AX500
Dual Channel Digital Motor Controller
 AX500 Motor Controller User’s Manual
 Revision History
Revision History
Date Version Changes
 AX500 Motor Controller User’s Manual
 Section
 Section
 Section
 101
 112
 Operating the AX500 over a Wired or Wireless LAN
 Important Safety
Avoid Shorts when Mounting Board against Chassis
Do not Connect to a RC Radio with a Battery Attached
To the Battery
 Important Safety Warnings
 Locating the Connectors
AX500
Quick Start
What you will need
 Power Must be con
AX500 Quick Start
Nected to VCon
VMot for the controller
 Connecting to the Batteries and Motors
Connecting to the Batteries and Motors
 Connecting to the 15-pin Connector
Connecting the R/C Radio
Signal Pin RC Mode RS232 Mode Analog Mode
 Powering On the Controller
Powering On the Controller
 Default Controller Configuration
Connecting the controller to your PC using Roborun
Parameter Default Values Letter
 Obtaining the Controller’s Software Revision Number
Obtaining the Controller’s Software Revision Number
 Exploring further
 AX500 Motor Controller Overview
Product Description
 Technical features
 Technical features
Low Power Consumption
High Efficiency Motor Power Outputs
Advanced Safety Features
 Data Logging Capabilities
 Connecting Power and Motors to the Controller
Power Connections
Power Connections
 Controller Power
Connecting Power and Motors to the Controller
 Controller Powering Schemes
Powering the Controller from a single Battery
Controller Powering Schemes
VCon VMot Controller Status
 Connecting the Motors
Powering the Controller Using a Main and Backup Battery
 Single Channel Operation
Single Channel Operation
 Power Fuses
Converting the AX500 to Single Channel
 Wire Length Limits
Power Regeneration Considerations
Electrical Noise Reduction Techniques
 Overvoltage Protection
Undervoltage Protection
 Using the Controller with a Power Supply
Using the Controller with a Power Supply
 Connecting Power and Motors to the Controller
 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
 User Selected Current Limit Settings
Temperature-Based Current Limitation
Temperature Max Amps
 Battery Current vs. Motor Current
Battery Current vs. Motor Current
Motor Current = Battery Current / PWM ratio
 Programmable Acceleration
Off
 Programmable Acceleration
 Command Control Curves
 Left / Right Tuning Adjustment
Left / Right Tuning Adjustment
Exponentiation Parameter Value Selected Curve
 Parameter Value Speed Adjustment
 Emergency Stop using External Switch
Activating Brake Release or Separate Motor Excitation
Inverted Operation
Activating Brake Release or Separate Motor Excitation
 Special Use of Accessory Digital Inputs
Using the Inputs to Activate the Buffered Output
 Connecting Sensors and Actuators to Input/Outputs
AX500 Connections
AX500 Connections
 Connecting Sensors and Actuators to Input/Outputs
AX500’s Inputs and Outputs
 Signal Type Use Activated
AX500’s Inputs and Outputs
 Pin1
List and Pin Assignment
 Connecting devices to Output C
Connecting devices to Output C
 Connecting Switches or Devices to Input E
Connecting Switches or Devices to Input F
 Connecting Switches or Devices to EStop/Invert Input
Connecting Switches or Devices to EStop/Invert Input
 Connecting Position Potentiometers to Analog Inputs
Analog Inputs
 Connecting Tachometer to Analog Inputs
Connecting Tachometer to Analog Inputs
Ana 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 Inputs
Temp oC
Resistance kOhm
 Using the Analog Inputs to Monitor External Voltages
 Connecting User Devices to Analog Inputs
Internal Heatsink Temperature Sensors
Internal Voltage Monitoring Sensors
 Temperature Conversion C Source Code
 Internal Heatsink Temperature Sensors
 Connecting Sensors and Actuators to Input/Outputs
 Closed Loop Position Mode
Mode Description
Selecting the Position Mode
Mode Description
 Closed Loop Position Mode
Position Sensor Selection
Sensor Mounting
 Feedback Potentiometer wiring
Feedback Potentiometer wiring in RC or RS232 Mode
Feedback Potentiometer wiring in Analog Mode
Feedback Potentiometer wiring
 Analog Feedback on Single Channel Controllers
 Sensor and Motor Polarity
Sensor and Motor Polarity
 Encoder Error Detection and Protection
Adding Safety Limit Switches
 Adding Safety Limit Switches
 Using Current Limiting as Protection
Control Loop Description
 PID tuning in Position Mode
PID tuning in Position Mode
 Closed Loop Position Mode
 Closed Loop Speed Mode
Selecting the Speed Mode
 Tachometer wiring
Closed Loop Speed Mode
Tachometer or Encoder Mounting
Speed Sensor and Motor Polarity
 Adjust Offset and Max Speed
Adjust Offset and Max Speed
 Control Loop Description
 PID tuning in Speed Mode
PID tuning in Speed Mode
 Closed Loop Speed Mode
 Normal Fault Condition LED Messages
Diagnostic LED
Diagnostic LED
Normal Operation Flashing Pattern
 Output Off / Fault Condition
Normal and Fault Condition LED Messages
 C radio control mode
C Operation
 Selecting the R/C Input Mode
Connector I/O Pin Assignment R/C Mode
Pin Input or Number Output Signal Description
Operation
 Input Circuit Description
