Contents
Dual Channel High Power Digital Motor Controller
AX3500
User’s Manual
AX3500 Motor Controller User’s Manual
Version 1.9b. June 1
Date
Revision History
Revision History
Version
AX3500 Motor Controller User’s Manual
Revision History
General Operation
SECTION
SECTION
SECTION
SECTION
SECTION
SECTION
Programming using built-in Switches and Display
AX3500 Motor Controller User’s Manual
Do not Connect to a RC Radio with a Battery Attached
Important Safety
Avoid Shorts when Mounting Board against Chassis
Warnings
Important Safety Warnings
Quick Start
Locating the Switches and Connectors
AX3500
What you will need
AX3500 Quick Start
Connecting to the Batteries and Motors
Connecting to the Batteries and Motors
Signal
Connecting to the 15-pin Connector
Important Warning
RC Mode
Connecting the R/C Radio
Powering On the Controller
Connecting the R/C Radio
Button Operation
Prog and Set button status
Function
Default Values
Default Controller Configuration
Default Controller Configuration
Parameter
Connecting the controller to your PC using Roborun
Obtaining the Controller’s Software Revision Number
Obtaining the Controller’s Software Revision Number
Exploring further
= Software version 1.9b
SECTION 3AX3500 Motor Controller Overview
Product Description
Automatic Joystick Command Corrections
Technical features
Multiple Command Modes
AX3500 Motor Controller Overview
High Efficiency Motor Power Outputs
Technical features
Low Power Consumption
Optical Encoder Inputs
Advanced Safety Features
Data Logging Capabilities
Compact Open Frame PCB Design
Connecting Power and Motors to the Controller
Power Connections
Power Connections
Controller Power
Connecting Power and Motors to the Controller
And Main Battery
Controller Power
Power Control input is
mended Off Configuration
Controller Powering Schemes
Powering the Controller from a single Battery
Powering the Controller Using a Main and Backup Battery
Controller Powering Schemes
Connecting the Motors
Single Channel Operation
Converting the AX3500 to Single Channel
Single Channel Operation
Power Fuses
Electrical Noise Reduction Techniques
Wire Length Limits
Power Regeneration Considerations
Wire Length Limits
Overvoltage Protection
Undervoltage Protection
Using the Controller with a Power Supply
Using the Controller with a Power Supply
Connecting Power and Motors to the Controller
Basic Operation
Input Command Modes
General Operation
Basic Operation
Open Loop, Mixed Speed Control
Selecting the Motor Control Modes
Open Loop, Separate Speed Control
General Operation
Closed Loop Speed Control
Close Loop Position Control
Selecting the Motor Control Modes
Position Feedback Position Sensor Gear box
User Selected Current Limit Settings
Temperature-Based Current Limitation
Setting
Motor Current = Battery Current / PWM ratio
Battery Current vs. Motor Current
Battery Current vs. Motor Current
Temperature
Regeneration Current Limiting
Motor Current = Battery Current / PWM Ratio
Switches
Programmable Acceleration
Setting Using
Programmable Acceleration
17.97%
Command Control Curves
15 Hex
0.089 second
Exponentiation Parameter Value
Left / Right Tuning Adjustment
Left / Right Tuning Adjustment
Selected Curve
Speed Adjustment
Parameter Value
Activating Brake Release or Separate Motor Excitation
Emergency Shut Down Using Controller Switches
Emergency Stop using External Switch
Activating Brake Release or Separate Motor Excitation
Using the Inputs to turn Off/On the Power MOSFET transistors
Special Use of Accessory Digital Inputs
Using the Inputs to Activate the Buffered Output
Inverted Operation
Self-Test Mode
Self-Test Mode
Encoder Speed or Position
Connecting Sensors and Actuators to Input/Outputs
AX3500 Connections
AX3500 Connections
AX3500’s Inputs and Outputs
Connecting Sensors and Actuators to Input/Outputs
AX3500’s Inputs and Outputs
I/O type
Activated
Signal depending
Pin1
I/O List and Pin Assignment
Input or
Connecting devices to Output C
Connecting devices to Output C
Connecting Switches or Devices to Input F
Important warning
Connecting Switches or Devices to EStop/Invert Input
Connecting Switches or Devices to EStop/Invert Input
Connecting Position Potentiometers to Analog Inputs
Analog Inputs
Ana2
Connecting Tachometer to Analog Inputs
Connecting Tachometer to Analog Inputs
Operating Mode
Ana 3 p12
Ana 1 p11
Ana2 p10
Ana 4 p8
Temp oC
Connecting External Thermistor to Analog Inputs
Connecting External Thermistor to Analog Inputs
Resistance kOhm
Using the Analog Inputs to Monitor External Voltages
Internal Heatsink Temperature Sensors
Connecting User Devices to Analog Inputs
Internal Voltage Monitoring Sensors
Connecting User Devices to Analog Inputs
Temperature Conversion C Source Code
Value
Analog
LoTemp = i * 5
