Vex Robotics Falcon 500 User manual

217-6515-751
Falcon 500 Motor User Guide
vexpro.com ctr-electronics.com
Copyright 2019, VEX Robotics Inc.
2020-01-07
1

217-6515-751
Falcon 500 Motor User Guide
vexpro.com ctr-electronics.com
Copyright 2019, VEX Robotics Inc.
2020-01-07
2
Table of Contents
Falcon 500 Features ...................................................................................................3 
Specifications ...........................................................................................................14 
Performance Data........................................................................................................16 
General Warnings .....................................................................................................17 
Mounting a Falcon 500..............................................................................................18 
Wiring the Falcon 500...............................................................................................21 
Installing Gears & Pulleys ...........................................................................................25 
Using the Falcon 500 Cooling Port ..............................................................................29 
Changing the Output Shaft..........................................................................................31 
Installing the Falcon 500 In A VersaPlanetary................................................................36 
Additional Information ................................................................................................39 
Frequently Asked Questions ........................................................................................46 
Troubleshooting ........................................................................................................50 
What’s Included ........................................................................................................53 
FCC Compliance Statement (United States): ..................................................................54 
ICES-003 Compliance Statement (Canada): ...................................................................54 
Revision History ........................................................................................................54 
Support ...................................................................................................................55 

217-6515-751
Falcon 500 Motor User Guide
vexpro.com ctr-electronics.com
Copyright 2019, VEX Robotics Inc.
2020-01-07
3
Falcon 500 Features
The Falcon 500, powered by Talon FX, is a revolutionary new
brushless motor for FRC! With an integrated motor controller
and encoder, it raises the bar for motor and motor controller
performance.
The Falcon 500 introduces many new and innovative features
to the FIRST®Robotics Competition, some of which are the
first of their kind in the FRC market.
These features will not only change the way teams think about
motors, but will change the way teams interact with, use, and
maintain them. The bottom line is the Falcon 500, powered by
Talon FX, is changing competition as we know it.
Brushless Is More
The Falcon 500 is a brushless motor, custom designed specifically for the FIRST Robotics Competition,
through a collaboration between VEX Robotics and Cross the Road Electronics. Brushless motors are better
than their brushed counterparts for a variety of reasons:
More Reliable – The brushes inside a brushed motor will inevitably fail. Over time these brushes
deteriorate, leading to degraded performance. This is the reason why many FRC teams use new
motors every year – regardless of whether they still work or not. In fact, some FRC teams have
started replacing their brushed motors mid-season to make sure they’re always getting the most out
of their robot.
In theory, the bearings inside a brushless motor will be the first item to wear out. This means that
brushless motors have a significantly longer life span than brushed motor.
Cooler & More Efficient – Since there are no brushes creating a torque load on the shaft, brushless
motors produce more torque, making them more efficient.
More Power Density – Power density is how much mechanical power a motor can produce, relative
to its size. Due to their design, brushless motors have a much higher power density that wouldn’t be
available in a similar sized brushed motor. This means that the Falcon 500, powered by Talon FX is
smaller and lighter than most FRC legal brushed motors, while producing significantly more power.
Falcon 500, powered by Talon FX

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Falcon 500 Motor User Guide
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Power Up
The Falcon 500 produces just under 400W of Power at 40A and 12VDC. Without a doubt, it is the most
powerful motor in FRC. At peak power the Falcon 500 can produce over 780W of power!
On top of this unprecedented power, the Falcon 500 is the most efficient motor in FRC, with a peak efficiency
of 87%. In fact, the Falcon 500 is greater than 80% efficient across the entire FRC operating range (7A –
40A).
With this kind of power and efficiency, the Falcon 500 is the perfect motor for almost any FRC application.
Don’t rob your robot of valuable power and efficiency by using any other motor.

