Dual Channel Digital Motor Controller
AX1500
User’s Manual
AX1500 Motor Controller User’s Manual
Version 1.9b. June 1
Date
Revision History
Revision History
Version
AX1500 Motor Controller User’s Manual
Version 1.9b. June 1
Revision History
General Operation
Recommended Encoder Types
SECTION
Connector I/O Pin Assignment RS232 Mode
Controller Identification Register
Logging Data to Disk
AX1500 Motor Controller User’s Manual
Version 1.9b. June 1
Do not Connect to a RC Radio with a Battery Attached
Important Safety
Avoid Shorts when Mounting Board against Chassis
Warnings
Important Safety Warnings
AX1500 Motor Controller User’s Manual
Version 1.9b. June 1
Quick Start
Locating the Connectors
AX1500
What you will need
AX1500 Quick Start
AX1500 Motor Controller User’s Manual
Connecting to the Batteries and Motors
Connecting to the Batteries and Motors
AX1500 Motor Controller User’s Manual
Signal
Connecting to the 15-pin Connector
Important Warning
RC Mode
Important Warning
Connecting the R/C Radio
Connecting the R/C Radio
AX1500 Motor Controller User’s Manual
Default Values
Powering On the Controller
Default Controller Configuration
AX1500 Quick Start
Connecting the controller to your PC using Roborun
Connecting the controller to your PC using Roborun
AX1500 Motor Controller User’s Manual
AX1500 Quick Start
Obtaining the Controller’s Software Revision Number
Exploring further
AX1500 Motor Controller User’s Manual
SECTION 3AX1500 Motor Controller Overview
Product Description
AX1500 Motor Controller User’s Manual
Automatic Joystick Command Corrections
Technical features
Multiple Command Modes
AX1500 Motor Controller Overview
High Efficiency Motor Power Outputs
Technical features
Low Power Consumption
Optical Encoder Inputs optional
Data Logging Capabilities
Advanced Safety Features
AX1500 Motor Controller Overview
Compact Open Frame PCB Design
Power Connections
Connecting Power and Motors to the Controller
Power Connections
Important Warning
Controller Power
Connecting Power and Motors to the Controller
AX1500 Motor Controller User’s Manual
And Main Battery
Controller Power
Power Control input is
mended Off Configuration
Connecting Power and Motors to the Controller
Controller Powering Schemes
Powering the Controller from a single Battery
Power Control input is
Important Warning
Powering the Controller Using a Main and Backup Battery
Controller Powering Schemes
AX1500 Motor Controller User’s Manual
Important Warning
Connecting the Motors
Connecting Power and Motors to the Controller
Important Warning
Single Channel Operation
Single Channel Operation
Converting the AX1500 to Single Channel
AX1500 Motor Controller User’s Manual
Connecting Power and Motors to the Controller
Power Fuses
Wire Length Limits
Important Warning
Important Warning
Power Regeneration Considerations
Electrical Noise Reduction Techniques
Electrical Noise Reduction Techniques
Undervoltage Protection
Using the Controller with a Power Supply
Overvoltage Protection
Connecting Power and Motors to the Controller
Using the Controller with a Power Supply
AX1500 Motor Controller User’s Manual
Connecting Power and Motors to the Controller
AX1500 Motor Controller User’s Manual
Version 1.9b. June 1
Basic Operation
Input Command Modes
General Operation
Basic Operation
Open Loop, Mixed Speed Control
Selecting the Motor Control Modes
Open Loop, Separate Speed Control
General Operation
Selecting the Motor Control Modes
Closed Loop Speed Control
Close Loop Position Control
AX1500 Motor Controller User’s Manual
Temperature
User Selected Current Limit Settings
Temperature-Based Current Limitation
Position Feedback Position Sensor Gear box
Motor Current = Battery Current / PWM ratio
Battery Current vs. Motor Current
Battery Current vs. Motor Current
AX1500 Motor Controller User’s Manual
Important Warning
Regeneration Current Limiting
Motor Current = Battery Current / PWM Ratio
General Operation
