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RoboteQ AX500 manual Dual Channel Digital Motor Controller

Models: AX500

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AX500

Dual Channel

Digital Motor

Controller

User’s Manual

v1.9b, June 1, 2007

visit www.roboteq.com to download the latest revision of this manual ©Copyright 2003-2007 Roboteq, Inc.

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RoboteQ AX500 manual Dual Channel Digital Motor Controller

Contents

Dual Channel Digital Motor Controller AX500AX500 Motor Controller User’s Manual Revision History Revision HistoryDate Version Changes AX500 Motor Controller User’s Manual Section Section Section 101 112 Operating the AX500 over a Wired or Wireless LAN Avoid Shorts when Mounting Board against Chassis Important SafetyDo not Connect to a RC Radio with a Battery Attached To the BatteryImportant Safety Warnings AX500 Locating the ConnectorsQuick Start What you will needAX500 Quick Start Power Must be conNected to VCon VMot for the controllerConnecting to the Batteries and Motors Connecting to the Batteries and MotorsConnecting the R/C Radio Connecting to the 15-pin ConnectorSignal Pin RC Mode RS232 Mode Analog Mode Powering On the Controller Powering On the ControllerConnecting the controller to your PC using Roborun Default Controller ConfigurationParameter Default Values Letter Obtaining the Controller’s Software Revision Number Obtaining the Controller’s Software Revision NumberExploring further Product Description AX500 Motor Controller OverviewTechnical features Low Power Consumption Technical featuresHigh Efficiency Motor Power Outputs Advanced Safety FeaturesData Logging Capabilities Power Connections Connecting Power and Motors to the ControllerPower Connections Connecting Power and Motors to the Controller Controller PowerPowering the Controller from a single Battery Controller Powering SchemesController Powering Schemes VCon VMot Controller StatusPowering the Controller Using a Main and Backup Battery Connecting the MotorsSingle Channel Operation Single Channel OperationConverting the AX500 to Single Channel Power FusesPower Regeneration Considerations Wire Length LimitsElectrical Noise Reduction Techniques Undervoltage Protection Overvoltage ProtectionUsing the Controller with a Power Supply Using the Controller with a Power SupplyConnecting Power and Motors to the Controller General Operation Input Command ModesBasic Operation Basic OperationOpen Loop, Separate Speed Control Selecting the Motor Control ModesOpen Loop, Mixed Speed Control General OperationClose Loop Position Control Closed Loop Speed ControlSelecting the Motor Control Modes Temperature-Based Current Limitation User Selected Current Limit SettingsTemperature Max Amps Battery Current vs. Motor Current Battery Current vs. Motor CurrentMotor Current = Battery Current / PWM ratio Off Programmable AccelerationProgrammable Acceleration Command Control Curves Left / Right Tuning Adjustment Left / Right Tuning AdjustmentExponentiation Parameter Value Selected Curve Parameter Value Speed Adjustment Activating Brake Release or Separate Motor Excitation Emergency Stop using External SwitchInverted Operation Activating Brake Release or Separate Motor ExcitationUsing the Inputs to Activate the Buffered Output Special Use of Accessory Digital InputsAX500 Connections Connecting Sensors and Actuators to Input/OutputsAX500 Connections AX500’s Inputs and Outputs Connecting Sensors and Actuators to Input/OutputsAX500’s Inputs and Outputs Signal Type Use ActivatedList and Pin Assignment Pin1Connecting devices to Output C Connecting devices to Output CConnecting Switches or Devices to Input F Connecting Switches or Devices to Input EConnecting Switches or Devices to EStop/Invert Input Connecting Switches or Devices to EStop/Invert InputAnalog Inputs Connecting Position Potentiometers to Analog InputsConnecting Tachometer to Analog Inputs Connecting Tachometer to Analog InputsAna Ana2 Operating Mode Pin Operating Mode Ana 1 p11 Ana2 p10 Ana 3 p12 Ana 4 p8 Connecting External Thermistor to Analog Inputs Connecting External Thermistor to Analog InputsTemp oC Resistance kOhmUsing the Analog Inputs to Monitor External Voltages Internal Heatsink Temperature Sensors Connecting User Devices to Analog InputsInternal Voltage Monitoring Sensors Temperature Conversion C Source Code Internal Heatsink Temperature Sensors Connecting Sensors and Actuators to Input/Outputs Mode Description Closed Loop Position ModeSelecting the Position Mode Mode DescriptionPosition Sensor Selection Closed Loop Position ModeSensor Mounting Feedback Potentiometer wiring in RC or RS232 Mode Feedback Potentiometer wiringFeedback Potentiometer wiring in Analog Mode Feedback Potentiometer wiringAnalog Feedback on Single Channel Controllers Sensor and Motor Polarity Sensor and Motor PolarityAdding Safety Limit Switches Encoder Error Detection and ProtectionAdding Safety Limit Switches Control Loop Description Using Current Limiting as ProtectionPID tuning in Position Mode PID tuning in Position ModeClosed Loop Position Mode Selecting the Speed Mode Closed Loop Speed ModeClosed Loop Speed Mode Tachometer wiringTachometer or Encoder Mounting Speed Sensor and Motor PolarityAdjust Offset and Max Speed Adjust Offset and Max SpeedControl Loop Description PID