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RoboteQ Dual Channel Digital Motor Controller AX500 User Manual

Dual channel digital motor controller
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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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Summary of Contents for RoboteQ Dual Channel Digital Motor Controller AX500

  • Page 1 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.
  • Page 2 AX500 Motor Controller User’s Manual Version 1.9b. June 1, 2007...

  • Page 3: Revision History

    Revision History Revision History Date Version June 1, 2007 1.9b January 10, 2007 March 7 , 2005 1.7b February 1, 2005 April 17 , 2004 March 15, 2004 August 25, 2003 August 15, 2003 April 15, 2003 March 15, 2003 The information contained in this manual is believed to be accurate and reliable.
  • Page 4 AX500 Motor Controller User’s Manual Version 1.9b. June 1, 2007...

  • Page 5: Table Of Contents

    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...
  • Page 6 SECTION 5 SECTION 6 SECTION 7 AX500 Motor Controller User’s Manual General Operation 35 Basic Operation 35 Input Command Modes 35 Selecting the Motor Control Modes 36 Open Loop, Separate Speed Control 36 Open Loop, Mixed Speed Control 36 Closed Loop Speed Control 37 Close Loop Position Control 37 User Selected Current Limit Settings 38 Temperature-Based Current Limitation 38...
  • Page 7 Position Sensor Selection 64 Sensor Mounting 64 Feedback Potentiometer wiring 65 Feedback Potentiometer wiring in RC or RS232 Mode 65 Feedback Potentiometer wiring in Analog Mode 65 Analog Feedback on Single Channel Controllers 66 Feedback Wiring in RC or RS232 Mode on Single Channel Controllers 66 Feedback Wiring in Analog Mode on Single Channel Controllers 67...
  • Page 8 SECTION 11 SECTION 12 AX500 Motor Controller User’s Manual Reception Watchdog 87 R/C Transmitter/Receiver Quality Considerations 88 Joystick Deadband Programming 88 Command Control Curves 89 Left/Right Tuning Adjustment 90 Joystick Calibration 90 Data Logging in R/C Mode 91 Analog Control and Operation 93 Mode Description 93 Connector I/O Pin Assignment (Analog Mode) 94 Connecting to a Voltage Source 95...
  • Page 9 Query Digital Inputs 111 Reset Controller 111 Accessing & Changing Configuration Parameter in Flash 112 Apply Parameter Changes 112 Flash Configuration Parameters List 113 Input Control Mode 114 Motor Control Mode 114 Amps Limit 115 Acceleration 116 Input Switches Function 116 RC Joystick or Analog Deadband 117 Exponentiation on Channel 1 and Channel 2 117 Left/Right Adjust 118...
  • Page 10 SECTION 14 AX500 Motor Controller User’s Manual Operating the AX500 over a Wired or Wireless LAN 144 Updating the Controller’s Software 146 Updating the Encoder Software 146 Creating Customized Object Files 147 Mechanical Specifications 149 Mechanical Dimensions 149 Mounting Considerations 150 Thermal Considerations 150 Attaching the Controller Directly to a Chassis 151 Precautions to observe 152...

  • Page 11: Section 1 Important Safety Warnings

    Important Safety SECTION 1 Warnings Read this Section First The AX500 is a power electronics device. Serious damage, including fire, may occur to the unit, motors, wiring and batteries as a result of its misuse. Please review the User’s Manual for added precautions prior to applying full battery or full load power.
  • Page 12 Important Safety Warnings AX500 Motor Controller User’s Manual Version 1.9b. June 1, 2007...

  • Page 13: Section 2 Ax500 Quick Start

    AX500 SECTION 2 Quick Start This section will give you the basic information needed to quickly install, setup and run your AX500 controller in a minimal configuration. What you will need For a minimal installation, gather the following components: • One AX500 Controller and its provided cables •...
  • Page 14 AX500 Quick Start The front side contains 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 Status LED FIGURE 1. AX500 Controller Front View At the back of the controller (shown in the figure below) are located all the that must be connected to the batteries and the motors.

  • Page 15: Connecting To The Batteries And Motors

    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 Motor1 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 motor power cables needs to be connected.

  • Page 16: Connecting To The 15-Pin Connector

    AX500 Quick Start Important Warning The controller includes large capacitors. When connecting the Motor Power Cables, a spark will be generated at the connection point. This is a normal occurrence and should be expected. Connecting to the 15-pin Connector The controller’s I/O are located on it’s standard 15-pin D-Sub Connector. The functions of some pins varies depending on controller model and operating mode.

  • Page 17: Powering On The Controller

    Powering On the Controller Channel 2 Channel 1 FIGURE 4. R/C connector wiring for 3 channels and battery elimination (BEC) This wiring - with the wire loop uncut - assumes that the R/C radio will be powered by the AX500 controller. Other wiring options are described in “R/C Operation” on page 81 of the User’s Manual.

  • Page 18: Connecting The Controller To Your Pc Using Roborun

    Version 1.9b of the AX500 software is configured with the factory defaults shown in the table below. Although Roboteq strives to keep the same parameters and values from one version to the next, changes may occur from one revision to the next. Make sure that you have the matching manual and software versions.

  • Page 19: Obtaining The Controller's Software Revision Number

    USB to serial adapter if needed. Apply power to the controller to turn it on. Load your CD or download the latest revision of Roborun software from www.Roboteq.com, install it on your PC and launch the program. The software will auto- matically establish communication with the controller, retrieve the software revision num- ber and present a series of buttons and tabs to enable its various possibilities.

  • Page 20: Exploring Further

    PC connection discussed previously. Now that you know your controller’s software version number, you will be able to see if a new version is available for download and installation from Roboteq’s web site and which features have been added or improved.

  • Page 21: Product Description

    SECTION 3 Controller Overview Congratulations! By selecting Roboteq’s AX500 you have empowered yourself with the industry’s most versatile, and programmable DC Motor Controller for mobile robots. This manual will guide you step by step through its many possibilities. Product Description The AX500 is a highly configurable, microcomputer-based, dual-channel digital speed or position controller with built-in high power drivers.

