Connecting Power and Motors to the Controller

Contents

User’s Manual Dual Channel High Power Digital Motor ControllerAX3500 Version 1.9b. June 1 AX3500 Motor Controller User’s Manual Revision History Revision HistoryDate Version Version 1.9b. June 1 Revision History General Operation SECTION SECTIONSECTION SECTION SECTION SECTION Programming using built-in Switches and Display Version 1.9b. June 1 Avoid Shorts when Mounting Board against Chassis Important SafetyDo not Connect to a RC Radio with a Battery Attached Warnings Important Safety Warnings AX3500 Locating the Switches and ConnectorsQuick Start What you will need AX3500 Quick Start Connecting to the Batteries and Motors Connecting to the Batteries and Motors Important Warning Connecting to the 15-pin ConnectorSignal RC Mode Connecting the R/C Radio Connecting the R/C RadioPowering On the Controller Function Button OperationProg and Set button status Default Controller Configuration Default Controller ConfigurationDefault Values Parameter Connecting the controller to your PC using Roborun Obtaining the Controller’s Software Revision Number Obtaining the Controller’s Software Revision Number = Software version 1.9b Exploring further Product Description SECTION 3AX3500 Motor Controller Overview Multiple Command Modes Technical featuresAutomatic Joystick Command Corrections AX3500 Motor Controller Overview Low Power Consumption Technical featuresHigh Efficiency Motor Power Outputs Optical Encoder Inputs Compact Open Frame PCB Design Advanced Safety FeaturesData Logging Capabilities Power Connections Connecting Power and Motors to the ControllerPower Connections Connecting Power and Motors to the Controller Controller Power Power Control input is Controller PowerAnd Main Battery mended Off Configuration Powering the Controller from a single Battery Controller Powering Schemes Controller Powering Schemes Powering the Controller Using a Main and Backup Battery Connecting the Motors Single Channel Operation Single Channel OperationConverting the AX3500 to Single Channel Power Fuses Power Regeneration Considerations Wire Length LimitsElectrical Noise Reduction Techniques Wire Length Limits Undervoltage Protection Overvoltage Protection Using the Controller with a Power Supply Using the Controller with a Power Supply Version 1.9b. June 1 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-Based Current Limitation User Selected Current Limit SettingsPosition Feedback Position Sensor Gear box Setting Battery Current vs. Motor Current Battery Current vs. Motor CurrentMotor Current = Battery Current / PWM ratio Temperature Motor Current = Battery Current / PWM Ratio Regeneration Current Limiting Setting Using Programmable AccelerationSwitches Programmable Acceleration 15 Hex Command Control Curves17.97% 0.089 second Left / Right Tuning Adjustment Left / Right Tuning AdjustmentExponentiation Parameter Value Selected Curve Parameter Value Speed Adjustment Emergency Stop using External Switch Emergency Shut Down Using Controller SwitchesActivating Brake Release or Separate Motor Excitation Activating Brake Release or Separate Motor Excitation Using the Inputs to Activate the Buffered Output Special Use of Accessory Digital InputsUsing the Inputs to turn Off/On the Power MOSFET transistors Inverted Operation Self-Test Mode Self-Test Mode Encoder Speed or Position AX3500 Connections Connecting Sensors and Actuators to Input/OutputsAX3500 Connections Connecting Sensors and Actuators to Input/Outputs AX3500’s Inputs and Outputs Activated AX3500’s Inputs and OutputsI/O type I/O List and Pin Assignment Pin1Signal depending Input or Connecting devices to Output C Connecting devices to Output C Important warning Connecting Switches or Devices to Input F Connecting Switches or Devices to EStop/Invert Input Connecting Switches or Devices to EStop/Invert Input Analog Inputs Connecting Position Potentiometers to Analog Inputs Connecting Tachometer to Analog Inputs Connecting Tachometer to Analog InputsAna2 Operating Mode Ana2 p10 Ana 1 p11Ana 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 Connecting User Devices to Analog Inputs Analog Temperature Conversion C Source CodeValue else Internal Heatsink Temperature SensorsLoTemp = i * 5 HiTemp = LoTemp + 5 lobound = TempTablei hibound = TempTablei+1 Version 1.9b. June 1 RC Pulse Output Overview RC Pulses OutputRC Pulse Output Overview Connecting Servos to Controllers Connector Location and PinoutServo Connection to RevA Controllers RC Pulses Output Connecting to Slave Controllers Connecting to Slave ControllersServo Connection to RevB Controllers Command Value Pulse Timing InformationPulse Width 1.00ms 1.50ms RC Channel Testing Using the PC Utility RC Channel Testing Using the PC Utility Version 1.9b. June 1 Optical Incremental Encoders Overview Connecting and Using the Encoder FunctionOptical Incremental Encoders Overview Connecting and Using the Encoder Function Recommended Encoder Types Pulse Frequency