Main
Revision History
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SECTION 1
SECTION 2
SECTION 3
SECTION 4
SECTION 5
SECTION 6
SECTION 7
SECTION 8
SECTION 9
SECTION 10
SECTION 11
SECTION 12
SECTION 13
SECTION 14
SECTION 15
Quick Start
Important Safety Warnings
This product is intended for use with recharge able ba tteries
What you will need
Locating Switches, Wires and Connectors
Connecting to the Batteries and Motors
Using the Power Control Wire
Connecting the R/C Radio
Powering On the Controller
Button Operation
Default Controller Configuration
Checking and Changing Configuration s
Connecting the controller to your PC using Roborun
Obtaining the Controllers Software Revision Number
Exploring further
= Software version 1.7
SECTION 2 AX2500/2850
Motor Controller Overview
Product Description
Technical features
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Controller Power
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Powering the Controller using the Motor Batteries
Using a Backup Battery
Power Fu ses
Wire Length Limits
Electrical Noise Reduction Techniques
Power Regeneration Considerations
Overvoltage Protection
Undervoltage Protection
Using the Controller with a Power Supply
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Operation
Basic Operation
Input Command Modes
Selecting the Motor Control Modes
Open Loop, Separate Speed Control
Open Loop, Mixed Speed Control
Closed Loop Speed Control
Close Loop Position Control
Tachometer or Optical Encoder (AX2850 & AX3500 only) Speed Feedback
Current Limit Settings
Continuous and Extended Current Lim itation
Position Sensor Gear box
Position Feedback
Temperature-Based Current Limitation
Surge Current Protection
Regeneration Current Limiting
Programmable Acceleration
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Command Control Curves
Left / Right Tuning Adjustment
Emergency Shut Down Using Controller Switches
Emergency Stop using External Switch
Inverted Operation
Special Use of Accessory Digital Inputs
Using the Inputs to Activate the Buffered Output
Using the Inputs to turn Off/On the Power MOSFET transistors
Self-Test Mode
= Software version 1.7
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AX2500/2850s Inputs and Outputs
I/O List and Pin Assignment
Connecting devices to Output C
Connecting devices to Output D
Connecting Switches or Devices to Input E
Connecting Switches or Devices to Input F
Connecting Switches or Devices to EStop/Invert Input
Connecting Position Potentiometers to Analog Inputs
Connecting Tachometer to Analog Inputs
Connecting External Thermistor to Analog Inputs
Using the Analog Inputs to Monitor External Voltages
Connecting User Devices to Analog Inputs
Internal Voltage Monitoring Sensors
Internal Heatsink Temperature Sensors
AX2500/2850 Motor Controller Users Manual 63
Temperature Conversion C Source Code
FIGURE 35. Analog reading by controller vs. internal heat sink temperature
Temperature Conversion C Source Code
Reported Analog Value
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Fault Condition LED Messages
Use of the LED Display
Motor Direction Status
Fault Messages
No Control
MOSFET Transistors are OFF
Emergency Stop
Self-Test Display
= Software version 1.7 = Software version 2.0.c
SECTION 7 R/C Operation
Selecting the R/C Input Mode
Typical Wiring
Connector I/O Pin Assignment (R/C Mode)
Pin1 8
15
9
R/C Input Circuit Description
Supplied Cable Description
Cabling to R/C Receiver using Full Opto-Isolation
Cabling to R/C Receiver with Partial Opto-Isolation
Powering the Radio from the controller
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Operating the Controller in R/C mode
Reception Watchdog
Important Notice about PCM Radios
R/C Transmitter/Receiver Quality Considerations
Joystick Deadband Programming
Command Control Curves
Left/Right Tuning Adjustment
Joystick Calibration
Automatic Joystick Calibration
Activating the Accessory Outputs
Data Logging in R/C Mode
AX2500/2850 Motor Controller Users Manual 85
Data Logging in R/C Mode
FIGURE 56. Modified R/C cable with RS232 output for data logging to a PDA
GND
GND
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Controls and Operation
Use and benefits of RS232
Connector I/O Pin Assignment (RS232 Mode)
Cable configuration
TX Data
Extending the RS232 Cable
RX Data Data Out Data In GNDGND
DB9 Female To PC
Communication Settings
TX Data
9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity
Establishing Manual Communication with a PC