  • Page 22: Section 3 Ax500 Motor Controller Overview

    AX500 Motor Controller Overview ate from 12 to 24VDC and can sustain up to 15A of controlled current, delivering up to 360W (approximately 0.5 HP) of useful power to each motor. The many programmable options of the AX500 are easily configured using the supplied PC utility.
  • Page 23 Technical features • User defined purpose (RS232 mode only) • One Switch input configurable as • Emergency stop command • Reversing commands when running vehicle inverted • General purpose digital input • One general purpose 12V, 100mA output for accessories •...
  • Page 24 AX500 Motor Controller Overview Data Logging Capabilities AX500 Motor Controller User’s Manual • Watchdog for automatic motor shutdown in case of command loss (R/C and RS232 modes) • Diagnostic LED • Programmable motor acceleration • Built-in controller overheat sensor • Emergency Stop input signal and button •...

  • Page 25: Section 4 Connecting Power And Motors To The Controller

    Power Connections Connecting SECTION 4 Power and Motors to the Controller This section describes the AX500 Controller’s connections to power sources and motors. Important Warning Please follow the instructions in this section very carefully. Any problem due to wir- ing errors may have very serious consequences and will not be covered by the prod- uct’s warranty.

  • Page 26: Controller Power

    Connecting Power and Motors to the Controller Note: Both VMot terminals are connected to each other in the board and must be wired to the same voltage. FIGURE 7 . AX500 Controller Rear View Controller Power The AX500 uses a flexible power supply scheme that is best described in Figure 8. In this diagram, it can be seen that the power for the Controller’s processor is separate from this of the motor drivers.

  • Page 27: Powering The Controller From A Single Battery

    Controller Powering Schemes The table below shows the state of the controller depending on the voltage applied to Vcon and Vmot. TABLE 2. Controller status depending on Vcon and Vmot voltage VCon VMot 5-24V 8-24V 8-24V 5-24V Controller Powering Schemes Powering the Controller from a single Battery The diagram on Figure 19 show how to wire the controller to a single battery circuit and how to turn power On and Off.

  • Page 28: Powering The Controller Using A Main And Backup Battery

    Connecting Power and Motors to the Controller There is no need to insert a separate switch on Power cables, although for safety reasons, it is highly recommended that a way of quickly disconnecting the Motor Power be provided in the case of loss of control and all of the AX500 safety features fail to activate. Powering the Controller Using a Main and Backup Battery In typical applications, the main motor batteries will get eventually weaker and the voltage will drop below the level needed for the internal microcomputer to properly operate.

  • Page 29: Single Channel Operation

    Single Channel Operation After connecting the motors, apply a minimal amount of power using the Roborun PC util- ity with the controller configured in Open Loop speed mode. Verify that the motor spins in the desired direction. Immediately stop and swap the motor wires if not. In Closed Loop Speed or Position mode, beware that the motor polarity must match this of the feedback.

  • Page 30: Converting The Ax500 To Single Channel

    Connecting Power and Motors to the Controller Converting the AX500 to Single Channel The AX500 can be easily modified into a Single Channel version by placing a jumper on the PCB. This step must be undertook only if you have the proper tooling and technical skills. Before paralleling the outputs, It will be safe to wire in parallel the controller’s outputs only after you have verified that both outputs react identically to channel 1 commands.

  • Page 31: Electrical Noise Reduction Techniques

    Wire Length Limits Fuses are typically slow to blow and will thus allow temporary excess current to flow through them for a time (the higher the excess current, the faster the fuse will blow). This characteristic is desirable in most cases, as it will allow motors to draw surges during acceleration and braking.

  • Page 32: Undervoltage Protection

    This can be accomplished by inserting a diode across the fuse . Please download the Application Note “Understanding Regeneration” from the www.roboteq.com for an in-depth discussion of this complex but important topic. Important Warning Use the AX500 only with a rechargeable battery as supply to the Motor Power wires(VMot terminals).

  • Page 33: Using The Controller With A Power Supply

    Using the Controller with a Power Supply Using the Controller with a Power Supply Using a transformer or a switching power supply is possible but requires special care, as the current will want to flow back from the motors to the power supply during regenera- tion.
  • Page 34 Connecting Power and Motors to the Controller AX500 Motor Controller User’s Manual Version 1.9b. June 1, 2007...

  • Page 35: Section 5 General Operation

    Basic Operation General SECTION 5 Operation This section discusses the controller’s normal operation in all its supported operating modes. Basic Operation The AX500’s operation can be summarized as follows: • Receive commands from a radio receiver, joystick or a microcomputer •...

  • Page 36: Selecting The Motor Control Modes

    General Operation Selecting the Motor Control Modes For each motor, the AX500 supports multiple motion control modes. The controller’s fac- tory default mode is Open Loop Speed control for each motor. The mode can be changed using any of the methods described in “Loading, Changing Controller Parameters” on page 134.

  • Page 37: Close Loop Position Control

    Selecting the Motor Control Modes Controller FIGURE 14. Effect of commands to motors examples in mixed mode Closed Loop Speed Control In this mode, illustrated in Figure 16, an analog tachometer is used to measure the actual motor speed. If the speed changes because of changes in load, the controller automatically compensates the power output.

  • Page 38: Temperature-Based Current Limitation

    General Operation FIGURE 16. Motor with potentiometer assembly for Position operation User Selected Current Limit Settings The AX500 has current sensors at each of its two output stages. Every 16 ms, this current is measured and a correction to the output power level is applied if higher than the user preset value.

  • Page 39: Battery Current Vs. Motor Current

    Battery Current vs. Motor Current The numbers in the table are the max Amps allowed by the controller at a given tempera- ture point. If the Amps limit is manually set to a lower value, then the controller will limit the current to the lowest of the manual and temperature-adjusted max values.

  • Page 40: Programmable Acceleration

    General Operation FIGURE 17 . Current flow during operation FIGURE 18. Instant and average current waveforms The relation between Battery Current and Motor current is given in the formula below: Example: If the controller reports 10A of battery current while at 10% PWM, the current in the motor is 10 / 0.1 = 100A.
  • Page 41 Programmable Acceleration When using the serial port, acceleration can be one of 24 possible values, selectable using the Roborun utility or entering directly a value in the MCU’s configuration EEPROM. Table 4 shows the corresponding acceleration for all Switch and RS232 settings. Numerically speaking, each acceleration value corresponds to a fixed percentage speed increment, applied every 16 milliseconds.

