 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 Lan­guage scripts. The controller can be reprogrammed in the field
with the latest features by downloading new operating soft­ware 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

• Auto switch between USB, RS232, 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

• Operates from a single 10V-50V 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 6 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

• Closed loop position control with analog or pulse/fre-

quency feedback

2 HDC2450 Motor Controller Datasheet Version 1.2. July 20, 2010

• Precise speed and position control when Encoder feed-

back 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 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 1.5 mOhm ON resistance MOSFETs

• Orderable as single channel version up to 300A

• Stall detection and selectable triggered action if Amps is

outside user-selected range

• Short circuit protection with selectable sensitivity levels

• 10 to 32kHz user programmable Pulse Width Modulation

(PWM) output.

• Overvoltage and Undervoltage protection

• Programmable 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 AWG8 cables

• 9” (228.5mm) L, 5.5” W (140mm), 1.6” (40mm) H

• -40o to +85o C operating environment

• 3 lbs (1,350g)

• Easy configuration, tuning and monitory using provided

PC utility

• Field upgradeable software for installing latest features

via the internet

Orderable Product References

TABLE 1.

Reference Number of Channels Amps/Channel Volts

HDC2450 2 150 50V

HDC2450S 1 300 50V

HDC2450 Motor Controller Datasheet 3

Power Wires Identifications and Connection

Power Wires Identifications and Connection

Power connections are made by means of heavy gauge wires located at the back of the controller.

The diagram below shows how to wire the controller and how to turn power On and Off.

Ground (-)

Black

(top)

Power Control

Yellow

Motor 2

VBat (+)

Red

Ground (-)

Black

Motor (-)

White

Motor (+)

White

Motor 1

VBat (+)

Red

Motor (-)

Green

Motor (+)

White

FIGURE 8. Rear Controller Layout

Motor 1

VMot/Red

PwrCtrl/Yellow

SW1 Main
On/Off Switch 1A

F2
1A

Diode
>20A

Resistor
1K, 0.5W

+-

SW2
Emergency
Cut-off Switch

F1

White/M1+

Green/M1-

White/M2+

Green/M2-

Earth Tab

I/O Connector

VMot/Red

Ground/Black

Ground/Black

Ground/Black

Motor 2

Main
Battery

Backup
Battery

Note 5

Note 6
Do not Connect!

Note 1

Note 4

Note 3 Note 2

FIGURE 9. Powering the controller. Thick lines identify MANDATORY connections

4 HDC2450 Motor Controller Datasheet Version 1.2. July 20, 2010

Important Warning

Carefully follow the wiring Instructions provided in the Read Me First sheet that comes with the control­ler, 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 trou­ble-free operation. All connections shown as thick black lines line are mandatory. The controller must be powered
On/Off using switch SW1on the Yellow wire. 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 Red wires via a high-power emergency switch
SW2 as additional safety measure.

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
blown.

Note4: Optionally ground the VBat wires 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: 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.

Note6: Beware not to create a path from the ground pins on the I/O connector and the battery’s minus terminal.

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.

Auxiliary Connector
(Reserved)

USB connect, Power and Status LEDs

FIGURE 10. Front Controller Layout

Communication and I/O Connectors

USB
Connector

HDC2450 Motor Controller Datasheet 5

Sensor and Commands Connection

TABLE 4.

Connector Pin Power Dout Com Pulse Ana Dinput Enc Default Config

1 GND

14 5VOut

2 TxData RS232Tx

15 RC1 ANA1 DIN1 RCRadio1

3 RxData RS232Rx

16 RC2 ANA2 DIN2 RCRadio2

4 RC3 ANA3 DIN3 AnaCmd1

17 RC 4 AN A4 DIN4 An aC md2

5 GND

18 DOUT1 DIN12 Unused

6 DOUT2 DIN13 Unused

19 DOUT3 DIN14 Unused

7 DOUT4 DIN15 Unused

20 DOUT5 DIN16 Unused

8 DOUT6 DIN17 Status LED

21 RC5 ANA5 DIN5 Unused

9 GND

22 RC6 ANA6 DIN6 Unused

10 ANA7 DIN7 Unused

23 ANA8 DIN8 ENC2B Unused

11 ANA9 DIN9 ENC2A Unused

24 ANA10 DIN10 ENC1B Unused

12 ANA11 DIN11 ENC1A Unused

25 5VOut

13 GND

113

14 25

FIGURE 11. Main Connector pin locations

6 HDC2450 Motor Controller Datasheet Version 1.2. July 20, 2010

Default I/O Configuration

While 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 two outputs to motor brake solenoids and another output to an external status
LED. You may omit any connection that is not required in your application. The controller automatically arbitrates
the command priorities depending on the presence of a valid command signal in the following order: 1-RS232, 2­RC Pulse, 3-Analog. If needed, use the Roborun+ PC Utility to change the pin assignments and the command pri­ority order.

TABLE 5.

Connector Pin Power Dout Com Pulse Ana Dinput Default Config

5 DOUT7 DIN18 Unused

95VOut

4SCLI Reserved

8SDAI Reserved

3 GND

7 CANH Reserved

2 CANL Reserved

6 GND

1 DOUT8 DIN19 Unused

15

69

FIGURE 12. Secondary Connector pin locations

113

14 25

21

Pot 1

Ext. Status LED

RS232

Ground

TxOut
RxIn

Motor 1

Motor 2

Pot 2

RC Ch2RC Ch1

FIGURE 13. Factory default pins assignment

HDC2450 Motor Controller Datasheet 7

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.