217-6515-751
Falcon 500 Motor User Guide
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Copyright 2019, VEX Robotics Inc.
2020-01-07
5
Size & Packaging
The Falcon 500 is smaller than a Mini CIM and just as light as a 775pro and Talon
SRX. In fact, the Falcon 500 and Talon FX have one of the smallest volumes of any
FRC motor and motor controller. Combine this with the Falcon 500’s cutting edge
power, and you have the best power-to-weight ratio of any FRC motor.
Motor
Total
Weight
(lbs)
% of
Robot
Weight
(120 Lbs)
Power
@ 20A
Power-To-
Weight Ratio
(W/lbs)
Falcon 500 + Talon FX 1.1 0.92% 203W 184.55
NEO + Spark Max 1.2 1.00% 202W 168.33
775pro + Talon SRX 1.1 0.92% 171W 156.88
BAG Motor + Talon SRX 1.1 0.92% 137W 124.55
Mini CIM + Talon SRX 2.4 2.02% 137W 56.61
CIM + Talon SRX 3.06 2.55% 157W 51.31
As teams have been trying to build smaller and smaller robots, fitting motor controllers has become a
challenge. Since the Falcon 500 has an integrated Talon FX motor controller, this problem is a thing of the
past. The Falcon 500 will dramatically change the way teams layout their robot’s electronics and revolutionize
their abilities to iterate their robot mid-season and mid-competition.
Above (Top to Bottom): CIM.
Mini CIM, Falcon 500.
Above: (3x) CIM motors, (3x) Talon SRX,
and (1x) Mag Encoder wired to a robot
Above: (3x) Falcon 500 motors wired to a
robot

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Failure Point Reduction
Each wire connection on a robot represents a possible failure point. A loose wire, a bad crimp, something
plugged in backwards – all of these can lead to significant problems during a match. The Falcon 500 helps
reduce the number of connections (failure points) by up to 50%. This means that your robot will be more
robust than ever before. Simply plug in the Falcon 500 to your robot’s power distribution system, connect it
to CAN or PWM, and you’re ready to go! Let’s look at some examples:
The diagram to the left is what
it would look like to wire (3x)
CIM Motors and a Mag
Encoder to your robot.
Each of the (20x) orange dots
represent a connection that
can fail, causing problems for
your robot in the middle of a
match.
The diagram to the left is what it looks like to wire (3x)
Falcon 500 motors to your robot. Both diagrams have
the same number of motors and sensor capability.
While the brushed motor example shows (20x) possible
failure points, the Falcon 500 example has just (12x).
This is a significant reduction in the number of possible
wiring problems that can exist on a robot by switching
from common brushed motors to the Falcon 500.
What about other brushless options in FRC? Since the
motor controller is integrated into the Falcon 500, so is
the sensor and sensor wiring. This means that there is
no sensor cable between the motor and controller that
can become unplugged during a match, eliminating more potential failures. In addition, the phase wiring
between the controller and the motor is handled inside the Falcon 500. This makes it impossible for teams to
mismatch the motor’s phases with the motor controller’s phases, eliminating even more failure points on a
robot.
Above: (3x) CIM motors, (3x) Talon SRX, and (1x) Mag Encoder wired to a robot. Each
orange dot is a possible failure point in the wiring.
Above: (3x) Falcon 500 motors wired to a robot. Each
orange dot is a possible failure point in the wiring.