  • Page 42: Command Control Curves

    General Operation an equally large, or possibly larger, regeneration current surge. Always experiment with the lowest acceleration value first and settle for the slowest acceptable value. Command Control Curves The AX500 can also be set to translate the joystick or RS232 motor commands so that the motors respond differently whether or not the joystick is near the center or near the extremes.

  • Page 43: Left / Right Tuning Adjustment

    Left / Right Tuning Adjustment FIGURE 19. Exponentiation curves The AX500 is delivered with the “linear” curves selected for both joystick channels. To select different curves, the user will need to change the values of “E” (channel 1) and “F” (channel 2) according to the table below.
  • Page 44 General Operation is found on all R/C transmitters, and which is actually an offset correction, the Left/Right Adjustment is a true multiplication factor as shown in Figure 20 FIGURE 20. Left Right adjustment curves The curves on the left show how a given forward direction command value will cause the motor to spin 3 or 5.25% slower than the same command value applied in the reverse direction.

  • Page 45: Activating Brake Release Or Separate Motor Excitation

    Activating Brake Release or Separate Motor Excitation TABLE 6. Left/Right Adjustment Parameter selection Parameter Value Speed Adjustment -1.5% -0.75% Activating Brake Release or Separate Motor Excitation The controller may be configured so that the Output C will turn On whenever one of the two motors is running.

  • Page 46: Using The Inputs To Turn Off/On The Power Mosfet Transistors

    General Operation Special Use of Accessory Digital Inputs The AX500 includes two general purpose digital inputs identified as Input E and Input F . The location of these inputs on the DB15 connector can be found in the section “I/O List and Pin Assignment”...

  • Page 47: Section 6 Connecting Sensors And Actuators To Input/Outputs

    AX500 Connections Connecting SECTION 6 Sensors and Actuators to Input/Outputs This section describes the various inputs and outputs and provides guidance on how to connect sensors, actuators or other accessories to them. AX500 Connections The AX500 uses a set of power wires (located on the back of the unit) and a DB15 connec- tor for all necessary connections.

  • Page 48: Ax500'S Inputs And Outputs

    Connecting Sensors and Actuators to Input/Outputs DC Motors Optional sensors: - Tachometers (Closed loop Speed mode) - Potentiometers (Servo mode) Motor Power supply wires Logic Power supply wire (connected optionally)5- Controller FIGURE 21. Typical controller connections AX500’s Inputs and Outputs In addition to the RS232 and R/C channel communication lines, the AX500 includes several inputs and outputs for various sensors and actuators.
  • Page 49 AX500’s Inputs and Outputs When the controller operates in modes that do not use these I/O, these signals become available for user application. Below is a summary of the available signals and the modes in which they are used by the controller or available to the user. TABLE 7 .

  • Page 50: I/O List And Pin Assignment

    Connecting Sensors and Actuators to Input/Outputs I/O List and Pin Assignment The figure and table below lists all the inputs and outputs that are available on the AX500. FIGURE 22. Controller’s DB15 connector pin numbering TABLE 8. DB15 connector pin assignment Input or Number Output...

  • Page 51: Connecting Devices To Output C

    Connecting devices to Output C TABLE 8. DB15 connector pin assignment Input or Signal depending Number Output on Mode RC/RS232: Ana in 2 Analog in Analog: Command 2 Analog in RC/RS232: Ana in 1 Analog: Command 1 Analog in RC: Unused RS232: Ana in 3 Ana: Ana in 3 Power Out...

  • Page 52: Connecting Switches Or Devices To Input E

    Connecting Sensors and Actuators to Input/Outputs Important warning: This output is unprotected. If your load draws more than 100mA, permanent damage will occur to the power transistor inside the controller. Overvoltage spikes induced by switching inductive loads, such as solenoids or relays, will destroy the transistor unless a protection diode is used.

  • Page 53: Connecting Switches Or Devices To Estop/Invert Input

    Connecting Switches or Devices to EStop/Invert Input +5V Out 14 +5V Out 14 +5V Out 14 +5V Out 14 +5V In 7 +5V In 7 +5V In 7 +5V In 7 10kOhm 10kOhm 10kOhm 10kOhm Input F 4 Input F 4 Input F 4 Input F 4 GND In 6...

  • Page 54: Connecting Position Potentiometers To Analog Inputs

    Connecting Sensors and Actuators to Input/Outputs FIGURE 26. Emergency Stop / Invert switch wiring The status of the EStop/Inv can be read at all times in the RS232 mode with the ?i com- mand string. The controller will respond with three sets of 2 digit numbers. The status of the ES/Inv Input is contained in the last set of numbers and may be 00 to indicate an Off state, or 01 to indicate an On state.

  • Page 55: Connecting Tachometer To Analog Inputs

    Connecting Tachometer to Analog Inputs Connecting the potentiometer to the controller is as simple as shown in the diagram on Figure 28. FIGURE 28. Potentiometer wiring in Position mode The potentiometer must be attached to the motor frame so that its body does not move in relationship with the motor.
  • Page 56 Connecting Sensors and Actuators to Input/Outputs Since the controller only accepts a 0 to 5V positive voltage as its input, the circuit shown in Figure 29 must be used between the controller and the tachometer: a 10kOhm potentiom- eter is used to scale the tachometer output voltage to -2.5V (max reverse speed) and +2.5V (max forward speed).

  • Page 57: Connecting External Thermistor To Analog Inputs

    Connecting External Thermistor to Analog Inputs Connecting External Thermistor to Analog Inputs Using external thermistors, the AX500 can be made to supervise the motor’s temperature and adjust the power output in case of overheating. Connecting thermistors is done according to the diagram show in Figure 30. The AX500 is calibrated using a 10kOhm Neg- ative Coefficient Thermistor (NTC) with the temperature/resistance characteristics shown in the table below.

  • Page 58: Using The Analog Inputs To Monitor External Voltages

    Connecting Sensors and Actuators to Input/Outputs FIGURE 31. Signed binary reading by controller vs. NTC temperature To read the temperature, use the ?p command to have the controller return the A/D con- verter’s value. The value is a signed 8-bit hexadecimal value. Use the chart data to convert the raw reading into a temperature value.

  • Page 59: Connecting User Devices To Analog Inputs

    Connecting User Devices to Analog Inputs Measured volts = ((controller reading + 128) * 0.255) -5 Note: The A/D converter’s reading is returned by the ?p command and is a signed 8-bit hexadecimal value. You must add 128 to bring its range from -127/+127 to 0/255. Connecting User Devices to Analog Inputs The two analog inputs can be used for any other purpose.