Internal Heatsink Temperature Sensors
else
HiTemp = LoTemp + 5 lobound = TempTablei hibound = TempTablei+1
Connecting Sensors and Actuators to Input/Outputs
RC Pulses Output
RC Pulse Output Overview
RC Pulse Output Overview
Servo Connection to RevA Controllers
Connector Location and Pinout
Connecting Servos to Controllers
RC Pulses Output
Connecting to Slave Controllers
Servo Connection to RevB Controllers
Connecting to Slave Controllers
Pulse Width 1.00ms
Pulse Timing Information
Command Value
1.50ms
RC Channel Testing Using the PC Utility
RC Channel Testing Using the PC Utility
RC Pulses Output
Connecting and Using the Encoder Function
Optical Incremental Encoders Overview
Optical Incremental Encoders Overview
Recommended Encoder Types
Connecting and Using the Encoder Function
Connecting the Encoder
Connecting the Encoder
Pulse Frequency in Hz = RPM / 60 * PPR
Name
Cable Length and Noise Considerations
Motor - Encoder Polarity Matching
Cable Color
Voltage Levels, Thresholds and Limit Switches
Voltage Levels, Thresholds and Limit Switches
Wiring Optional Limit Switches
Wiring Limit Switches Without Encoders
Wiring Limit Switches Without Encoders
Effect of Limit Switches
Motor 1 Fwd
Motor 2 Fwd
Using the Encoder Module to Measure Distance
Using the Encoder to Measure Speed
Motor 2 Rev
Using the Encoder to Track Position
Important Notice
Using the Encoder to Track Position
The actual formula is as follows
Distance = Destination - Counter value / Divider
Encoder Testing and Setting Using the PC Utility
RS232 Communication with the Encoder Module
RS232 Communication with the Encoder Module
Connecting and Using the Encoder Function
Selecting the Position Mode
Closed Loop Position Mode
Mode Description
Mode Description
Position Feedback Position Sensor Gear box
Position Sensor Selection
Sensor Mounting
Closed Loop Position Mode
Feedback Potentiometer wiring
Feedback Potentiometer wiring in RC or RS232 Mode
Feedback Potentiometer wiring
Feedback Potentiometer wiring in Analog Mode
Analog Feedback on Single Channel Controllers
Feedback Wiring in RC or RS232 Mode on Single Channel Controllers
Feedback Wiring in Analog Mode on Single Channel Controllers
Analog Feedback on Single Channel Controllers
Using Optical Encoders in Position Mode
Sensor and Motor Polarity
Adding Safety Limit Switches
Important Safety Warning
Encoder Error Detection and Protection
Encoder Error Detection and Protection
FIGURE 62. Safety limit switches interrupting power to motors
Using Current Limiting as Protection
Control Loop Description
Using Current Limiting as Protection
PID tuning in Position Mode
PID tuning in Position Mode
Applied Power = Command Value - Actual Position * Proportional Gain
Closed Loop Position Mode
Closed Loop Speed Mode
Selecting the Speed Mode
Tachometer or Encoder Mounting
Using Optical Encoder for Speed FeedbackDigital Optical Encod
Tachometer wiring
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
Normal and Fault Condition LED Messages
Use of the LED Display
Use of the LED Display
Possible Display
Motor Direction Status
Normal and Fault Condition LED Messages
Motor
Fault Messages
Fault Messages
No Control
Rapidly Flashing
Temporary Faults
Permanent Faults
Self-Test Display
= Software version 1.9b
Self-Test Display
Normal and Fault Condition LED Messages
SECTION 12 R/C Operation
Pin1
Connector I/O Pin Assignment R/C Mode
Selecting the R/C Input Mode
R/C Operation
R/C Input Circuit Description
Supplied Cable Description
R/C Input Circuit Description
Powering the Radio from the controller
FIGURE 74. RC Cable wiring diagram
FIGURE 75. RC connection cable
Powering the Radio from the controller
Connecting to a Separately Powered Radio
Operating the Controller in R/C mode
Reception Watchdog
Reception Watchdog
Important Notice about PCM Radios
R/C Transmitter/Receiver Quality Considerations
Deadband Parameter Value
Joystick Deadband Programming
Joystick Deadband Programming
Deadband as Percent of full Joystick Travel
Left/Right Tuning Adjustment
Joystick Calibration
Automatic Joystick Calibration
Automatic Joystick Calibration
Data Logging in R/C Mode
On before entering joystick calibration
Data Logging in R/C Mode
DB15 Male
To Controller
R/C Operation
Analog Control and Operation
Connector I/O Pin Assignment Analog Mode
Analog Control and Operation
Connecting to a Voltage Source
Connecting a Potentiometer
Connecting to a Voltage Source
Selecting the Potentiometer Value
Analog Deadband Adjustment
Data Logging in Analog Mode
Power-On Safety
Under Voltage Safety
Motor Power at 0%
Data Logging in Analog Mode
Analog Control and Operation
Serial RS-232 Controls and Operation
Use and benefits of RS232
Use and benefits of RS232
Connector I/O Pin Assignment RS232 Mode