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Talon FX
The Talon FX is built upon years of development in motor controller technology from Cross the Road
Electronics. The Talon FX is the next evolution of the Talon family of motor controllers, which continues to be
a leader in FRC motor controller technology.
The Talon FX gives teams all the features they’ve come to
expect from a Talon motor controller, including Follow
Mode, limit switch feedback, and on-board motion control
using Motion Magic.
One new feature added to the Talon FX is that a 2048
CPR Encoder is now built in. This means that when you
buy a Falcon 500 you’re not just buying a motor and
motor controller. You’re also buying a high-resolution
encoder. For the first time in FRC history, a single
product is giving teams access to world championship
caliber motion control – out of the box, with no additional
hardware needed.
Another change from the Talon SRX is that the Talon FX
doesn’t have a Talon data port and can’t have an encoder
plugged into it directly. However, teams can use a CAN-
based encoder such as the Cross the Road Electronics
CANCODER (P/N 19-676768) as an input sensor for
Motion Magic.
Reverse Polarity Protection
The single largest cause of failure in FRC motor controllers is reversing the polarity of the input power. This
means a simple wiring mistake like wiring a motor controller backwards into the PDP (Power Distribution
Power) or wiring a robot battery backwards can be a costly mistake for a team. The Falcon 500 is the first
motor controller in FRC history to have reverse polarity protection built in. This means that if you do plug the
Falcon 500 in backwards, the Talon FX isn’t damaged or destroyed.
Field Oriented Control (FOC)
The Talon FX is also capable of commutating the Falcon 500 using Field Oriented Control (FOC). This is
different from trapezoidal commutation, which only energizes 2 of the motor’s 3 phases at any given
moment. With FOC, the Talon FX uses sinusoidal commutation to constantly energize all three phases.
Phoenix API Compatible
The Talon FX is a Phoenix compatible device. This means that teams can program the Talon FX using their
existing Phoenix-based code with only minor changes needed.

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2020-01-07
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Stall Whistle
When the Falcon 500 begins to stall, it will whistle an audible tone to inform the user of this event.
A Smart Motor for All Teams
The Falcon 500, powered by Talon FX has a built in 2048 CPR Encoder that teams can use to produce
reliable motion control, out of the box. This is yet another game changer in FRC.
For the first time ever, teams of all skill and resource levels can have advanced motion control out of the box,
without having to buy or setup additional hardware, or learn complicated programming concepts. Here’s just
some of the applications teams can do with a Falcon 500 and no additional sensor hardware:
Measure distance driven on a drivetrain - Use a Falcon 500 on a single speed drivetrain and get
accurate distance measurement without the need of an external encoder. For 2-speed drivetrains, teams
should still use an external encoder and an encoder, as the motor can’t measure the difference in wheel
speed between high and low gear.
Position control on an arm or elevator - Use a Falcon 500 on an arm or elevator to measure the
position of an arm or elevator.
Velocity control on a flywheel shooter - Use a Falcon 500 to drive a flywheel shooter and use the
integrated encoder to measure velocity.

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Falcon 500 Motor User Guide
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Copyright 2019, VEX Robotics Inc.
2020-01-07
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CIM Compatible
The Falcon 500 comes with (6x) #10-32 holes on a
2” bolt circle. This, combined with the motor’s
smaller diameter, means the Falcon 500 can be
used anywhere a CIM or Mini CIM were used
previously.
The extra #10-32 holes mean that teams have
more freedom in the direction the wires and cooling
port are facing in their application.
Out of the box, all mounting holes are ‘plugged’ with
a #10-32 set screw. It is recommended that any
unused mounting holes remain plugged to keep dirt
and debris out of the motor chamber.
Above: A diagram showing the pairs of mounting
holes on the Falcon 500

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Falcon 500 Motor User Guide
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Rethinking Motor Shafts
When making a game changing motor, why stop at
performance? Since the beginning of FRC, teams have
had to use keyed or press-fit motor shafts. While
these are adequate, VEX and Cross the Road
Electronics wanted to give teams a better option. The
Falcon Shaft was developed to eliminate many
common problems teams have with keyed and press-
fit shafts.
The Falcon Shaft is a new spline shaft designed specifically for FRC. Why are spline shafts better? First off,
spline shafts have a higher torque capacity than a similar sized keyed shaft. This is because torque transfer is
being spread across all the spline teeth, instead of a single key. This also helps with reversing loads where
the force of instantly reversing the direction of the motor
is absorbed by all the teeth instead of a single key.
Not only is the Falcon Shaft designed to be stronger
while eliminating keys, it is designed to make it even
easier on FRC teams. One example of this is that the
ends of the Falcon Shaft have a #8-32 tapped hole. This
hole is used to retain items on the shaft, which means
teams no longer need to use retaining clips or shaft
collars to keep items on their motor shafts.
Another small, but convenient detail of the Falcon Shaft
is that it has a shoulder built into it which prevents
items on the shaft from sliding past the face of the
mounting boss. This prevents items on the shaft from
rubbing against the inner and outer face of the output
bearing. This also eliminates the need for teams to use
spacers between the motor’s output bearing and the
gears and pulleys used on the shaft.
Profile of Falcon 500
Motor Shaf
t
Profile of CIM / Mini CIM
Shaf
t