  • Page 60: Temperature Conversion C Source Code

    Connecting Sensors and Actuators to Input/Outputs using the ?m query, or during data logging (see “Analog and R/C Modes Data Logging String Format” on page 126) The analog value that is reported will range from 0 (warmest) to 255 (coldest). Because of the non-linear characteristics of NTC thermistors, the conversion from measured value to temperature must be done using the correction curve below.
  • Page 61 Internal Heatsink Temperature Sensors HiTemp = LoTemp + 5; lobound = TempTable[i]; hibound = TempTable[i+1]; temp = LoTemp + (5 * ((AnaValue - lobound)*100/ (hibound - lobound)))/100; return temp; AX500 Motor Controller User’s Manual...
  • Page 62 Connecting Sensors and Actuators to Input/Outputs AX500 Motor Controller User’s Manual Version 1.9b. June 1, 2007...

  • Page 63: Section 7 Closed Loop Position Mode

    Mode Description Closed Loop SECTION 7 Position Mode This section describes the AX500 Position mode, how to wire the motor and position sen- sor assembly and how to tune and operate the controller in this mode. Mode Description In this mode, the axle of a geared-down motor is coupled to a position sensor that is used to compare the angular position of the axle versus a desired position.

  • Page 64: Position Sensor Selection

    Closed Loop Position Mode Position Sensor Selection The AX500 may be used with the following kind of sensors: The first two are used to generate an analog voltage ranging from 0V to 5V depending on their position. They will report an absolute position information at all times. Sensor Mounting Proper mounting of the sensor is critical for an effective and accurate position mode opera- tion.

  • Page 65: Feedback Potentiometer Wiring

    Feedback Potentiometer wiring manner that will allow it to turn throughout much of its range, when the mechanical assembly travels from the minimum to maximum position. Important Notice: Potentiometers are mechanical devices subject to wear. Use better quality potenti- ometers and make sure that they are protected from the elements. Consider using a solid state hall position sensor in the most critical applications.

  • Page 66: Feedback Wiring In Rc Or Rs232 Mode On Single Channel Controllers

    Closed Loop Position Mode Roborun will detect the new hardware revision and display Rev B on the screen. FIGURE 37 . Pot wiring for Analog Command and Analog Feedback Analog inputs 3 and 4 have different characteristics than inputs 1 and 2, and so require a lower resistance potentiometer in order to guarantee accuracy.

  • Page 67: Feedback Wiring In Analog Mode On Single Channel Controllers

    Sensor and Motor Polarity Feedback Wiring in Analog Mode on Single Channel Controllers When the controller is configured in Analog mode, the analog input 1 is used for com- mands while the analog input 4 is used for feedback. FIGURE 39. Pot wiring on Single Channel controllers (SC version) and Analog Command Analog inputs 3 and 4 have different characteristics than inputs 1 and 2, and so require a lower resistance potentiometer in order to guarantee accuracy.

  • Page 68: Encoder Error Detection And Protection

    Closed Loop Position Mode Important Safety Warning Never apply a command that is lower than the sensor’s minimum output value or higher than the sensor’s maximum output value as the motor would turn forever try- ing to reach a position it cannot. For example, if the max position of a potentiometer is 4.5V, which is a position value of 114, a destination command of 115 cannot be reached and the motor will not stop.
  • Page 69 Adding Safety Limit Switches in an attempt to reach a fictitious position. In many applications, this may lead to serious mechanical damage. To limit the risk of such breakage, it is recommended to add limit switches that will cause the motors to stop if unsafe positions have been reached independent of the potentiome- ter reading.

  • Page 70: Using Current Limiting As Protection

    Closed Loop Position Mode The principal restriction of this technique is that it depends on the controller to be fully functioning, and that once a switch is activated, the controller will remain inactive until the switch is released. In most situations, this will require manual intervention. Another limita- tion is that both channels will be disabled even if only one channel caused the fault.

  • Page 71: Pid Tuning In Position Mode

    PID tuning in Position Mode tance between the current and desired positions: when far apart, high power is applied, with the power being gradually reduced and stopped as the motor moves to the final posi- tion. The Proportional feedback is the most important component of the PID in Position mode.
  • Page 72 Closed Loop Position Mode Because many mechanical parameters such as motor power, gear ratio, load and inertia are difficult to model, tuning the PID is essentially a manual process that takes experimenta- tion. The Roborun PC utility makes this experimentation easy by providing one screen for chang- ing the Proportional, Integral and Differential gains and another screen for running and monitoring the motors.

  • Page 73: Section 8 Closed Loop Speed Mode

    Mode Description Closed Loop SECTION 8 Speed Mode This section discusses the AX500 Close Loop Speed mode. Mode Description In this mode, an analog speed sensor measures the actual motor speed and compares it to the desired speed. If the speed changes because of changes in load, the controller auto- matically compensates the power output.

  • Page 74: Tachometer Or Encoder Mounting

    Closed Loop Speed Mode Tachometer or Encoder Mounting Proper mounting of the speed sensor is critical for an effective and accurate speed mode operation. Figure 1 shows a typical motor and tachometer or encoder assembly. FIGURE 43. Motor and speed sensor assembly needed for Close Loop Speed mode Tachometer wiring The tachometer must be wired so that it creates a voltage at the controller’s analog input that is proportional to rotation speed: 0V at full reverse, +5V at full forward, and 0 when...

  • Page 75: Adjust Offset And Max Speed

    Adjust Offset and Max Speed Important Warning: If there is a polarity mismatch, the motor will turn in the wrong direction and the speed will never be reached. The motor will turn continuously at full speed with no way of stopping it other than cutting the power or hitting the Emergency Stop but- tons.

  • Page 76: Control Loop Description

    Closed Loop Speed Mode To set the potentiometer, use the Roborun utility to run the motors at the desired maxi- mum speed while in Open Loop mode (no speed feedback). While the tachometer is spin- ning, adjust the potentiometer until the analog speed value read is reaching 126. Note: The maximum desired speed should be lower than the maximum speed that the motors can spin at maximum power and no load.