Setting Using
Programmable Acceleration
Setting Using
Switches
Setting Using
Command Control Curves
Setting Using
Switches
Exponentiation Parameter Value
Left / Right Tuning Adjustment
Left / Right Tuning Adjustment
Selected Curve
General Operation
Speed Adjustment
Speed Adjustment
Parameter Value
Inverted Operation
Emergency Stop using External Switch
Activating Brake Release or Separate Motor Excitation
Speed Adjustment
Using the Inputs to turn Off/On the Power MOSFET transistors
Special Use of Accessory Digital Inputs
Using the Inputs to Activate the Buffered Output
General Operation
AX1500 Connections
Connecting Sensors and Actuators to Input/Outputs
AX1500 Connections
AX1500 Motor Controller User’s Manual
AX1500’s Inputs and Outputs
Connecting Sensors and Actuators to Input/Outputs
AX1500 Motor Controller User’s Manual
I/O type
Signal
AX1500’s Inputs and Outputs
Activated
Connecting Sensors and Actuators to Input/Outputs
Pin1
I/O List and Pin Assignment
Signal depending
Signal depending
Connecting devices to Output C
Connecting devices to Output C
on Mode
Important warning
Connecting Switches or Devices to Input E
Connecting Switches or Devices to Input F
Connecting Sensors and Actuators to Input/Outputs
Connecting Switches or Devices to EStop/Invert Input
Connecting Switches or Devices to EStop/Invert Input
AX1500 Motor Controller User’s Manual
Connecting Sensors and Actuators to Input/Outputs
Connecting Position Potentiometers to Analog Inputs
Analog Inputs
AX1500 Motor Controller User’s Manual
Operating Mode
Connecting Tachometer to Analog Inputs
Connecting Tachometer to Analog Inputs
Important Warning
Important Warning
Connecting Sensors and Actuators to Input/Outputs
Operating Mode
Ana 1 p11
Temp oC
Connecting External Thermistor to Analog Inputs
Connecting External Thermistor to Analog Inputs
Resistance kOhm
Using the Analog Inputs to Monitor External Voltages
Connecting Sensors and Actuators to Input/Outputs
AX1500 Motor Controller User’s Manual
Internal Voltage Monitoring Sensors
Connecting User Devices to Analog Inputs
Internal Heatsink Temperature Sensors
Connecting User Devices to Analog Inputs
AX1500 Motor Controller User’s Manual
Temperature Conversion C Source Code
Connecting Sensors and Actuators to Input/Outputs
Value
else
Internal Heatsink Temperature Sensors
AX1500 Motor Controller User’s Manual
LoTemp = i * 5
Connecting Sensors and Actuators to Input/Outputs
AX1500 Motor Controller User’s Manual
Version 1.9b. June 1
Optical Incremental Encoders Overview
Installing Connecting and Using the Encoder Module
Optical Incremental Encoders Overview
AX1500 Motor Controller User’s Manual
Recommended Encoder Types
Installing, Connecting and Using the Encoder Mod
AX1500 Motor Controller User’s Manual
Pulse Frequency in Hz = RPM / 60 * PPR
Installing the Encoder Module
Installing the Encoder Module
AX1500 Motor Controller User’s Manual
Connecting the Encoder
Installing, Connecting and Using the Encoder Mod
AX1500 Motor Controller User’s Manual
Name
Cable Length and Noise Considerations
Cable Length and Noise Considerations
Cable Color
Installing, Connecting and Using the Encoder Mod
Voltage Levels, Thresholds and Limit Switches
Motor - Encoder Polarity Matching
Important Warning
Important Warning
Wiring Optional Limit Switches
Wiring Optional Limit Switches
AX1500 Motor Controller User’s Manual
Installing, Connecting and Using the Encoder Mod
When the switch is activated, the module’s input is pulled to
AX1500 Motor Controller User’s Manual
Wiring Limit Switches Without Encoders
Wiring Limit Switches Without Encoders
Effect of Limit Switches
Motor 1 Fwd
Installing, Connecting and Using the Encoder Mod
Using the Encoder Module to Measure Distance
Using the Encoder to Measure Speed
Motor 2 Fwd
Using the Encoder to Track Position
Using the Encoder to Track Position
Important Notice
AX1500 Motor Controller User’s Manual
Important Notice
