Dual Channel Digital Motor Controller
AX1500
 AX1500 Motor Controller User’s Manual
 Date Version Changes
Revision History
Revision History
 AX1500 Motor Controller User’s Manual
 Section
 Section
 Section
 100
 122
 144
 173
 AX1500 Motor Controller User’s Manual
 Beware of Motor Runaway in Improperly Closed Loop
Important Safety
Do not Connect to a RC Radio with a Battery Attached
 Important Safety Warnings
 AX1500
Locating the Connectors
Quick Start
What you will need
 AX1500 Controller Rear View
AX1500 Quick Start
 Connecting to the Batteries and Motors
Connecting to the Batteries and Motors
 Signal Pin RC Mode RS232 Mode Analog Mode
Connecting to the 15-pin Connector
 Connecting the R/C Radio
Connecting the R/C Radio
 Parameter Default Values Letter
Powering On the Controller
Default Controller Configuration
 Connecting the controller to your PC using Roborun
Connecting the controller to your PC using Roborun
 Exploring further
Obtaining the Controller’s Software Revision Number
 Product Description
AX1500 Motor Controller Overview
 Technical features
 Low Power Consumption
Technical features
High Efficiency Motor Power Outputs
Optical Encoder Inputs optional
 Compact Open Frame PCB Design
Advanced Safety Features
Data Logging Capabilities
 Power Connections
Connecting Power and Motors to the Controller
Power Connections
 Connecting Power and Motors to the Controller
Controller Power
 Mended Off Configuration
Controller Power
 Powering the Controller from a single Battery
Controller Powering Schemes
 Controller Powering Schemes
Powering the Controller Using a Main and Backup Battery
 Powering the AX1500 with a Main and Backup Supply
Connecting the Motors
 Converting the AX1500 to Single Channel
Single Channel Operation
 Wire Length Limits
Power Fuses
 Electrical Noise Reduction Techniques
Power Regeneration Considerations
Electrical Noise Reduction Techniques
 Undervoltage Protection
Using the Controller with a Power Supply
Overvoltage Protection
 Using the Controller with a Power Supply
 Connecting Power and Motors to the Controller
 General Operation
Input Command Modes
Basic Operation
Basic Operation
 Open Loop, Separate Speed Control
Selecting the Motor Control Modes
Open Loop, Mixed Speed Control
General Operation
 Selecting the Motor Control Modes
Closed Loop Speed Control
Close Loop Position Control
 Temperature Max Amps
User Selected Current Limit Settings
Temperature-Based Current Limitation
 Motor Current = Battery Current / PWM ratio
Battery Current vs. Motor Current
Battery Current vs. Motor Current
 Off
Regeneration Current Limiting
 Programmable Acceleration
Programmable Acceleration
 Command Control Curves
 Exponentiation Parameter Value Selected Curve
Left / Right Tuning Adjustment
Left / Right Tuning Adjustment
 Parameter Value Speed Adjustment
 Activating Brake Release or Separate Motor Excitation
Emergency Stop using External Switch
Inverted Operation
Activating Brake Release or Separate Motor Excitation
 Using the Inputs to Activate the Buffered Output
Special Use of Accessory Digital Inputs
 AX1500 Connections
Connecting Sensors and Actuators to Input/Outputs
AX1500 Connections
 AX1500’s Inputs and Outputs
Connecting Sensors and Actuators to Input/Outputs
 AX1500’s Inputs and Outputs
Signal Type Use Activated
 List and Pin Assignment
Pin1
 Connecting devices to Output C
Connecting devices to Output C
 Connecting Switches or Devices to Input F
Connecting Switches or Devices to Input E
 Connecting Switches or Devices to EStop/Invert Input
Connecting Switches or Devices to EStop/Invert Input
 Analog Inputs
Connecting Position Potentiometers to Analog Inputs
 Ana Ana2 Operating Mode Pin
Connecting Tachometer to Analog Inputs
Connecting Tachometer to Analog Inputs
 Operating Mode Ana 1 p11 Ana2 p10 Ana 3 p12 Ana 4 p8
 Connecting External Thermistor to Analog Inputs
Connecting External Thermistor to Analog Inputs
Temp oC
Resistance kOhm
 Using the Analog Inputs to Monitor External Voltages
 Internal Voltage Monitoring Sensors
Connecting User Devices to Analog Inputs
Internal Heatsink Temperature Sensors
 Temperature Conversion C Source Code
 Internal Heatsink Temperature Sensors
 Connecting Sensors and Actuators to Input/Outputs
