Section | RoboteQ AX500 manual

	Revision History	3
SECTION 1	Important Safety Warnings			11
	This product is intended for use with rechargeable batteries 11
	Avoid Shorts when Mounting Board against Chassis 11
	Do not Connect to a RC Radio with a Battery Attached						11
	Beware of Motor Runaway in Improperly Closed Loop						11
SECTION 2	AX500
	Quick Start 13
	What you will need		13
	Locating the Connectors			13
	Connecting to the Batteries and Motors 15
	Connecting to the 15-pin Connector 16
	Connecting the R/C Radio			16
	Powering On the Controller 17
	Default Controller Configuration				18
	Connecting the controller to your PC using Roborun					18
	Obtaining the Controller’s Software Revision Number					19
	Exploring further	20
SECTION 3	AX500 Motor Controller Overview				21
	Product Description		21
	Technical features		22
SECTION 4	Connecting Power and Motors to the Controller 25
	Power Connections		25
	Controller Power	26

Controller Powering Schemes 27

Powering the Controller from a single Battery 27

Powering the Controller Using a Main and Backup Battery 28

Connecting the Motors 28

Single Channel Operation 29

Converting the AX500 to Single Channel 30

Power Fuses 30
Wire Length Limits 31
Electrical Noise Reduction Techniques		31
Power Regeneration Considerations		31
Overvoltage Protection	32
Undervoltage Protection	32

Using the Controller with a Power Supply 33

AX500 Motor Controller User’s Manual

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RoboteQ AX500 manual Section