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Falcon 500 Motor User Guide
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Speaking of spacers, the Falcon 500 comes with a set of spacers that are specifically designed to help
teams position items on their motor within a 1/16”. This is meant to eliminate washer stacks and/or
retaining clips to keep gears and pulleys positioned and retained on the motor shaft.
This system is designed so that (1x) 1/16” spacer, (1x) 1/8” spacer, (1x) 1/4” spacer, and any Falcon bore
pinion or pulley made by VEXpro will equal the length of the motor’s shaft. Since this combination equals the
length of the motor’s shaft, you just need to put a #8-32 screw into the end of the motor to keep everything
retained.
One of the biggest benefits of the Falcon Shaft
being a spline shaft is that teams can now use
smaller gears. The Falcon 500 is the only motor in
FRC that allows teams to use as small as an 8T
pinion on their drivetrain. This opens the door for
teams to make smaller and lighter drivetrain
gearboxes.
While press-fits have worked for teams, it’s a non-
trivial task that when done improperly, can damage
motors. The spline eliminates this risk for all
teams, while opening new design opportunities
only available for teams using the Falcon 500.
Pinions Falcon 500
Compatible
CIM Shaft
Compatible
8 Tooth Pinion
9 Tooth Pinion
(Press-fit Only)
10 Tooth Pinion
11 Tooth Pinion
12 Tooth Pinion
13 Tooth Pinion
14 Tooth Pinion

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Lastly, the Falcon 500 is the first motor
in FRC history that has a replaceable
output shaft. In the past, a damaged or
cut shaft was permanent. With the
Falcon 500, teams now can replace the
output shaft instead of replacing the
entire motor.
There’s also the option to replace the
included long shaft with the “Falcon
Motor Short Shaft” (217-6958). This
shaft is already cut to the length needed
to make the Falcon 500 work with a
VersaPlanetary.
Staying Cool Under Pressure
Heat buildup is a problem with any FRC motor. When heat
builds up, the motor’s internal resistance changes, which
decreases its overall performance and efficiency. To combat
this, teams have been using fans and freeze spray to try and
cool their motors between matches. The Falcon 500 is the first
motor in FRC to have a dedicated cooling port designed into the
side of the motor. Teams can use this cooling port to connect a
#10-32 push-to-connect pneumatic fitting. By using this, teams
now have several options for actively cooling their motors. Some
examples of how the cooling port can be utilized are:
Pneumatic Exhaust - Plumb the exhaust from your pneumatic
system to the Falcon 500(s). This way every time a cylinder is actuated, cool air is forced into your motors.
Dedicated Air or Vacuum Pump - Use a dedicated air or vacuum pump on your robot to force cool air into
your Falcon 500(s).
Off-Board Compressor - Hook up an external air-source such as a shop compressor to push cool air into
your motors after a match.