RS232 Communication with the Encoder Module
Installing, Connecting and Using the Encoder Mod
Distance = Destination - Counter value / Divider
Encoder Testing and Setting Using the PC Utility
Encoder Testing and Setting Using the PC Utility
AX1500 Motor Controller User’s Manual
Installing, Connecting and Using the Encoder Mod
AX1500 Motor Controller User’s Manual
Version 1.9b. June 1
Selecting the Position Mode
Closed Loop Position Mode
Mode Description
Mode Description
Closed Loop Position Mode
Position Sensor Selection
Sensor Mounting
Position Feedback Position Sensor Gear box
Feedback Potentiometer wiring
Feedback Potentiometer wiring
Feedback Potentiometer wiring in RC or RS232 Mode
Important Notice
Important Notice
Feedback Potentiometer wiring in Analog Mode
Closed Loop Position Mode
AX1500 Motor Controller User’s Manual
Analog Feedback on Single Channel Controllers
Feedback Wiring in RC or RS232 Mode on Single Channel Controllers
Feedback Wiring in Analog Mode on Single Channel Controllers
Important Notice
Closed Loop Position Mode
Using Optical Encoders in Position Mode
Sensor and Motor Polarity
Important Warning
Adding Safety Limit Switches
Important Safety Warning
Encoder Error Detection and Protection
Encoder Error Detection and Protection
Closed Loop Position Mode
FIGURE 53. Safety limit switches interrupting power to motors
AX1500 Motor Controller User’s Manual
Using Current Limiting as Protection
Using Current Limiting as Protection
Control Loop Description
Important Warning
PID tuning in Position Mode
Closed Loop Position Mode
AX1500 Motor Controller User’s Manual
PID tuning in Position Mode
Applied Power = Command Value - Actual Position * Proportional Gain
AX1500 Motor Controller User’s Manual
Closed Loop Position Mode
AX1500 Motor Controller User’s Manual
Version 1.9b. June 1
Using Optical Encoder for Speed FeedbackDigital Optical Encod
Closed Loop Speed Mode
Selecting the Speed Mode
Mode Description
Closed Loop Speed Mode
Tachometer wiring
Tachometer or Encoder Mounting
AX1500 Motor Controller User’s Manual
Speed Sensor and Motor Polarity
Speed Sensor and Motor Polarity
Important Warning
AX1500 Motor Controller User’s Manual
Important Warning
Adjust Offset and Max Speed
Closed Loop Speed Mode
Control Loop Description
PID tuning in Speed Mode
PID tuning in Speed Mode
AX1500 Motor Controller User’s Manual
Closed Loop Speed Mode
In Speed Mode, the Integral component of the PID is the most important and must be set first. The Proportional and Differential component will help improve the response time and loop stability
AX1500 Motor Controller User’s Manual
Diagnostic LED
Normal and Fault Condition LED Messages
Power On LED
Normal Operation Flashing Pattern
Output Off / Fault Condition
Normal and Fault Condition LED Messages
AX1500 Motor Controller User’s Manual
Mode Description
SECTION 11 R/C Operation
Mode Description
AX1500 Motor Controller User’s Manual
Signal
Selecting the R/C Input Mode
Connector I/O Pin Assignment R/C Mode
Pin1
Signal
R/C Input Circuit Description
Supplied Cable Description
R/C Input Circuit Description
R/C Operation
Powering the Radio from the controller
FIGURE 64. RC Cable wiring diagram
FIGURE 65. RC connection cable
6 Radio battery - Ground 7 Radio battery + 8 Channel 3 Command Pulses
Powering the Radio from the controller
3 Channel 1 Command Pulses 4 Channel 2 Command Pulses
Wire loop bringing power from controller to RC radio
R/C Operation
Connecting to a Separately Powered Radio
Operating the Controller in R/C mode
AX1500 Motor Controller User’s Manual
Reception Watchdog
Reception Watchdog
AX1500 Motor Controller User’s Manual
Joystick Deadband Programming
Important Notice about PCM Radios
R/C Transmitter/Receiver Quality Considerations
R/C Operation
Deadband Parameter Value
Command Control Curves
Command Control Curves
Deadband as Percent of full Joystick Travel
Joystick Calibration