  • Page 77: Pid Tuning In Speed Mode

    PID tuning in Speed Mode Tachometer Optical Encoder FIGURE 45. PID algorithm used in Speed mode PID tuning in Speed Mode As discussed above, three parameters - Proportional Gain, Integral Gain, and Differential Gain - can be adjusted to tune the Closed Loop Speed control algorithm. The ultimate goal in a well tuned PID is a motor that reaches the desired speed quickly without overshoot or oscillation.
  • Page 78 Closed Loop Speed Mode AX500 Motor Controller User’s Manual Version 1.9b. June 1, 2007...

  • Page 79: Section 9 Normal And Fault Condition Led Messages

    Diagnostic LED Normal and SECTION 9 Fault Condition LED Messages This section discusses the meaning of the various messages and codes that may be dis- played on the LED display during normal operation and fault conditions. Diagnostic LED The AX500 features a single diagnostic LED which helps determine the controller’s operat- ing mode and signal a few fault conditions.

  • Page 80: Output Off / Fault Condition

    Normal and Fault Condition LED Messages Output Off / Fault Condition The controller LED will tun On solid to signal that the output stage is off as a result of a any of the recoverable conditions listed below. FIGURE 47 . Status LED Flashing pattern during faults or other exceptions The controller will resume the normal flashing pattern when the fault condition disappears.

  • Page 81: Section 10 R/C Operation

    Mode Description R/C Operation SECTION 10 This section describes the controller’s wiring and functions specific to the R/C radio control mode. Mode Description The AX500 can be directly connected to an R/C receiver. In this mode, the speed or posi- tion information is contained in pulses whose width varies proportionally with the joysticks’...

  • Page 82: Connector I/O Pin Assignment (R/C Mode)

    R/C Operation Selecting the R/C Input Mode The R/C Input Mode is the factory default setting. If the controller has been previously set to a different Input Mode, it will be necessary to reset it to the R/C mode using the serial port and the PC utility. See “Using the Roborun Configuration Utility”...

  • Page 83: R/C Input Circuit Description

    R/C Input Circuit Description R/C Input Circuit Description The AX500 R/C inputs are directly connected to the MCU logic. Figure 50 shows an electri- cal representation of the R/C input circuit. +5V Output R/C Channel 1 R/C Channel 2 R/C Channel 3 FIGURE 50.

  • Page 84: Powering The Radio From The Controller

    R/C Operation FIGURE 52. RC connection cable Powering the Radio from the controller The 5V power and ground signals that are available on the controller’s connector may be used to power the R/C radio. The wire loop is used to bring the controller’s power to the the radio as well as for powering the optocoupler stage.

  • Page 85: Connecting To A Separately Powered Radio

    Connecting to a Separately Powered Radio R/C Radio Power R/C Radio FIGURE 54. R/C Radio powered by controller electrical diagram Important Warning Do not connect a battery to the radio when in this mode. The battery voltage will flow directly into the controller and cause permanent damage if its voltage is higher than 5.5V.

  • Page 86: Operating The Controller In R/C Mode

    R/C Operation to the controller does not inject power into the controller. The figure below show the cable with the loop cut. Figure 56 shows the equivalent electrical diagram. FIGURE 55. Wiring when receiver is powered by its own separate battery Battery FIGURE 56.

  • Page 87: Reception Watchdog

    Reception Watchdog the controller captures the full joystick movement, the AX500 defaults to the timing values shown in Figure 57. These vales can be changed and stored as new defaults. joystick position: center 1.05ms 0.45ms R/C pulse timing: 0.9ms FIGURE 57 . Joystick position vs. pulse duration default values The AX500 has a very accurate pulse capture input and is capable of detecting changes in joystick position (and therefore pulse width) as small as 0.4%.

  • Page 88: R/C Transmitter/Receiver Quality Considerations

    R/C Operation Note: the Accessory Outputs C will be turned Off when radio is lost. Important Notice about PCM Radios PCM radios have their own watchdog circuitry and will output a signal (normally a “safe condition” value) when radio communication is lost. This signal will be inter- preted by the AX500 as a valid command and the controller will remain active.

  • Page 89: Command Control Curves

    Command Control Curves The deadband is measured as a percentage of total normal joystick travel. For example, a 16% deadband means that the first 16% of joystick motion in either direction will have no effect on the motors. TABLE 13. Selectable deadband values Deadband Parameter Value d = 0 d = 1...

  • Page 90: Left/Right Tuning Adjustment

    R/C Operation Left/Right Tuning Adjustment When operating in mixed mode with one motor on each side of the robot, it may happen that one motor is spinning faster than the other one at identically applied power, causing the vehicle to pull to the left or to the right. To compensate for this, the AX500 can be made to give one side up to 10% more power than the other at the same settings.

  • Page 91: Data Logging In R/C Mode

    Data Logging in R/C Mode Data Logging in R/C Mode Output C FIGURE 60. Using Channel 3 to activate accessory outputs While in R/C Mode, the AX500 will continuously send a string of characters on the RS232 output line. This string will contain 12 two-digit hexadecimal numbers representing the fol- lowing operating parameters.
  • Page 92 R/C Operation FIGURE 61. Modified R/C cable with RS232 output for data logging to a PC AX500 Motor Controller User’s Manual DB9 Female DB15 Male To PC To Controller RX Data RS232 Data Out R/C Ch 1 R/C Ch 2 R/C GND R/C +5V Version 1.9b.

  • Page 93: Section 11 Analog Control And Operation

    Mode Description Analog Control SECTION 11 and Operation This section describes how the motors may be operated using analog voltage commands. Mode Description The AX500 can be configured to use a 0 to 5V analog voltage, typically produced using a potentiometer, to control each of its two motor channels.

  • Page 94: Connector I/O Pin Assignment (Analog Mode)

    Analog Control and Operation Connector I/O Pin Assignment (Analog Mode) When used in the Analog mode, the pins on the controller’s DB15 connector are mapped as described in the table below TABLE 14. DB15 Connector pin assignment in Analog mode Number Signal Output C...

  • Page 95: Connecting To A Voltage Source

    Connecting to a Voltage Source Connecting to a Voltage Source The analog inputs expect a DC voltage of 0 to 5V which can be sourced by any custom cir- cuitry (potentiometer, Digital to Analog converter). The controller considers 2.5V to be the zero position (Motor Off). 0V is the maximum reverse command and +5V is the maximum forward command.