in Hz = RPM / 60 * PPR Connecting the EncoderConnecting the Encoder Motor - Encoder Polarity Matching Cable Length and Noise ConsiderationsName Cable Color Voltage Levels, Thresholds and Limit Switches Voltage Levels, Thresholds and Limit Switches Wiring Optional Limit Switches Effect of Limit Switches Wiring Limit Switches Without EncodersWiring Limit Switches Without Encoders Motor 1 Fwd Using the Encoder to Measure Speed Using the Encoder Module to Measure DistanceMotor 2 Fwd Motor 2 Rev Using the Encoder to Track Position Using the Encoder to Track PositionImportant Notice Distance = Destination - Counter value / Divider The actual formula is as follows RS232 Communication with the Encoder Module Encoder Testing and Setting Using the PC UtilityRS232 Communication with the Encoder Module Version 1.9b. June 1 Mode Description Closed Loop Position ModeSelecting the Position Mode Mode Description Sensor Mounting Position Sensor SelectionPosition Feedback Position Sensor Gear box Closed Loop Position Mode Feedback Potentiometer wiring Feedback Potentiometer wiringFeedback Potentiometer wiring in RC or RS232 Mode Feedback Potentiometer wiring in Analog Mode Feedback Wiring in Analog Mode on Single Channel Controllers Feedback Wiring in RC or RS232 Mode on Single Channel ControllersAnalog Feedback on Single Channel Controllers Analog Feedback on Single Channel Controllers Sensor and Motor Polarity Using Optical Encoders in Position Mode Encoder Error Detection and Protection Important Safety WarningAdding Safety Limit Switches Encoder Error Detection and Protection FIGURE 62. Safety limit switches interrupting power to motors Using Current Limiting as Protection Using Current Limiting as ProtectionControl Loop Description PID tuning in Position Mode Applied Power = Command Value - Actual Position * Proportional Gain PID tuning in Position Mode Version 1.9b. June 1 Selecting the Speed Mode Closed Loop Speed Mode Tachometer wiring Using Optical Encoder for Speed FeedbackDigital Optical EncodTachometer or Encoder Mounting Closed Loop Speed Mode Speed Sensor and Motor Polarity Speed Sensor and Motor Polarity Adjust Offset and Max Speed PID tuning in Speed Mode PID tuning in Speed Mode In Speed Mode, the Integral component of the PID is the most important and must be set first. The Proportional and Differential component will help improve the response time and loop stability Use of the LED Display Normal and Fault Condition LED MessagesUse of the LED Display Normal and Fault Condition LED Messages Motor Direction StatusPossible Display Motor No Control Fault MessagesFault Messages Rapidly Flashing Self-Test Display Temporary FaultsPermanent Faults Self-Test Display = Software version 1.9b Version 1.9b. June 1 SECTION 12 R/C Operation Selecting the R/C Input Mode Connector I/O Pin Assignment R/C ModePin1 R/C Operation R/C Input Circuit Description R/C Input Circuit DescriptionSupplied Cable Description FIGURE 75. RC connection cable Powering the Radio from the controllerFIGURE 74. RC Cable wiring diagram Powering the Radio from the controller Operating the Controller in R/C mode Connecting to a Separately Powered Radio Reception Watchdog Reception Watchdog R/C Transmitter/Receiver Quality Considerations Important Notice about PCM Radios Joystick Deadband Programming Joystick Deadband ProgrammingDeadband Parameter Value Deadband as Percent of full Joystick Travel Joystick Calibration Left/Right Tuning Adjustment Automatic Joystick Calibration Automatic Joystick Calibration On before entering joystick calibration Data Logging in R/C Mode To Controller Data Logging in R/C ModeDB15 Male Version 1.9b. June 1 Analog Control and Operation Analog Control and Operation Connector I/O Pin Assignment Analog Mode Connecting to a Voltage Source Connecting to a Voltage SourceConnecting a Potentiometer Selecting the Potentiometer Value Analog Deadband Adjustment Under Voltage Safety Power-On SafetyData Logging in Analog Mode Motor Power at 0% Data Logging in Analog Mode Version 1.9b. June 1 Use and benefits of RS232 Serial RS-232 Controls and OperationUse and benefits of RS232 Serial RS-232 Controls and Operation Connector I/O Pin Assignment RS232 Mode Cable configuration Cable configurationExtending the RS232 Cable Establishing Manual Communication with a PC Communication Settings9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Roboteq v1.9b 06/01/07 s RS232 Communication with the Encoder ModuleEstablishing Manual Communication with a PC Data Logging String in R/C or Analog mode Entering RS232 from R/C or Analog mode RS232 Mode if default Commands Acknowledge and Error MessagesCommand Acknowledgement Command Error RS-232 Watchdog Controller Commands and QueriesCommand Type Set Accessory Output Set Motor Command ValueQuery Power Applied to Motors Controller Commands and Queries Syntax Query Amps from Battery to each Motor Channel Query Heatsink Temperatures Query Analog Inputs?r or ?R ?m or ?M Reset