Left/Right Tuning Adjustment
Activating the Accessory Outputs
R/C Operation
Data Logging in R/C Mode
Data Logging in R/C Mode
AX1500 Motor Controller User’s Manual
DB15 Male
R/C Operation
AX1500 Motor Controller User’s Manual
To Controller
Mode Description
Analog Control and Operation
Mode Description
Important Notice
Pin1
Connector I/O Pin Assignment Analog Mode
Signal
Analog Control and Operation
Connecting to a Voltage Source
Connecting to a Voltage Source
Connecting a Potentiometer
AX1500 Motor Controller User’s Manual
Selecting the Potentiometer Value
Important Notice
Analog Deadband Adjustment
Data Logging in Analog Mode
Power-On Safety
Under Voltage Safety
Motor Power at 0%
Data Logging in Analog Mode
AX1500 Motor Controller User’s Manual
Analog Control and Operation
AX1500 Motor Controller User’s Manual
Version 1.9b. June 1
Use and benefits of RS232
Serial RS-232 Controls and Operation
Use and benefits of RS232
AX1500 Motor Controller User’s Manual
Pin1
Connector I/O Pin Assignment RS232 Mode
Signal
Serial RS-232 Controls and Operation
Cable configuration
Cable configuration
Extending the RS232 Cable
AX1500 Motor Controller User’s Manual
Establishing Manual Communication with a PC
Communication Settings
9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity
Serial RS-232 Controls and Operation
Roboteq v1.9b 06/01/07 s
RS232 Communication with the Encoder Module
Establishing Manual Communication with a PC
AX1500 Motor Controller User’s Manual
Serial RS-232 Controls and Operation
Entering RS232 from R/C or Analog mode
Data Logging String in R/C or Analog mode
AX1500 Motor Controller User’s Manual
Command Acknowledgement
Commands Acknowledge and Error Messages
RS232 Mode if default
Command Error
Command
Controller Commands and Queries
RS-232 Watchdog
Serial RS-232 Controls and Operation
Controller Commands and Queries
Set Motor Command Value
Set Accessory Output
Command
Important Notice
Query Power Applied to Motors
Query Amps from Battery to each Motor Channel
Important Notice
Query Analog Inputs
Query Heatsink Temperatures
Query Battery Voltages
Controller Commands and Queries
Serial RS-232 Controls and Operation
Reset Controller
Query Digital Inputs
Syntax
Accessing & Changing Configuration Parameter in Flash
Accessing & Changing Configuration Parameter in Flash
Apply Parameter Changes
Read parameter
Location
Flash Configuration Parameters List
Serial RS-232 Controls and Operation
Description
Accessing & Changing Configuration Parameter in Flash
Input Control Mode
Motor Control Mode
Access
After Reset or FF
Amps Limit
Access
Serial RS-232 Controls and Operation
Accessing & Changing Configuration Parameter in Flash
Input Switches Function
Acceleration
Access
Access
RC Joystick or Analog Deadband
Exponentiation on Channel 1 and Channel
After Reset or FF
Accessing & Changing Configuration Parameter in Flash
Left/Right Adjust
Default Encoder Time Base 1 and
Access
Joystick Min, Max and Center Values
Default Encoder Distance Divider
Default PID Gains
Access
1C - Joystick Max 2 MS 1D - Joystick Max 2 LS Effective Instantly
Reading & Changing Operating Parameters at Runtime
Reading & Changing Operating Parameters at Runtime
Definition
Access
Operating Modes Registers
Read/Change PID Values
Important Notice
87 - D2 Access Read/Write Effective Instantly
PWM Frequency Register
Controller Status Register
Address Access Read/Write Effective Instantly
Fault Condition
Controller Identification Register
Current Amps Limit Registers
Access
Read Encoder Counter
RS232 Encoder Command Set
Set/Reset Encoder Counters and Destination Registers
RS232 Encoder Command Set
Syntax
Read Speed
q or !Q n
AX1500 Motor Controller User’s Manual
Read Speed/Distance
Read Encoder Limit Switch Status
Read Distance
RS232 Encoder Command Set
Switch
Important Note
Read / Modify Encoder Module Registers and Parameters
Switch
Modify parameter
RS232 Encoder Command Set