Supplied Cable Description
Input Circuit Description
 Powering the Radio from the controller
RC connection cable
 Connecting to a Separately Powered Radio
Connecting to a Separately Powered Radio
 Operating the Controller in R/C mode
Wiring when receiver is powered by its own separate battery
 Reception Watchdog
Reception Watchdog
 Transmitter/Receiver Quality Considerations
Joystick Deadband Programming
 Command Control Curves
Effect of deadband on joystick position vs. motor speed
 Left/Right Tuning Adjustment
Joystick Calibration
 Data Logging in R/C Mode
Data Logging in R/C Mode
 DB9 Female
 Analog Control and Operation
 Connector I/O Pin Assignment Analog Mode
Pin Input or Number Signal Output Description
Analog Control and Operation
 Connecting to a Voltage Source
Connecting a Potentiometer
Connecting to a Voltage Source
 Selecting the Potentiometer Value
= U/R = 5V / 1000 Ohms = 0.005A = 5mA
 Analog Deadband Adjustment
Analog Deadband Adjustment
 Power-On Safety
Under Voltage Safety
Data Logging in Analog Mode
 Data Logging in Analog Mode
Modified Analog cable with RS232 output data logging for PC
 100
 Serial RS-232 Controls Operation
Use and benefits of RS232
Use and benefits of RS232
 Connector I/O Pin Assignment RS232 Mode
Serial RS-232 Controls and Operation
 Cable configuration
Cable configuration
Extending the RS232 Cable
 Communication Settings
Bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity
Establishing Manual Communication with a PC
 Entering RS232 from R/C or Analog mode
Data Logging String in R/C or Analog mode
Establishing Manual Communication with a PC
Roboteq v1.9b 06/01/07 s
 Commands Acknowledge and Error Messages
RS232 Mode if default
Command Acknowledgement
Command Error
 Controller Commands and Queries
Command Type Description
RS-232 Watchdog
Watchdog time-out
 Set Motor Command Value
Set Accessory Output
 Query Power Applied to Motors
Query Amps from Battery to each Motor Channel
Syntax
 Query Heatsink Temperatures
Query Analog Inputs
?r or ?R
?m or ?M
 Query Battery Voltages
Reset Controller
Controller Commands and Queries
Query Digital Inputs
 Accessing & Changing Configuration Parameter in Flash
Apply Parameter Changes
Read parameter
Modify parameter
 Flash Configuration Parameters List
Accessing & Changing Configuration Parameter in Flash
Location Description Active after
 Input Control Mode
Motor Control Mode
Address Access Read/Write Effective After Reset
Value Mode See pages
 Amps Limit
Bit Definition See pages
 Input Switches Function
Acceleration
 Address Channel Access Read/Write Effective Instantly
RC Joystick or Analog Deadband
Exponentiation on Channel 1 and Channel
 Left/Right Adjust
Default PID Gains
 Reading & Changing Operating Parameters at Runtime
Joystick Min, Max and Center Values
Reading & Changing Operating Parameters at Runtime
 Operating Modes Registers
Location Function
Bit Function
 Read/Change PID Values
PWM Frequency Register
Controller Status Register
 Bit Fault Condition Effect
Controller Identification Register
Current Amps Limit Registers
Bit Model or Function
 AX500 Motor Controller User’s Manual 123
 124
 Automatic Switching from RS232 to RC Mode
Automatic Switching from RS232 to RC Mode
 Analog and R/C Modes Data Logging String Format
Data Logging Cables
 Decimal to Hexadecimal Conversion Table
Decimal to Hexadecimal Conversion Table
Dec Hex
 UDec Hex
 AX500 Motor Controller User’s Manual 129
 130
 Using the Roborun Configuration Utility
Downloading and Installing the Utility
System Requirements
 Connecting the Controller to the PC
Using the Roborun Configuration Utility
 Parameter Selection and Setting and Special Functions
Roborun Frame, Tab and Menu Descriptions
Roborun Frame, Tab and Menu Descriptions
 File and Program Management Commands
View Controller Connector Pinout
Getting On-Screen Help
Loading, Changing Controller Parameters
 Control Settings
Motor Control Mode
Input Command Adjustment
Loading, Changing Controller Parameters
 Power Settings
 Analog or R/C Specific Settings
Deadband
Joystick Timing
 Running the Motors
Closed Loop Parameters
 Motor Power setting
Running the Motors
Run/Stop Button
Measurement
 Real-Time Strip Chart Recorder
Input Status and Output Setting
Data Logging and Timer
Transmit and Receive Data
 Logging Data to Disk
 Using the Console
Connecting a Joystick
 Using the Console
Command Entry
Send Reset String
Terminal Screen
 Operating the AX500 over a Wired or Wireless LAN
Viewing and Logging Data in Analog and R/C Modes
Loading and Saving Profiles to Disk
 Operating the AX500 over a Wired or Wireless LAN
Roboserver screenshot when idle
 Updating the Controller’s Software
Updating the Encoder Software
 Objectmaker creates controller firmware with custom defaults
Creating Customized Object Files
 148
 Mechanical Specifications
Mechanical Dimensions
Mechanical Dimensions
 Mechanical Specifications
Mounting Considerations
Thermal Considerations
 Attaching the Controller Directly to a Chassis
Attaching the Controller Directly to a Chassis
 Precautions to observe
 Wire Dimensions
Weight
Wire Dimensions
 154