 Optical Incremental Encoders Overview
Installing Connecting Using Encoder Module
Optical Incremental Encoders Overview
 Recommended Encoder Types
Installing, Connecting and Using the Encoder Mod
 Pulse Frequency in Hz = RPM / 60 * PPR
Installing the Encoder Module
Installing the Encoder Module
 Connecting the Encoder
 Pin Name Cable Color
Cable Length and Noise Considerations
Cable Length and Noise Considerations
 Motor Encoder Polarity Matching
Voltage Levels, Thresholds and Limit Switches
 Wiring Optional Limit Switches
Wiring Optional Limit Switches
 SW1 SW2 GND
 Effect of Limit Switches
Wiring Limit Switches Without Encoders
Wiring Limit Switches Without Encoders
Motor 1 Fwd Motor 1 Rev
 Motor Fwd Motor Rev
Using the Encoder Module to Measure Distance
Using the Encoder to Measure Speed
 Using the Encoder to Track Position
Using the Encoder to Track Position
 Distance = Destination Counter value / Divider
RS232 Communication with the Encoder Module
 Encoder Testing and Setting Using the PC Utility
Encoder Testing and Setting Using the PC Utility
 Installing, Connecting and Using the Encoder Mod
 Mode Description
Closed Loop Position Mode
Selecting the Position Mode
Mode Description
 Sensor Mounting
Closed Loop Position Mode
Position Sensor Selection
 Feedback Potentiometer wiring
Feedback Potentiometer wiring
Feedback Potentiometer wiring in RC or RS232 Mode
 Pot wiring for RS232 or RC Command and Analog Feedback
Feedback Potentiometer wiring in Analog Mode
 Analog Feedback on Single Channel Controllers
Analog Feedback on Single Channel Controllers
 Sensor and Motor Polarity
Using Optical Encoders in Position Mode
 Encoder Error Detection and Protection
Encoder Error Detection and Protection
Adding Safety Limit Switches
 SW1 SW2
 Control Loop Description
Using Current Limiting as Protection
Using Current Limiting as Protection
 PID tuning in Position Mode
 PID tuning in Position Mode
 Closed Loop Position Mode
 Selecting the Speed Mode
Closed Loop Speed Mode
 Tachometer or Encoder Mounting
Tachometer wiring
Closed Loop Speed Mode
 Speed Sensor and Motor Polarity
Speed Sensor and Motor Polarity
 Adjust Offset and Max Speed
 PID tuning in Speed Mode
PID tuning in Speed Mode
 Closed Loop Speed Mode
 Power On LED
Normal Fault Condition LED Messages
Diagnostic LED
Power On LED
 Normal and Fault Condition LED Messages
Output Off / Fault Condition
 C Operation
C radio control mode
 Connector I/O Pin Assignment R/C Mode
Selecting the R/C Input Mode
Pin Input or Number Output Signal Description
Operation
 Input Circuit Description
Input Circuit Description
Supplied Cable Description
 RC Cable wiring diagram
Powering the Radio from the controller
 Wiring for powering R/C radio from controller
Powering the Radio from the controller
 Operating the Controller in R/C mode
Connecting to a Separately Powered Radio
 Reception Watchdog
Reception Watchdog
 Joystick Deadband Programming
Transmitter/Receiver Quality Considerations
 Effect of deadband on joystick position vs. motor speed
Command Control Curves
 Joystick Calibration
Left/Right Tuning Adjustment
Activating the Accessory Outputs
 Data Logging in R/C Mode
Data Logging in R/C Mode
 112
 Analog Control and Operation
 Analog Control and Operation
Connector I/O Pin Assignment Analog Mode
Pin Input or Number Signal Output Description
 Connecting to a Voltage Source
Connecting to a Voltage Source
Connecting a Potentiometer
 = U/R = 5V / 1000 Ohms = 0.005A = 5mA
Selecting the Potentiometer Value
 Analog Deadband Adjustment
Analog Deadband Adjustment
 Data Logging in Analog Mode
Power-On Safety
Under Voltage Safety
 Modified Analog cable with RS232 output data logging for PC
Data Logging in Analog Mode
 120
 Use and benefits of RS232
Serial RS-232 Controls Operation
Use and benefits of RS232
 Serial RS-232 Controls and Operation
Connector I/O Pin Assignment RS232 Mode
 Extending the RS232 Cable
Cable configuration
Cable configuration
 Establishing Manual Communication with a PC
Communication Settings
Bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity
 Roboteq v1.9b 06/01/07 s
RS232 Communication with the Encoder Module
Establishing Manual Communication with a PC