Access
Address
Encoder Hardware ID code
Switch Status
Register Description
Speed or Distance 1 or
Destination Register 1 and
Counter Read/Write Mailbox
Counter 1 and
Register Description
Time Base 1 and
Distance 1 and
Speed 1 and
Encoder Threshold
Counter Read Data Format
Counter Read Data Format
Encoder Testing and Setting Using the PC Utility
Decimal
AX1500 Motor Controller User’s Manual
Version 1.9b. June 1
Automatic Switching from RS232 to RC Mode
Automatic Switching from RS232 to RC Mode
AX1500 Motor Controller User’s Manual
Data Logging Cables
00 11 22 33 44 55 66 77 88 99 AA BB CC
Analog and R/C Modes Data Logging String Format
AX1500 Motor Controller User’s Manual
Decimal to Hexadecimal Conversion Table
Decimal to Hexadecimal Conversion Table
AX1500 Motor Controller User’s Manual
AX1500 Motor Controller User’s Manual
Decimal to Hexadecimal Conversion Table
AX1500 Motor Controller User’s Manual
AX1500 Motor Controller User’s Manual
Version 1.9b. June 1
System Requirements
SECTION 14 Using the Roborun Configuration Utility
Downloading and Installing the Utility
AX1500 Motor Controller User’s Manual
Connecting the Controller to the PC
Using the Roborun Configuration Utility
AX1500 Motor Controller User’s Manual
Roborun Frame, Tab and Menu Descriptions
Roborun Frame, Tab and Menu Descriptions
3- Parameter Selection and Setting and Special Functions
1- Program Revision Number
Using the Roborun Configuration Utility
Getting On-Screen Help
Loading, Changing Controller Parameters
4- File and Program Management Commands
3- Input Command Adjustment
Control Settings
2- Motor Control Mode
Loading, Changing Controller Parameters
4- Emergency Stop or Invert Switch Select
Power Settings
Using the Roborun Configuration Utility
2- Left/Right Adjust
1- Deadband
Analog or R/C Specific Settings
Loading, Changing Controller Parameters
2- Joystick Timing
Using the Roborun Configuration Utility
Encoder Setting and Testing
Closed Loop Parameters
AX1500 Motor Controller User’s Manual
Encoder Module Parameters Setting
Encoder Setting and Testing
AX1500 Motor Controller User’s Manual
Viewing Encoder Data
Running the Motors
Exercising the Motors
Using the Roborun Configuration Utility
1- Run/Stop Button
2- Motor Power setting
Running the Motors
3- Measurement
6- Input Status and Output Setting
Using the Roborun Configuration Utility
4- Real-Time Strip Chart Recorder
5- Transmit and Receive Data
8- Joystick Enable
Logging Data to Disk
Running the Motors 7- Data Logging and Timer
4- Reset Timer button
Using the Roborun Configuration Utility
Using the Console
Connecting a Joystick
Parameter Header
1- Terminal Screen
Using the Console
2- Command Entry
3- Keep Watchdog Alive
Loading and Saving Profiles to Disk
Operating the AX1500 over a Wired or Wireless LAN
Viewing and Logging Data in Analog and R/C Modes
Using the Roborun Configuration Utility 4- Send Reset String
Operating the AX1500 over a Wired or Wireless LAN
AX1500 Motor Controller User’s Manual
Using the Roborun Configuration Utility
Updating the Controller’s Software
Updating the Encoder Software
Important Warning
Creating Customized Object Files
Creating Customized Object Files
AX1500 Motor Controller User’s Manual
Using the Roborun Configuration Utility
AX1500 Motor Controller User’s Manual
Version 1.9b. June 1
Mechanical Dimensions
Mechanical Specifications
Mechanical Dimensions
AX1500 Motor Controller User’s Manual
Mechanical Specifications
Mounting Considerations
Thermal Considerations
AX1500 Motor Controller User’s Manual
Attaching the Controller Directly to a Chassis
Attaching the Controller Directly to a Chassis
AX1500 Motor Controller User’s Manual
Precautions to observe
Mechanical Specifications
AX1500 Motor Controller User’s Manual
Wire Dimensions
Wire Dimensions
Weight
AX1500 Motor Controller User’s Manual
Mechanical Specifications
AX1500 Motor Controller User’s Manual
Version 1.9b. June 1