Controller Query Battery VoltagesQuery Digital Inputs Examples Apply Parameter Changes Accessing & Changing Configuration Parameter in FlashAccessing & Changing Configuration Parameter in Flash Read parameter Active after Flash Configuration Parameters ListLocation Motor Control Mode Input Control ModeAccess After Reset Definition Amps LimitAcceleration Input Switches Function RC Joystick or Analog Deadband Left/Right AdjustExponentiation on Channel 1 and Channel 08 - Channel Default Encoder Distance Divider Default Encoder Time Base 1 and0B - Encoder 0C - Encoder Joystick Min, Max and Center Values Default PID Gains0F - Proportional Gain 10 - Integral Gain Reading & Changing Operating Parameters at Runtime Reading & Changing Operating Parameters at Runtime Read/Change PID Values Operating Modes RegistersAccess Read/Write Effective Instantly 80 - Channel Controller Status Register PWM Frequency RegisterAddress Access Read/Write Effective Instantly Fault Condition Current Amps Limit Registers Controller Identification RegisterModel or Function 8B - Channel Set/Reset Encoder Counters and Destination Registers RS232 Encoder Command SetRead Encoder Counter RS232 Encoder Command Set q or !Q n Read Speed7 Set Encoder 1 destination register with value in buffer 8 Set Encoder 2 destination register with value in buffer Read Speed/Distance Read Encoder Limit Switch StatusRead Distance Read / Modify Encoder Module Registers and Parameters Important NoteSwitch n Value Size Parameter Description Register Description Switch StatusEncoder Hardware ID code Address *84 Counter Read/Write Mailbox Speed or Distance 1 orCounter 1 and Destination Register 1 and Speed 1 and Distance 1 andTime Base 1 and Encoder Threshold RC Pulse Outputs Activation Counter Read Data FormatDefault Value Counter Read Data Format Controller Output Decimal32-bit Hex Automatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC Mode Data Logging Cables 00 11 22 33 44 55 66 77 88 99 AA BB CCAnalog and R/C Modes Data Logging String Format Decimal to Hexadecimal Conversion Table Decimal to Hexadecimal Conversion Table AX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Decimal to Hexadecimal Conversion Table Version 1.9b. June 1 Programming Methods SECTION 15 Configuring the Controller using the SwitchesProgramming using built-in Switches and Display Program Entering Programming ModeConfiguring the Controller using the Switches Programming using built-in Switches and Display Changing parametersThe Special Case of Joystick Calibration Exiting the Parameter Setting Mode Restoring factory defaultsProgrammable Parameters List This manual is for software version 1.9b For safety reasons, the modes below Possible Values defaultcannot be selected using the switches Programmable Parameters List Possible Values default System Requirements SECTION 16 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 Roborun Frame, Tab and Menu Descriptions1- Program Revision Number 2- Controller and Communication Link Information 3- Parameter Selection and Setting and Special Functions Getting On-Screen Help4- File and Program Management Commands 5- View Controller Connector Pinout Loading, Changing Controller Parameters Control SettingsLoading, Changing Controller Parameters 1- Controller Input 3- Input Command Adjustment Power Settings4- Emergency Stop or Invert Switch Select 5- Effect of Digital Inputs Loading, Changing Controller Parameters 2- Left/Right Adjust Analog or R/C Specific Settings3- Acceleration Setting 1- Deadband Closed Loop Parameters Encoder Setting and Testing Encoder Setting and Testing Encoder Module Parameters Setting Viewing Encoder Data RC Output TestingExercising the Motors Running the Motors Running the Motors 3- Measurement 2- Motor Power setting1- Run/Stop Button 5- Transmit and Receive Data 4- Real-Time Strip Chart Recorder6- Input Status and Output Setting 7- Data Logging and Timer Logging Data to Disk8- Joystick Enable 4- Reset Timer button Parameter Header Connecting a JoystickData type/range Measured Parameter 1- Terminal Screen Using the Console2- Command Entry Loading and Saving Profiles to Disk Viewing and Logging Data in Analog and R/C Modes4- Send Reset String Viewing and Logging Data in Analog and R/C Modes Operating the AX3500 over a Wired or Wireless LAN Updating the Controller’s Software Updating the Controller’s Software Updating the Encoder Software Creating Customized Object Files Creating Customized Object Files Version 1.9b. June 1 Mechanical Dimensions Mechanical SpecificationsMechanical Dimensions Mechanical Specifications Mounting ConsiderationsThermal Considerations Attaching the Controller Directly to a Chassis Attaching the Controller Directly to a Chassis Precautions to observe Wire Dimensions Wire DimensionsWeight Version 1.9b. June 1 Mechanical SpecificationsAX3500 Motor Controller User’s Manual

RoboteQ AX3500 user manual Connecting Power and Motors to the Controller, Power Connections

Models: AX3500