MDC2230 "Controller has been lost"

Hello Everyone!! My Name is Daniel Suarez, and i´m just register because i´m having an issue that is mentioned in some other topic but does not match with our situation...

We build an AGV guided by a colored tape through a Cam, this one sends Error to PID control in order to give instructions to Roboteq to move... our HMI just send an error indicating that it is not able to communicate to COM2 Port (here is where we connect Robotec Controller).

Running Roborun+ Software, it appears a message saying "Controller Has Been Lost", we use a little script in order to control battery level and our specific motor settings, that´s all we use. Unfortunately the Robotec Controller power supply drops to voltages like 5,7,10 VDC before it starts showing this message, and it was powered this way during 12 hours, and after all of this, we cant work with controller.

What can we do?:
- i´m able to program the script
- I´m able to connect it just via USB
- I´m not able to write the firmware on it

Thanks in advance for all your support... Have a nice day

I'm a little bit puzzled about what is going on. Is the issue just that you can no longer connect to it over the serial port? If it's possible, please confirm this using a serial to USB converter.

Regarding the power supply voltage drop, it is unlclear where and when the voltage drop is actually occuring. Is it happening randomly, or naturally as your power supply runs out and has to be recharged?

I am mainly just unclear on what is happening in your application. Let me know if you can clear up any of the confusion I am having and I'll get back to you.

Hi!! and thanks for your prompt response...

"I'm a little bit puzzled about what is going on. Is the issue just that you can no longer connect to it over the serial port? If it's possible, please confirm this using a serial to USB converter."

Which we can no longer connect to it over serial port... is just a part of the problem. Using an USB Cable we are able to read controller, write a script to controller, but, we cannot reinstall Firmware.

"Regarding the power supply voltage drop, it is unlclear where and when the voltage drop is actually occuring. Is it happening randomly, or naturally as your power supply runs out and has to be recharged?"

Our AGV has 2 Switches, one of them is for a Computer, and a second for all other circuits (including Robotec controller), when the battery runs out, our HMI shows a messages about running out of battery "please connect to power supply of turn off both pc and all other circuit switches", and if this message is ignored, the pc shuts down and AGV just stop and looks like is already turned off... but if user does not realize or forgot to switch off the entire AGV, batteries just start dropping their voltage level, and after 12 hours in this situation.. batteries drop to levels like 2.5 - 5 V per battery (AGV uses 2 batteries of 12V with a serial connection to give 24 volts to the entire system, including Robotec controller.

"I am mainly just unclear on what is happening in your application. Let me know if you can clear up any of the confusion I am having and I'll get back to you."

I hope this can unclear even a little of what is going on in our application...
Thanks in advance

The main issue is that you are not able to communicate with the controller over RS232 serial? I'm not sure that we can do anything about the batteries - we recommend a minimum of 12V supply to our controllers.

"The main issue is that you are not able to communicate with the controller over RS232 serial?" Yes

"I'm not sure that we can do anything about the batteries - we recommend a minimum of 12V supply to our controllers." Ok we appreciatte your recommendation, for sure is up to us to find a way to keep at least 12 V as a minimun voltage.

We were thinking on the possibility to do a "HARD RESET" in order to recover Robotec functionality, is this possible? or a kind of recovery process to accomplish this...

Thank you...

Sorry for the late response,

You could try to power cycle, but I am still curious about how USB connection is working, but the RS232 isn't. I'm assuming that the RS232 was working and then stopped at some point. Can you confirm how you have the RS232 pins wired?

Hi!! and thanks for all your support, at this high we solve this issue, we are aware that it is our specific application and maybe i did not show all details of it.

The problem was that in our HMI 2 process were trying to use COM 2 Port (com port dedicated to Robotec Controller) at the same time, sabotaging communication. We are working on this right now to prevent any future problem.

Thanks again for all your support.

Ah, I see, your HMI was hogging the COM port. Glad you were able to resolve your issue!