  • Page 96: Selecting The Potentiometer Value

    Analog Control and Operation FIGURE 63. Potentiometer connection wiring diagram The controller includes two 47K ohm resistors pulling the input to a mid-voltage point of 2.5V. When configured in the Analog Input mode, this will cause the motors to be at the Off state if the controller is powered with nothing connected to its analog inputs.

  • Page 97: Analog Deadband Adjustment

    Analog Deadband Adjustment Voltage at Input 10K Pot FIGURE 64. Effect of the controller’s internal resistors on various potentiometers Analog Deadband Adjustment The controller may be configured so that some amount of potentiometer or joystick travel off its center position is required before the motors activate. The deadband parameter can be one of 8 values, ranging from 0 to 7 , which translate into a deadband of 0% to 16%.

  • Page 98: Data Logging In Analog Mode

    Analog Control and Operation TABLE 15. Analog deadband parameters and their effects Parameter Value 3 (default) Important Notice Some analog joysticks do not cause the potentiometer to reach either extreme. This may cause the analog voltage range to be above 0V and below 5V when the stick is moved to the extreme, and therefore the controller will not be able to deliver full for- ward or reverse power.
  • Page 99 Data Logging in Analog Mode Data in Analog and R/C Modes” on page 144). It may also be stored in a PDA that can be placed in the mobile robot. The string and data format is described in “Analog and R/C Modes Data Logging String For- mat”...
  • Page 100 Analog Control and Operation AX500 Motor Controller User’s Manual Version 1.9b. June 1, 2007...

  • Page 101: Section 12 Serial (Rs-232) Controls And Operation

    Use and benefits of RS232 Serial (RS-232) SECTION 12 Controls and Operation This section describes the communication settings and the commands accepted by the AX500 in the RS232 mode of operations. This information is useful if you plan to write your own controlling software on a PC or microcomputer.

  • Page 102: Connector I/O Pin Assignment (Rs232 Mode)

    Serial (RS-232) Controls and Operation Connector I/O Pin Assignment (RS232 Mode) FIGURE 1. Pin locations on the controller’s 15-pin connector When used in the RS232 mode, the pins on the controller’s DB15 connector are mapped as described in the table below TABLE 16.

  • Page 103: Extending The Rs232 Cable

    Cable configuration Cable configuration The RS232 connection requires the special cabling as described in the figure below. The 9- pin female connector plugs into the PC (or other microcontroller). The 15-pin male connec- tor plugs into the AX500. It is critical that you do not confuse the connector’s pin numbering. The pin numbers on the drawing are based on viewing the connectors from the front (facing the sockets or pins).

  • Page 104: Establishing Manual Communication With A Pc

    To save time and avoid errors, a hyperterm configuration file is automatically installed in your PC’s Start button menu when the Roboteq’s Roborun utility is installed (See “Down- loading and Installing the Utility” on page 131). The configuration file is set to use the AX500 Motor Controller User’s Manual...

  • Page 105: Data Logging String In R/C Or Analog Mode

    In all cases, immediately after reset or power up, the controller will output a short identity message followed by a software revision number and software revision date as follows: Roboteq v1.9b 06/01/07 The letter below the prompt message is a code that provides information on the hardware and can be ignored.

  • Page 106: Commands Acknowledge And Error Messages

    Serial (RS-232) Controls and Operation This information can be safely ignored and the controller will still be able to switch to RS232 mode upon receiving 10 continuous Carriage Returns as described above. The format of the data logging string and it content is described in Figure , “Analog and R/C Modes Data Logging String Format, ”...

  • Page 107: Controller Commands And Queries

    RS-232 Watchdog Watchdog time-out If the RS232 watchdog is enabled, the controller will stop the motors and issue a “W” character if it has not received a valid character from the PC or microcontroller within the past 1 seconds. RS-232 Watchdog For applications demanding the highest operating safety, the controller may be configured to automatically stop the motors (but otherwise remain fully active) if it fails to receive a character on its RS232 port for more than 1 seconds.

  • Page 108: Set Motor Command Value

    Serial (RS-232) Controls and Operation TABLE 17 . Controller’s basic Commands and Queries Command ?a or ?A ?v or ?V ?p or ?P ?r or ?R ?m or ?M ?e or ?E ?i or ?I Set Motor Command Value Description: Send a speed of position value from 0 to 127 in the forward or reverse direction for a given channel.

  • Page 109: Query Amps From Battery To Each Motor Channel

    Controller Commands and Queries turn C output off turn C output on Query Power Applied to Motors Description: This query will cause the controller to return the actual amount of power that is being applied to the motors at that time. The number is a hexadecimal number ranging from 0 to +127 (0 to 7F in Hexadecimal).

  • Page 110: Query Heatsink Temperatures

    Figure 34 on page 60 shows this correlation. Sample conversion software code is available from Roboteq upon request. The values are unsigned Hexadecimal numbers ranging from 0 to 255. The lowest read value represents the highest temperature.

  • Page 111: Query Battery Voltages

    Controller Commands and Queries Query Battery Voltages Description: This query will cause the controller to return values based on two internally measured volt- ages: the first is the Main Battery voltage present at the thick red and black wires. The sec- ond is the internal 12V supply needed for the controller’s microcomputer and MOSFET drivers.

  • Page 112: Accessing & Changing Configuration Parameter In Flash

    Serial (RS-232) Controls and Operation Reply: Accessing & Changing Configuration Parameter in Flash It is possible to use RS232 commands to examine and change the controller’s parameters stored in Flash. These commands will appear cryptic and difficult to use for manual param- eter setting.

  • Page 113: Flash Configuration Parameters List

    Accessing & Changing Configuration Parameter in Flash Syntax: Reply: + Success, changed parameters are now active - if error Table 18 below lists the complete set of configuration parameters that may be accessed and changed using RS232 commands. Flash Configuration Parameters List TABLE 18.

  • Page 114: Input Control Mode

    Serial (RS-232) Controls and Operation TABLE 18. Configuration parameters in Flash Location These parameters are stored in the controller’s Flash memory and are not intended to be changed at runtime. Important Notice The above parameters are stored in the MCU’s configuration flash. Their storage is perma- nent even after the controller is powered off.

  • Page 115: Amps Limit

    Accessing & Changing Configuration Parameter in Flash This parameters selects the various open loop and closed loop operating modes as well as the feedback method. Definition Motor Control Mode Reserved Ch1 Feedback type Ch2 Feedback type Amps Limit Address: Access: Read/Write Effective: After Reset or ^FF...