RX Data Data Out Data In GNDGND
Entering RS232 from R/C or Analog mode
Data Logging String in R/C or Analog mode
RS232 Mode if default
RS232 Commands Set
Set Motor Command Value
Set Accessory Outputs
Query Power Applied to Motors
Query Amps Consumed by Motors
Query Analog Inputs
Query Heatsink Temperatures
Query Battery Voltages
Query Digital Inputs
Read and Modify Controller Settings
Apply Parameter Changes
Reset Controller
Optical Encoder Commands
Commands Acknowledge and Error Messages
Character Echo
Command Acknowledgement
RS-232 Watchdog
RS232 Accessible Parameter Table
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Automatic Switching from RS232 to RC Mode
Analog and R/C Modes Data Logging String Format
: 00 11 22 33 44 55 66 77 88 99 AA BB CC
Data Logging Cables
Decimal to Hexadecimal Conversion Table
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SECTION 9 Analog Control
and Operation
Connector I/O Pin Assignment (Analog Mode)
Connecting to a Voltage Source
Connecting a Potentiometer
Selecting the Potentiometer Value
Analog Deadband Adjustment
Power-On Safety
Under Voltage Safety
Data Logging in Analog Mode
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SECTION 10 Closed Loop
Position Mode
Selecting the Position Mode
Position Sensor Selection
Sensor Mounting
Position Sensor Gear box
Position Feedback
Important Notice:
Potentiometer wiring
Using Optical Encoders in Position Mode
Sensor and Motor Polarity
Important Safety Warning
Adding Safety Limit Switches
Using Current Limiting as Protection
Control Loop Description
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PID tuning in Position Mode
SECTION 11 Closed Loop
Speed Mode
Selecting the Speed Mode
Using Optical Encoder for Speed Feedback (AX2850 only)
Tachometer or Encoder Mounting
Tachometer wiring
Tachometer or Optical Encoder (AX2850 & AX3500 only) Speed Feedback
Speed Sensor and Motor Polarity
Adjust Offset and Max Speed
Control Loop Description
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PID tuning in Speed Mode
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SECTION 12 Installing,
Connecting and Using the Encoder Module
Optical Incremental Encoders Overview
Recommended Encoder Types
Installing the Encoder Module
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Connecting the Encoder
Motor - Encoder Polarity Matching
Voltage Levels, Thresholds and Limit Switches
Wiring Optional Limit Switches
Using the Encoder Module to Measure Distance
Using the Encoder to Measure Speed
Using the Encoder to Track Position
RS232 Communication with the Encoder Module
RS232 Encoder Command Set
Read Encoder Counter
Set/Reset Encoder Counters and Destination Registers
Read Speed
Read Distance
Read Speed/Distance
Read Encoder Limit Switch Status
Read / Modify Encoder Module Registers and Parameters
Important Note
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Register Description
Encoder Hardware ID code
Switch Status
Speed or Distance 1 or 2
Counter Read/Write Mailbox
Counter 1 and 2
Destination Register 1 and 2
Counter Read Data Format
Encoder Testing and Setting Using the PC Utility
Encoder Module Parameters Setting
Exercising the Motors
Viewing Encoder Data
Updating the Encoder Software
SECTION 13 Configuring the
Controller using the Switches
Programming Methods
Programming using built-in Switches and Display
Entering Programming Mode
Changing parameters
The Special Case of Joystick Calibration
Restoring factory defaults
Exiting the Parameter Setting Mode
Programmable Parameters List
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Configuration Utility
System Requirements
Downloading and Installing the Utility
Connecting the Controller to the PC
Roborun Frame, Tab and Menu Descriptions
Getting On-Screen Help
Loading, Changing Controller Parameters
Controls Settings
Power Settings
Analog or R/C Specific Settings
Closed Loop Parameters
Viewing the Parameters Summary
Important Notes:
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Logging Data to Disk
Connecting a Joystick
Viewing and Logging Data in Analog and R/C Modes
Loading and Saving Profiles to Disk
Operating the AX2500/2850 over a Wired or Wireless LAN
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Updating the Controllers Software
Creating Customized Object Files
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SECTION 15 Mechanical
Specifications
Mechanical Dimensions
Mounting Considerations
Thermal Considerations
Wire Dimensions
Weight