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 VBat 55 Volts

Reverse Voltage on Battery
Leads

Ground to VBat -1 Volts

Power Control Voltage Ground to Pwr Control wire 65 Volts

Motor Leads Voltage Ground to M1+, M1-, M2+, M2- 55(1) Volts

Digital Output Voltage Ground to Output pins 30 Volts

Analog and Digital Inputs Volt­age

Ground to any signal pin on 25 & 9-pin
connectors

15 Volt s

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

RS232/USB Mode

Idle - Waiting for Command

RC Pulse Mode

Analog Mode

FIGURE 14. Normal Operation Flashing Patterns

Under or Over Voltage

Power Stage Off

Short Detected

Overheat

FIGURE 15. Exception or Fault Flashing Patterns

8 HDC2450 Motor Controller Datasheet Version 1.2. July 20, 2010

Power Stage Electrical Specifications (at 25oC ambient)

TABLE 7.

Parameter Measure point Models Min Typ Max Units

Battery Leads Voltage Ground to VBat All 0 (1) 50 Volts

Motor Leads Voltage Ground to M1+, M1-,

M2+, M2-

All 0 (1) 50 (2) Volts

Power Control Voltage Ground to Power Control

wire

All 0 (1) 65 Volts

Minimum Operating Voltage VBat or Pwr Ctrl wires All 9 (3) Volts

Over Voltage protection
range

Ground to VBat All 5 50 (4) 55 Volts

Under Voltage protection
range

Ground to VBat All 0 5 (4) 55 Volts

Idle Current Consumption VBat or Pwr Ctrl wires All 50 100 (5) 150 mA

ON Resistance (Excluding
wire resistance)

VBat to M+, plus M- to
Ground at 100% power.
Per channel

HDC2450 3 mOhm

HDC2450S 1,5 mOhm

Max Current per channel for
30s

Ch1 or Ch2 Motor current HDC2450 150 Amps

HDC2450S 300 (6) Amps

Continuous Max Current per
channel

Ch1 or Ch2 Motor current HDC2450 80 (7) Amps

HDC2450S 160 (6)(7) Amps

Current Limit range Ch1 or Ch2 Motor current HDC2450 10 100 (8) 150 Amps

HDC2450S 10 200 (8) 300 (6) Amps

Stall Detection Amps range Ch1 or Ch2 Motor current HDC2450 10 100 (8) 150 Amps

HDC2450S 10 200 (8) 300 (6) Amps

Stall Detection timeout
range

Ch1 or Ch2 Motor current All 1 65000 (9) 65000 millisec-

onds

Short Circuit Detection
threshold (10)

Between Motor wires or
Between Motor wire and
Ground

HDC2450 550 (11) 1600 (11) Amps

HDC2450S 1100 3000 (6) Amps

Short Circuit Detection
threshold

Between Motor wires and
VBat

All No Protection. Permanent damage will result

Motor Acceleration/Deceler­ation range

Ch1 or Ch2 All 100 500 (12) 65000 millisec-

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 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 controller’s VBat or PwrCtrl wires

Note 6: Current is sum of both synchronized channels. Current must be balanced between channel to obtain max current.

Note 7: Estimate. Limited by case temperature. Current may be higher with better cooling

Note 8: Factory default value. Adjustable in 0.1A increments

Note 9: Factory default value. Time in ms that Stall current must be exceeded for detection

Note 10: Controller will stop until restarted in case of short circuit detection

Note 11: Sensitivity selectable by software

Note 12: Factory default value. Time in ms for power to go from 0 to 100%

HDC2450 Motor Controller Datasheet 9

Electrical Specifications

Command, I/O and Sensor Signals Specifications

Operating & Timing 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

5V Output Current 5V pins on RJ45 and DSub15 200 (1) mA

Digital Output Voltage Ground to Output pins 30 Volts

Digital Output Current Output pins, sink current 1 (2) 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 (except
DIN12-19)

AIN/DIN Input to Ground 53 kOhm

Input Impedance (DIN12-19) Input to 5V 50 kOhm

Digital Input 0 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

Encoder count Internal -2.147 2.15 10^9

Counts

Encoder frequency Encoder input pins 1 MHz

Note 1: Sum of all 5VOut outputs

Note 2: Total average current on all outputs not to exceed 4.5A

TABLE 9.

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

USB Rate USB pins 12 MBits/s

RS232 baud rate Rx & 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

10 HDC2450 Motor Controller Datasheet Version 1.2. July 20, 2010

Scripting

Thermal Specifications

Mechanical Specifications

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

TABLE 11.

Parameter Measure Point Model Min Typ Max Units

Case Temperature Case All -40 85 (1) oC

Thermal Protection range Case All 80 90 (2) oC

Power Dissipation Case All 70 Watts

Thermal resistance Power MOSFETs to case All 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

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)

5.50" (140 mm)

4.00" (102 mm)

1.60"

(40 mm)

FIGURE 16. HDC2450 front view and dimensions

HDC2450 Motor Controller Datasheet 11

Electrical Specifications

0.25"

(6.3 mm)

7.00" (177.8 mm)

5.50" (140 mm)

4.00" (101.6 mm)

3.00" (76.2 mm)

3.60" (91.4 mm)

8.00" (203 mm)

9.00" (228.6 mm)

FIGURE 17. HDC2450 top view and dimensions

12 HDC2450 Motor Controller Datasheet Version 1.2. July 20, 2010