  • Page 116: Input Switches Function

    Serial (RS-232) Controls and Operation Acceleration Address: Access: Effective: This parameter configures the rate at which the controller internally changes the command value from the one it was to the one just received. Definition 0 = very slow 1 = slow (2) = medium-slow (default) 3 = medium 4 = fast...

  • Page 117: Exponentiation On Channel 1 And Channel 2

    Accessing & Changing Configuration Parameter in Flash Definition Input E Input F RC Joystick or Analog Deadband Address: Access: Read/Write Effective: After Reset or ^FF This parameter configures the amount of joystick or potentiometer motion can take place around the center position without power being applied to the motors. Definition Values are for Joystick deadband 0 = no deadband...

  • Page 118: Left/Right Adjust

    Serial (RS-232) Controls and Operation This parameter configures the transfer curve that is applied the input command. Definition (0) = Linear (no exponentiation - default) 1 = strong exponential 2 = normal exponential 3 = normal logarithmic 4 = strong logarithmic Left/Right Adjust Address: Access:...

  • Page 119: Reading & Changing Operating Parameters At Runtime

    Reading & Changing Operating Parameters at Runtime Joystick Min, Max and Center Values Address: ^12 - Joystick Center 1 MS ^13 - Joystick Center 1 LS ^14 - Joystick Center 2 MS ^15 - Joystick Center 2 LS ^16 - Joystick Min 1 MS ^17 - Joystick Min 1 LS ^18 - Joystick Min 2 MS ^19 - Joystick Min 2 LS...

  • Page 120: Operating Modes Registers

    Serial (RS-232) Controls and Operation The table below lists the available parameters TABLE 19. Runtime R/W Parameters list Location Important Notice: Do not write in the locations marked as Read Only. Doing so my cause Controller malfunction. Operating Modes Registers Address: Access: Effective:...

  • Page 121: Controller Status Register

    Reading & Changing Operating Parameters at Runtime TABLE 20. Operating Modes Register Definition Function 0: Speed Mode 1: Position Mode 0: Analog Feedback 1: Encoder Feedback Read/Change PID Values Address: ^82 - P1 ^83 - I1 ^84 - D1 ^85 - P2 ^86 - I2 ^87 - D2 Access:...

  • Page 122: Controller Identification Register

    Serial (RS-232) Controls and Operation The Controller Status Register can be polled at any time to see if there is a pending fault condition. Any one bit set will cause the controller to turn off the Power Output stage. Con- ditions marked as Temporary mean that the controller will resume operation as soon as the fault condition disappears.
  • Page 123 Reading & Changing Operating Parameters at Runtime These registers can be polled to view what the Amps limit is at the current time. This limit normally is the one that is preset by the user except when the controller is operating at high temperature, in which case the allowable current drops as temperature rises.
  • Page 124 Serial (RS-232) Controls and Operation AX500 Motor Controller User’s Manual Version 1.9b. June 1, 2007...

  • Page 125: Automatic Switching From Rs232 To Rc Mode

    Automatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC Mode In many computer controlled applications, it may be useful to allow the controller to switch back to the RC mode. This would typically allow a user to take over the control of a robotic vehicle upon computer problem.

  • Page 126: Analog And R/C Modes Data Logging String Format

    Controller is on, Radio is turned Off (or Radio On with RC ch3 Off) Note: Wait 5 seconds for the capacitor to discharge before attempting to switch to RC mode if doing this repeatedly. Controller will not reset otherwise. Analog and R/C Modes Data Logging String Format When the controller is configured in R/C or Analog mode, it will automatically and continu- ously send a string of ASCII characters on the RS232 output.

  • Page 127: Decimal To Hexadecimal Conversion Table

    Decimal to Hexadecimal Conversion Table logging purposes. This cable has a 15-pin male connector and 3 15-pin connectors. The Front View FIGURE 72. ASCII string sent by the controller while in R/C or Analog mode male connector plugs into the controller. The application cable that would normally plug into the controller may now be plugged into one of the adapter’s female connector 2.
  • Page 128 TABLE 23. 0 to +127 signed or unsigned decimal to hexadecimal conversion table TABLE 24. +128 to 255 unsigned and -1 to -128 signed decimal to hexadecimal conversion table UDec -128 -127 -126 -125 -124 -123 -122 AX500 Motor Controller User’s Manual UDec UDec UDec...
  • Page 129 Decimal to Hexadecimal Conversion Table TABLE 24. +128 to 255 unsigned and -1 to -128 signed decimal to hexadecimal conversion table UDec UDec -121 -120 -119 -118 -117 -116 -115 -114 -113 -112 -111 -110 -109 -108 -107 -106 -105 -104 -103 -102...
  • Page 130 AX500 Motor Controller User’s Manual Version 1.9b. June 1, 2007...

  • Page 131: Section 13 Using The Roborun Configuration Utility

    Configuration Utility A PC-based Configuration Utility is available, free of charge, from Roboteq. This pro- gram makes configuring and operating the AX500 much more intuitive by using pull- down menus, buttons and sliders. The utility can also be used to update the control- ler’s software in the field as described in “Updating the Controller’s Software”...

  • Page 132: Connecting The Controller To The Pc

    Leave VMot unconnected unless you want to exercise the Motors. AX500 Motor Controller User’s Manual • after the installation is complete, run the program from your Start Menu > Programs > Roboteq • to read the current parameters stored in the controller and display them on the computer •...

  • Page 133: Roborun Frame, Tab And Menu Descriptions

    1- Program Revision Number This is the revision and date of the Roborun utility. It is recommended that you always ver- ify that you have the latest revision of the utility from Roboteq’s web site at www.roboteq.com 2- Controller and Communication Link Information This frame will automatically be updated with an indication that a free communication port was found and opened by the utility.

  • Page 134: Loading, Changing Controller Parameters

    Using the Roborun Configuration Utility This is the program’s main frame and includes several types of tabs, each of which has sev- eral buttons, menus and other User Interface objects. These tabs and the functions they contain are described in detail in the following sections. Navigate from one set of commands to another by clicking on the desired tab.

