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