Contents

Dual Channel Digital Motor Controller AX500 AX500 Motor Controller User’s Manual Date Version Changes Revision HistoryRevision History 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 Battery Important Safety Warnings AX500 Locating the ConnectorsQuick Start What you will need AX500 Quick Start Power Must be conNected to VCon VMot for the controller 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 ConnectorConnecting the R/C Radio Powering On the Controller Powering On the Controller Parameter Default Values Letter Default Controller ConfigurationConnecting the controller to your PC using Roborun Obtaining the Controller’s Software Revision Number Obtaining the Controller’s Software Revision Number Exploring further Product Description AX500 Motor Controller Overview Technical features Low Power Consumption Technical featuresHigh Efficiency Motor Power Outputs Advanced Safety Features Data Logging Capabilities Power Connections Connecting Power and Motors to the ControllerPower Connections Connecting Power and Motors to the Controller Controller Power Powering the Controller from a single Battery Controller Powering SchemesController Powering Schemes VCon VMot Controller Status Powering the Controller Using a Main and Backup Battery Connecting the Motors Single Channel Operation Single Channel Operation Converting the AX500 to Single Channel Power Fuses Electrical Noise Reduction Techniques Wire Length LimitsPower Regeneration Considerations Undervoltage Protection Overvoltage Protection Using the Controller with a Power Supply Using the Controller with a Power Supply Connecting Power and Motors to the Controller General Operation Input Command ModesBasic Operation Basic Operation Open Loop, Separate Speed Control Selecting the Motor Control ModesOpen Loop, Mixed Speed Control General Operation Selecting the Motor Control Modes Closed Loop Speed ControlClose Loop Position Control Temperature Max Amps User Selected Current Limit SettingsTemperature-Based Current Limitation Motor Current = Battery Current / PWM ratio Battery Current vs. Motor CurrentBattery Current vs. Motor Current Off Programmable Acceleration Programmable Acceleration Command Control Curves Exponentiation Parameter Value Selected Curve Left / Right Tuning AdjustmentLeft / Right Tuning Adjustment Parameter Value Speed Adjustment Activating Brake Release or Separate Motor Excitation Emergency Stop using External SwitchInverted Operation Activating Brake Release or Separate Motor Excitation Using the Inputs to Activate the Buffered Output Special Use of Accessory Digital Inputs AX500 Connections Connecting Sensors and Actuators to Input/OutputsAX500 Connections AX500’s Inputs and Outputs Connecting Sensors and Actuators to Input/Outputs AX500’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 InputsConnecting 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 InputsTemp oC Resistance kOhm Using the Analog Inputs to Monitor External Voltages Internal Voltage Monitoring Sensors Connecting User Devices to Analog InputsInternal Heatsink Temperature 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 Description Sensor Mounting Closed Loop Position ModePosition Sensor Selection Feedback Potentiometer wiring in RC or RS232 Mode Feedback Potentiometer wiringFeedback Potentiometer wiring in Analog Mode Feedback Potentiometer wiring Analog Feedback on Single Channel Controllers Sensor and Motor Polarity Sensor and Motor Polarity Adding Safety Limit Switches Encoder Error Detection and Protection Adding Safety Limit Switches Control Loop Description 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 Closed Loop Speed Mode Tachometer wiringTachometer 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 Diagnostic LED Normal Fault Condition LED MessagesDiagnostic LED Normal Operation Flashing Pattern 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 ModePin Input or Number Output Signal Description Operation Input Circuit Description Input Circuit DescriptionSupplied Cable Description RC connection cable Powering the Radio from the controller Connecting to a Separately Powered Radio Connecting to a Separately Powered Radio Wiring when receiver is powered by its own separate battery Operating the Controller in R/C mode 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 Data Logging in R/C Mode Data Logging in R/C Mode DB9 Female Analog Control and Operation Analog Control and Operation Connector I/O Pin Assignment Analog ModePin Input or Number Signal Output Description Connecting to a Voltage Source Connecting to a Voltage SourceConnecting 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 SafetyUnder Voltage Safety Modified Analog cable with RS232 output data logging for PC Data Logging in Analog Mode 100 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 Mode Extending the RS232 Cable Cable configurationCable configuration Establishing Manual Communication with a PC Communication SettingsBits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity 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 s RS232 Mode if default Commands Acknowledge and Error MessagesCommand Acknowledgement Command Error Command Type Description Controller Commands and QueriesRS-232 Watchdog Watchdog time-out Set Accessory Output Set Motor Command Value Syntax Query Power Applied to MotorsQuery Amps from Battery to each Motor Channel Query Analog Inputs Query Heatsink Temperatures?r or ?R ?m or ?M Reset Controller Query Battery VoltagesController Commands and Queries Query Digital Inputs Apply Parameter Changes Accessing & Changing Configuration Parameter in FlashRead parameter Modify parameter Location Description Active after Flash Configuration Parameters ListAccessing & Changing Configuration Parameter in Flash Motor Control Mode Input Control ModeAddress 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 InstantlyRC Joystick or Analog Deadband Default PID Gains Left/Right Adjust Reading & Changing Operating Parameters at Runtime Reading & Changing Operating Parameters at RuntimeJoystick Min, Max and Center Values Bit Function Operating Modes RegistersLocation Function Controller Status Register Read/Change PID ValuesPWM Frequency Register Controller Identification Register Bit Fault Condition EffectCurrent 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 Data Logging Cables Analog and R/C Modes Data Logging String Format Dec Hex Decimal to Hexadecimal Conversion TableDecimal to Hexadecimal Conversion Table UDec Hex AX500 Motor Controller User’s Manual 129 130 System Requirements Using the Roborun Configuration UtilityDownloading 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 FunctionsRoborun Frame, Tab and Menu Descriptions View Controller Connector Pinout File and Program Management CommandsGetting On-Screen Help Loading, Changing Controller Parameters Motor Control Mode Control SettingsInput Command Adjustment Loading, Changing Controller Parameters Power Settings Joystick Timing Analog or R/C Specific SettingsDeadband Closed Loop Parameters Running the Motors Running the Motors Motor Power settingRun/Stop Button Measurement Input Status and Output Setting Real-Time Strip Chart RecorderData Logging and Timer Transmit and Receive Data Logging Data to Disk Connecting a Joystick Using the Console Command Entry Using the ConsoleSend Reset String Terminal Screen Loading and Saving Profiles to Disk Operating the AX500 over a Wired or Wireless LANViewing and Logging Data in Analog and R/C Modes Roboserver screenshot when idle Operating the AX500 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 148 Mechanical Dimensions Mechanical SpecificationsMechanical Dimensions Thermal Considerations Mechanical SpecificationsMounting Considerations Attaching the Controller Directly to a Chassis Attaching the Controller Directly to a Chassis Precautions to observe Wire Dimensions Wire DimensionsWeight 154