tuning in Speed Mode PID tuning in Speed ModeClosed Loop Speed Mode Diagnostic LED Normal Fault Condition LED MessagesDiagnostic LED Normal Operation Flashing PatternNormal and Fault Condition LED Messages Output Off / Fault ConditionC Operation C radio control modeConnector I/O Pin Assignment R/C Mode Selecting the R/C Input ModePin Input or Number Output Signal Description OperationSupplied Cable Description Input Circuit DescriptionInput Circuit Description RC connection cable Powering the Radio from the controllerConnecting to a Separately Powered Radio Connecting to a Separately Powered RadioWiring when receiver is powered by its own separate battery Operating the Controller in R/C modeReception Watchdog Reception WatchdogJoystick Deadband Programming Transmitter/Receiver Quality ConsiderationsEffect of deadband on joystick position vs. motor speed Command Control CurvesJoystick Calibration Left/Right Tuning AdjustmentData Logging in R/C Mode Data Logging in R/C ModeDB9 Female Analog Control and Operation Pin Input or Number Signal Output Description Connector I/O Pin Assignment Analog ModeAnalog Control and Operation Connecting a Potentiometer Connecting to a Voltage SourceConnecting to a Voltage Source = U/R = 5V / 1000 Ohms = 0.005A = 5mA Selecting the Potentiometer ValueAnalog Deadband Adjustment Analog Deadband AdjustmentUnder Voltage Safety Power-On SafetyData Logging in Analog Mode Modified Analog cable with RS232 output data logging for PC Data Logging in Analog Mode100 Use and benefits of RS232 Serial RS-232 Controls OperationUse and benefits of RS232 Serial RS-232 Controls and Operation Connector I/O Pin Assignment RS232 ModeCable configuration Cable configurationExtending the RS232 Cable Bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Communication SettingsEstablishing Manual Communication with a PC Data Logging String in R/C or Analog mode Entering RS232 from R/C or Analog modeEstablishing Manual Communication with a PC Roboteq v1.9b 06/01/07 sRS232 Mode if default Commands Acknowledge and Error MessagesCommand Acknowledgement Command ErrorCommand Type Description Controller Commands and QueriesRS-232 Watchdog Watchdog time-outSet Accessory Output Set Motor Command ValueQuery Amps from Battery to each Motor Channel Query Power Applied to MotorsSyntax Query Analog Inputs Query Heatsink Temperatures?r or ?R ?m or ?MReset Controller Query Battery VoltagesController Commands and Queries Query Digital InputsApply Parameter Changes Accessing & Changing Configuration Parameter in FlashRead parameter Modify parameterAccessing & Changing Configuration Parameter in Flash Flash Configuration Parameters ListLocation Description Active after Motor Control Mode Input Control ModeAddress Access Read/Write Effective After Reset Value Mode See pagesBit Definition See pages Amps LimitAcceleration Input Switches FunctionRC Joystick or Analog Deadband Address Channel Access Read/Write Effective InstantlyExponentiation on Channel 1 and Channel Default PID Gains Left/Right AdjustJoystick Min, Max and Center Values Reading & Changing Operating Parameters at RuntimeReading & Changing Operating Parameters at Runtime Location Function Operating Modes RegistersBit Function PWM Frequency Register Read/Change PID ValuesController Status Register Controller Identification Register Bit Fault Condition EffectCurrent Amps Limit Registers Bit Model or FunctionAX500 Motor Controller User’s Manual 123 124 Automatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC ModeData Logging Cables Analog and R/C Modes Data Logging String FormatDecimal to Hexadecimal Conversion Table Decimal to Hexadecimal Conversion TableDec Hex UDec Hex AX500 Motor Controller User’s Manual 129 130 Downloading and Installing the Utility Using the Roborun Configuration UtilitySystem Requirements Using the Roborun Configuration Utility Connecting the Controller to the PCRoborun Frame, Tab and Menu Descriptions Parameter Selection and Setting and Special FunctionsRoborun Frame, Tab and Menu Descriptions View Controller Connector Pinout File and Program Management CommandsGetting On-Screen Help Loading, Changing Controller ParametersMotor Control Mode Control SettingsInput Command Adjustment Loading, Changing Controller ParametersPower Settings Deadband Analog or R/C Specific SettingsJoystick Timing Closed Loop Parameters Running the MotorsRunning the Motors Motor Power settingRun/Stop Button MeasurementInput Status and Output Setting Real-Time Strip Chart RecorderData Logging and Timer Transmit and Receive DataLogging Data to Disk Connecting a Joystick Using the ConsoleCommand Entry Using the ConsoleSend Reset String Terminal ScreenViewing and Logging Data in Analog and R/C Modes Operating the AX500 over a Wired or Wireless LANLoading and Saving Profiles to Disk Roboserver screenshot when idle Operating the AX500 over a Wired or Wireless LANUpdating the Encoder Software Updating the Controller’s SoftwareCreating Customized Object Files Objectmaker creates controller firmware with custom defaults148 Mechanical Dimensions Mechanical SpecificationsMechanical Dimensions Mounting Considerations Mechanical SpecificationsThermal Considerations Attaching the Controller Directly to a Chassis Attaching the Controller Directly to a ChassisPrecautions to observe Weight Wire DimensionsWire Dimensions 154