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Using the cooling port in a match can reduce heat by up to 29˚C (84˚F)
1
. Similarly, using the cooling port
after a match can drop your motor’s temperature by 27˚C (80˚F) in just 3 minutes – that’s just half of a
field timeout during the playoffs.
1
30A @ 50% Duty Cycle
0
5
10
15
20
25
30
35
0 100 200 300 400 500 600 700 800
Change In Temperature (C)
Time (S)
40A Change In Temperature
No Cooling Cooling During Match Cooling After Match

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Falcon 500 Motor User Guide
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2020-01-07
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Specifications
Dimensions Performance
Dimensions 60mm (2.36”) Dia. X
81mm (3.18”) Long
Free Speed RPM 6380
RPM
Volume 199.54
cm^3
(12.17 mm^3)
Free Current 1.5A
Weight 1.1Lbs (0.49kg) Stall Current
257A
Output Shaft 14
Tooth, 0.5 Moldule
Spline Shaft
Stall Torque 4.69Nm
Mounting 6x #10-32 On 2” Bolt
Circle
Peak Efficiency 87% (294W In)
Cooling Port #10-32 On Side of
Motor
Power @ 40A /
12 VDC 400W
(83% Efficiency)
Free Current 1.5A
Peak Power 783W

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2020-01-07
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Talon FX Specifications Talon FX Inputs &
Outputs
Nominal Voltage 12 VDC
Motor Interface Integrated
PWM Input Pulse 1-2ms Nominal Power 2x 12AWG Silicone
Wires (Red & Black)
PWM Input Rate 2.9-100ms Communication
CAN
/ PWM
Minimum Throttle
(Deadband)
Adjustable 0.1%-25%
(4% Default)
Direct Sensor
Input Yes, Over CAN Only
Limit Switch Input 2x Through 4 Pin JST
Connector
Built-In Encoder
Feedback 2048 CPR Encoder
Motion Magic Yes, Using Built-In
Encoder or CAN Sensor
Wire Wire Color Wire Length
Positive Input Red 18in [457.2mm] ± 0.50in [12.70mm]
Input Ground Black 18in [457.2mm] ± 0.50in [12.70mm]
CAN-High / PWM Signal Yellow 18in [457.2mm] ± 0.50in [12.70mm]
CAN-Low / PWM Ground Green 18in [457.2mm] ± 0.50in [12.70mm]

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Falcon 500 Motor User Guide
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Copyright 2019, VEX Robotics Inc.
2020-01-07
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Performance Data

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Falcon 500 Motor User Guide
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2020-01-07
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General Warnings
Below are some warnings users should be aware of when working with the Falcon 500.
Warning
DO NOT remove the screws from the controller end cap. This can
result in a loss of calibration between the motor and motor controller.
A loss in calibration will result in decreased performance or
permanently damage your Falcon 500.
Warning
When using the cooling port, make sure you remove the set screw
from at least one additional mounting hole. This will prevent pressure
from building up inside the motor. The extra hole will also help air flow
through the motor, further assisting with the cooling process.

217-6515-751
Falcon 500 Motor User Guide
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Copyright 2019, VEX Robotics Inc.
2020-01-07
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Mounting a Falcon 500
The Falcon 500 comes with (6x) mounting holes so that teams have many options on the orientation of the
wires and cooling port. To prevent dust and debris from entering the motor chamber of the Falcon 500,
each mounting hole is plugged with a #10-32 set screw. It is recommended that any unused mounting holes
remain plugged to continue preventing dirt and debris from entering the motor chamber.
NOTE: If you are using the cooling part, it is recommended that you remove a set screw from an additional
mounting hole. This will prevent pressure from building up in the motor and assist with airflow through the
motor.
Step 1: Remove at least (2x) Set Screws from the Motor Mounting Holes
Using a 3/32” Hex Key, remove (2x) of the #10-32 set screws. If the Falcon 500 is being mounted on a
gearbox as an alternative to a CIM / Mini CIM, the two screws should be 180˚ apart.

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Step 2: Align Motor to Mounting Holes
Line up the (2x) open mounting holes on the motor to the mounting holes found wherever you can use a CIM.

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Step 3: Insert #10-32 Mounting Screws into Motor
Insert (2x) #10-32 screws through the mounting surface and into the motor. Secure the screws using a
9/64” hex hey.
WARNING: Mounting screws can go a little over a 1/4” into the motor. Screws that protrude further than
this may interfere with the motor’s rotation.