  • Page 135: Control Settings

    Loading, Changing Controller Parameters When starting Roborun, this screen is filled with the default values. If the controller is con- nected to your PC, Roborun will automatically detect it and ask you if you wish to read its settings. The controller’s setting in the PC at can be read any other time by pressing the “Load from Controller”...

  • Page 136: Power Settings

    Using the Roborun Configuration Utility 4- Emergency Stop or Invert Switch Select This pull down menu allows the selection of the controller’s response to changes on the optional switch input: Emergency Stop, Invert Commands, or no action. See “Emergency Stop using External Switch” on page 45 and “Inverted Operation” on page 45. 5- Effect of Digital Inputs This pull down menu allows the selection of the controller’s response to changes on either of the two digital inputs.

  • Page 137: Analog Or R/C Specific Settings

    Loading, Changing Controller Parameters accelerate a motor from idle to maximum speed. See “Programmable Acceleration” on page 40. Analog or R/C Specific Settings FIGURE 78. Power settings screen The screen shown in Figure 78 slightly changes in function of whether or not the Analog Input mode is selected.

  • Page 138: Closed Loop Parameters

    Using the Roborun Configuration Utility Closed Loop Parameters FIGURE 79. Closed Loop parameter setting screen The screen shown in Figure 79 is used to set the Proportional, Integral and Differential gains needed for the PID algorithm. These PID gains are loaded after reset and apply to both channels.
  • Page 139 Running the Motors FIGURE 80. Motor exercising and monitoring screen 1- Run/Stop Button This button will cause the PC to send the run commands to the controller and will update the screen with measurements received from the controller. When the program is running, the button’s caption changes to “Stop” . Pressing it again will stop the motors and halt the exchange of data between the PC and the controller.
  • Page 140 Using the Roborun Configuration Utility case the power level will be the one needed to keep the Amps within the limit. Note that the display value is not signed and thus does not provide rotation direction information. The Ana fields contain the analog input values that are measured and reported by the con- troller.

  • Page 141: Logging Data To Disk

    Running the Motors A timer is provided to keep track of time while running the motors. An additional set of but- tons and displays are provided to operate a data logger. The data logger is fully described in the section that follows. 8- Joystick Enable Enable and configure a joystick.

  • Page 142: Connecting A Joystick

    Using the Roborun Configuration Utility TABLE 25. Logged parameters order, type and definition Parameter Header Power2 Ana 1, Speed 1, Pos 1 or Temp 1 or Volt 1 Ana 2, Speed 2, Pos 2 Temp 2 or Volt 2 Amps1 Amps2 FET Temp1 FET Temp2...
  • Page 143 Using the Console development as you will be able to visualize, in real-time, the robot’s Amps consumption and other vital statistics during actual operating conditions. Figure 80 shows the Console Screen and its various components. FIGURE 81. Raw ASCII data exchange in Console 1- Terminal Screen This area displays the raw ASCII data as it comes out of the controller.

  • Page 144: Viewing And Logging Data In Analog And R/C Modes

    Using the Roborun Configuration Utility Clicking this button will cause Roborun to send ten consecutive “Carriage Return” charac- ter. If the controller is configured in Analog or RC mode, the Carriage Returns will cause it to switch to RS232 mode until the controller is reset again. Viewing and Logging Data in Analog and R/C Modes When the controller is configured in R/C or Analog mode, it will automatically and continu- ously send a string of ASCII characters on the RS232 output.
  • Page 145 Operating the AX500 over a Wired or Wireless LAN To operate over the network, two computers are required, as show in Figure 82 below. The top computer is connected to the controller via its COM port. Both computers are con- nected to a TCP/IP network.

  • Page 146: Updating The Controller's Software

    Using the Roborun Configuration Utility Updating the Controller’s Software The AX500’s operating software can be easily upgraded after it has left the factory. This feature makes it possible to add new features and enhance existing ones from time to time. Important Warning Updating the controller will cause all its parameters to reset to their default condi- tions.

  • Page 147: Creating Customized Object Files

    Select the latest official controller firmware issued by Roboteq. Select the profile file that was created and saved earlier. Select a revision letter. This letter will be added at the end of Roboteq’s own version identity number. Click on the Create button and save the new customized object file.
  • Page 148 Using the Roborun Configuration Utility Install the new object file in the controller using the Roborun utility. AX500 Motor Controller User’s Manual Version 1.9b. June 1, 2007...

  • Page 149: Section 14 Mechanical Specifications

    Mechanical Dimensions Mechanical SECTION 14 Specifications This section details the mechanical characteristics of the AX500 controller. Mechanical Dimensions The AX500 is delivered as an assembled and tested Printed Circuit Board. The board includes connectors for direct connection to the Optical Encoders and to the Radio, Joy- stick or microcomputer on one side.

  • Page 150: Mounting Considerations

    Mechanical Specifications FIGURE 86. AX500 top view and dimensions Mounting Considerations The AX500’s heatsink is located at the bottom of the board. This requires therefore that the board be mounted with spacers that are at minimum 0.6” (15mm). FIGURE 87 . Use spacers to provide clearance for heatsink Thermal Considerations When mounting the board, and if current is expected to be above 7A on average, ensure that there can be a natural or forced convection flow to remove the heat.

  • Page 151: Attaching The Controller Directly To A Chassis

    Attaching the Controller Directly to a Chassis board against a vertical surface as shown in the figure below will ensure a better natural convection flow and is, therefore, recommended. FIGURE 88. Mount the controller against a vertical surface to maximize convection flow For high current applications, it is possible that the controller may heat up faster and to a higher temperature than can be dissipated by the using natural convection alone.

  • Page 152: Precautions To Observe

    Mechanical Specifications Note that the back of the PCB has large copper areas exposed just under the power MOS Board Thermal Pad Metal Interposer Metal Chassis Spacer FIGURE 89. Mount the controller without heatsink against a chassis area. It is critical that the interposer either is insulated (example: anodized aluminum) or a layer of thermal conducting - but electrically insulating - pad is used.

  • Page 153: Wire Dimensions

    Wire Dimensions Wire Dimensions The AX500 uses screw terminals for the power connections to the batteries and motors. These connectors are rated to support the controller’s maximum specified current. It is rec- ommended that you use AWG 14 wire for all power connections to ground, batteries and motors.
  • Page 154 Mechanical Specifications AX500 Motor Controller User’s Manual Version 1.9b. June 1, 2007...

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