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AX1500
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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2 AX1500 Motor Controller User’s Manual Version 1.9b. June 1, 2007
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Revision History Revision History Date Version Changes June 1, 2007 1.9b Added Output C active when Motors On Fixed Encoder Limit Switches Protection in case of Encoder failure in Closed Loop Speed Added Short Circuit Protection (with supporting hardware) Added Analog 3 and 4 Inputs (with supporting hardware) Added Operating Mode Change on-the-fly Changeable PWM frequency Selectable polarity for Dead Man Switch Modified Flashing Pattern Separate PID Gains for Ch1 and C2, changeable on-the-fly Mi
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4 AX1500 Motor Controller User’s Manual Version 1.9b. June 1, 2007
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Revision History 3 SECTION 1 Important Safety Warnings 13 This product is intended for use with rechargeable batteries 13 Avoid Shorts when Mounting Board against Chassis 13 Do not Connect to a RC Radio with a Battery Attached 13 Beware of Motor Runaway in Improperly Closed Loop 13 SECTION 2 AX1500 Quick Start 15 What you will need 15 Locating the Connectors 15 Connecting to the Batteries and Motors 17 Connecting to the 15-pin Connector 18 Connecting the R/C Radio 19 Powering On the Controller 2
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SECTION 5 General Operation 39 Basic Operation 39 Input Command Modes 39 Selecting the Motor Control Modes 40 Open Loop, Separate Speed Control 40 Open Loop, Mixed Speed Control 40 Closed Loop Speed Control 41 Close Loop Position Control 41 User Selected Current Limit Settings 42 Temperature-Based Current Limitation 42 Battery Current vs. Motor Current 43 Regeneration Current Limiting 44 Programmable Acceleration 45 Command Control Curves 46 Left / Right Tuning Adjustment 47 Activating Brake Rel
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Recommended Encoder Types 68 Installing the Encoder Module 69 Connecting the Encoder 70 Cable Length and Noise Considerations 71 Motor - Encoder Polarity Matching 72 Voltage Levels, Thresholds and Limit Switches 72 Wiring Optional Limit Switches 73 Wiring Limit Switches Without Encoders 75 Effect of Limit Switches 75 Using the Encoder Module to Measure Distance 76 Using the Encoder to Measure Speed 76 Using the Encoder to Track Position 77 RS232 Communication with the Encoder Module 78 Encoder T
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Adjust Offset and Max Speed 96 Control Loop Description 96 PID tuning in Speed Mode 97 SECTION 10 Normal and Fault Condition LED Messages 99 Power On LED 99 Diagnostic LED 99 Normal Operation Flashing Pattern 99 Output Off / Fault Condition 100 SECTION 11 R/C Operation 101 Mode Description 101 Selecting the R/C Input Mode 102 Connector I/O Pin Assignment (R/C Mode) 102 R/C Input Circuit Description 103 Supplied Cable Description 103 Powering the Radio from the controller 104 Connecting to a Se
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Connector I/O Pin Assignment (RS232 Mode) 122 Cable configuration 123 Extending the RS232 Cable 123 Communication Settings 124 Establishing Manual Communication with a PC 124 RS232 Communication with the Encoder Module 125 Entering RS232 from R/C or Analog mode 126 Data Logging String in R/C or Analog mode 126 RS232 Mode if default 127 Commands Acknowledge and Error Messages 127 Character Echo 127 Command Acknowledgement 127 Command Error 127 Watchdog time-out 127 RS-232 Watchdog 128 Controller
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Controller Identification Register 144 Current Amps Limit Registers 144 RS232 Encoder Command Set 145 Read Encoder Counter 145 Set/Reset Encoder Counters and Destination Registers 145 Read Speed 146 Read Distance 147 Read Speed/Distance 147 Read Encoder Limit Switch Status 147 Read / Modify Encoder Module Registers and Parameters 148 Register Description 150 Encoder Hardware ID code 150 Switch Status 150 Speed or Distance 1 or 2 150 Counter Read/Write Mailbox 151 Counter 1 and 2 151 Destination
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Logging Data to Disk 173 Connecting a Joystick 174 Using the Console 174 Viewing and Logging Data in Analog and R/C Modes 176 Loading and Saving Profiles to Disk 176 Operating the AX1500 over a Wired or Wireless LAN 176 Updating the Controller’s Software 178 Updating the Encoder Software 178 Creating Customized Object Files 179 SECTION 15 Mechanical Specifications 181 Mechanical Dimensions 181 Mounting Considerations 182 Thermal Considerations 182 Attaching the Controller Directly to a Chassis 1
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12 AX1500 Motor Controller User’s Manual Version 1.9b. June 1, 2007
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SECTION 1 Important Safety Warnings Read this Section First The AX1500 is a high power electronics device. Serious damage, including fire, may occur to the unit, motors, wiring and batteries as a result of its misuse. Transistors may explode and require the use of safety glasses when operated in direct view. Please review the User’s Manual for added precautions prior to applying full battery or full load power. This product is intended for use with rechargeable batteries Unless special prec
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Important Safety Warnings 14 AX1500 Motor Controller User’s Manual Version 1.9b. June 1, 2007
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SECTION 2 AX1500 Quick Start This section will give you the basic information needed to quickly install, setup and run your AX1500 controller in a minimal configuration. What you will need For a minimal installation, gather the following components: One AX1500 Controller and its provided cables 12V to 40V high capacity, high current battery One or two brushed DC motors One R/C to DB15 connector (provided) Miscellaneous wires, connectors, fuses and switch Locating the Connectors Take a
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AX1500 Quick Start The front side (shown in Figure 1) contains the Power/Status LED and the 15-pin connector to the R/C radio, joystick or microcomputer, as well as connections to optional switches and sensors. Connector to Receiver/Controls and sensors Power LED Status LED FIGURE 1. AX1500 Controller Front View At the back of the controller (shown in the figure below) are located all the terminals that must be connected to the batteries and the motors. Note: Both VMot terminals are connect
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Connecting to the Batteries and Motors Connecting to the Batteries and Motors Connection to the batteries and motors is shown in the figure below and is done by con- necting wires to the controller’s terminal strip. Motor2 Power switch Optional Diode + Fuse On - Off + - Optional Motor1 Emergency Disconnect 12V to 24V Motor Battery Controller Notes: - The Battery Power connection are doubled in order to provide the maximum current to the controller. If only one motor is used, only one set of m
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AX1500 Quick Start Important Warning Do not rely on cutting power to the controller for it to turn off if the Power Control is left floating. If motors are spinning because the robot is pushed are pushed or because of inertia, they will act as generators and will turn the controller, possibly in an unsafe state. ALWAYS ground the Power Control wire to turn the controller Off and keep it Off. Important Warning The controller includes large capacitors. When connecting the Motor Power Cables,
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Connecting the R/C Radio Connecting the R/C Radio Connect the R/C adapter cables to the controller on one side and to two or three channels on the R/C receiver on the other side. If present, the third channel is for activating the accessory outputs and is optional. When operating the controller in “Separate” mode, the wire labelled Ch1 controls Motor1, and the wire labelled Ch2 controls Motor2. When operating the controller in “Mixed” mode, Ch1 is used to set the robot’s speed and directio
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AX1500 Quick Start Powering On the Controller Important reminder: There is no On-Off switch on the controller. You must insert a switch on the controller’s power terminal as described in section“Connecting to the Batteries and Motors” on page 17. To power the controller, center the joystick and trims on the R/C transmitter. In Analog mode, center the command potentiomenter or joystick.Then turn on the switch that you have placed on the on the Power Control input. A Power LED located next to