 Data Logging String in R/C or Analog mode
Entering RS232 from R/C or Analog mode
 Commands Acknowledge and Error Messages
 RS-232 Watchdog
Controller Commands and Queries
Command Type Description
 Controller Commands and Queries
Set Motor Command Value
Set Accessory Output
 Syntax
Query Power Applied to Motors
Query Amps from Battery to each Motor Channel
 Query Battery Voltages
Query Heatsink Temperatures
Query Analog Inputs
?r or ?R
 Query Digital Inputs
Reset Controller
 Accessing & Changing Configuration Parameter in Flash
Accessing & Changing Configuration Parameter in Flash
Apply Parameter Changes
Read parameter
 Location Description Active after
Flash Configuration Parameters List
 Motor Control Mode
Input Control Mode
Address Access Read/Write Effective After Reset
Value Mode See pages
 Bit Definition See pages
Amps Limit
 Acceleration
Input Switches Function
 Exponentiation on Channel 1 and Channel
Address Channel Access Read/Write Effective Instantly
RC Joystick or Analog Deadband
 Default Encoder Time Base 1
Left/Right Adjust
 Joystick Min, Max and Center Values
Default Encoder Distance Divider
Default PID Gains
 Location Function
Reading & Changing Operating Parameters at Runtime
 Read/Change PID Values
Operating Modes Registers
Bit Function
Address 82 P1 83 I1 84 D1 85 P2
 Controller Status Register
PWM Frequency Register
 Bit Model or Function
Controller Identification Register
Current Amps Limit Registers
 Read Encoder Counter
RS232 Encoder Command Set
Set/Reset Encoder Counters and Destination Registers
 Or !Q n
Read Speed
 Read Speed/Distance
Read Encoder Limit Switch Status
Read Distance
 DD= parameter value
Switch Value
Read / Modify Encoder Module Registers and Parameters
 Address Parameter Description Size Access
 Register Description
Switch Status
Encoder Hardware ID code
Speed or Distance 1 or
 Counter 1
Counter Read/Write Mailbox
Destination Register 1
Register Description
 Speed 1
Distance 1
Time Base 1
Encoder Threshold
 Decimal Bit Hex Controller Output
Counter Read Data Format
Counter Read Data Format
 154
 Automatic Switching from RS232 to RC Mode
Automatic Switching from RS232 to RC Mode
 Data Logging Cables
Analog and R/C Modes Data Logging String Format
 Dec Hex
Decimal to Hexadecimal Conversion Table
Decimal to Hexadecimal Conversion Table
 UDec Hex
 AX1500 Motor Controller User’s Manual 159
 160
 System Requirements
Using the Roborun Configuration Utility
Downloading and Installing the Utility
 Using the Roborun Configuration Utility
Connecting the Controller to the PC
 Roborun Frame, Tab and Menu Descriptions
Parameter Selection and Setting and Special Functions
Roborun Frame, Tab and Menu Descriptions
 View Controller Connector Pinout
File and Program Management Commands
Getting On-Screen Help
Loading, Changing Controller Parameters
 Motor Control Mode
Control Settings
Input Command Adjustment
Loading, Changing Controller Parameters
 Power Settings
 Joystick Timing
Analog or R/C Specific Settings
Deadband
 Closed Loop Parameters
Encoder Setting and Testing
 Encoder Setting and Testing
Encoder Module Parameters Setting
 Viewing Encoder Data
Running the Motors
Exercising the Motors
 Running the Motors
Motor Power setting
Run/Stop Button
Measurement
 Transmit and Receive Data
Real-Time Strip Chart Recorder
Input Status and Output Setting
 Logging Data to Disk
 Connecting a Joystick
Using the Console
 Command Entry
Using the Console
Terminal Screen
Keep Watchdog Alive
 Using the Roborun Configuration Utility Send Reset String
Operating the AX1500 over a Wired or Wireless LAN
Viewing and Logging Data in Analog and R/C Modes
Loading and Saving Profiles to Disk
 Roboserver screenshot when idle
Operating the AX1500 over a Wired or Wireless LAN
 Updating the Encoder Software
Updating the Controller’s Software
 Creating Customized Object Files
Objectmaker creates controller firmware with custom defaults
 180
 Mechanical Dimensions
Mechanical Specifications
Mechanical Dimensions
 Thermal Considerations
Mechanical Specifications
Mounting Considerations
 Attaching the Controller Directly to a Chassis
Attaching the Controller Directly to a Chassis
 Precautions to observe
 Wire Dimensions
Wire Dimensions
Weight
 186