Serial RS-232 Controls and Operation
Cable configuration
Extending the RS232 Cable
Cable configuration
Communication Settings
9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity
Establishing Manual Communication with a PC
RS232 Communication with the Encoder Module
Establishing Manual Communication with a PC
Roboteq v1.9b 06/01/07 s
Entering RS232 from R/C or Analog mode
Data Logging String in R/C or Analog mode
Command Acknowledgement
Commands Acknowledge and Error Messages
RS232 Mode if default
Command Error
Command
Controller Commands and Queries
RS-232 Watchdog
Type
Query Power Applied to Motors
Set Motor Command Value
Set Accessory Output
Controller Commands and Queries
Query Amps from Battery to each Motor Channel
Syntax
?r or ?R
Query Analog Inputs
Query Heatsink Temperatures
?m or ?M
Query Digital Inputs
Query Battery Voltages
Reset Controller
Examples
Accessing & Changing Configuration Parameter in Flash
Accessing & Changing Configuration Parameter in Flash
Apply Parameter Changes
Read parameter
Flash Configuration Parameters List
Location
Active after
Access
Input Control Mode
Motor Control Mode
After Reset
Amps Limit
Acceleration
Definition
Input Switches Function
Exponentiation on Channel 1 and Channel
Left/Right Adjust
RC Joystick or Analog Deadband
08 - Channel
0B - Encoder
Default Encoder Time Base 1 and
Default Encoder Distance Divider
0C - Encoder
0F - Proportional Gain
Default PID Gains
Joystick Min, Max and Center Values
10 - Integral Gain
Reading & Changing Operating Parameters at Runtime
Reading & Changing Operating Parameters at Runtime
Access Read/Write Effective Instantly
Operating Modes Registers
Read/Change PID Values
80 - Channel
Address Access Read/Write Effective Instantly
PWM Frequency Register
Controller Status Register
Fault Condition
Model or Function
Controller Identification Register
Current Amps Limit Registers
8B - Channel
Read Encoder Counter
RS232 Encoder Command Set
Set/Reset Encoder Counters and Destination Registers
RS232 Encoder Command Set
7 Set Encoder 1 destination register with value in buffer
Read Speed
q or !Q n
8 Set Encoder 2 destination register with value in buffer
Read Encoder Limit Switch Status
Read Distance
Read Speed/Distance
Switch
Important Note
Read / Modify Encoder Module Registers and Parameters
n Value
Parameter Description
Size
Encoder Hardware ID code
Switch Status
Register Description
Address *84
Counter 1 and
Speed or Distance 1 or
Counter Read/Write Mailbox
Destination Register 1 and
Time Base 1 and
Distance 1 and
Speed 1 and
Encoder Threshold
Default Value
Counter Read Data Format
RC Pulse Outputs Activation
Counter Read Data Format
Decimal
32-bit Hex
Controller Output
Automatic Switching from RS232 to RC Mode
Automatic Switching from RS232 to RC Mode
00 11 22 33 44 55 66 77 88 99 AA BB CC
Analog and R/C Modes Data Logging String Format
Data Logging Cables
Decimal to Hexadecimal Conversion Table
Decimal to Hexadecimal Conversion Table
AX3500 Motor Controller User’s Manual
Decimal to Hexadecimal Conversion Table
AX3500 Motor Controller User’s Manual
AX3500 Motor Controller User’s Manual
SECTION 15 Configuring the Controller using the Switches
Programming using built-in Switches and Display
Programming Methods
Entering Programming Mode
Configuring the Controller using the Switches
Program
Changing parameters
The Special Case of Joystick Calibration
Programming using built-in Switches and Display
Programmable Parameters List
Restoring factory defaults
Exiting the Parameter Setting Mode
This manual is for software version 1.9b
cannot be selected using the switches
Possible Values default
For safety reasons, the modes below
Programmable Parameters List
Order
SECTION 16 Using the Roborun Configuration Utility
Downloading and Installing the Utility
System Requirements
Connecting the Controller to the PC
Using the Roborun Configuration Utility
1- Program Revision Number
Roborun Frame, Tab and Menu Descriptions
Roborun Frame, Tab and Menu Descriptions
2- Controller and Communication Link Information
4- File and Program Management Commands
Getting On-Screen Help
3- Parameter Selection and Setting and Special Functions
5- View Controller Connector Pinout
Loading, Changing Controller Parameters
Control Settings
Loading, Changing Controller Parameters
1- Controller Input
4- Emergency Stop or Invert Switch Select
Power Settings
3- Input Command Adjustment
5- Effect of Digital Inputs
3- Acceleration Setting
Analog or R/C Specific Settings
Loading, Changing Controller Parameters 2- Left/Right Adjust
1- Deadband
Encoder Setting and Testing
Closed Loop Parameters
Encoder Module Parameters Setting
Encoder Setting and Testing
RC Output Testing
Exercising the Motors
Viewing Encoder Data
Running the Motors
Running the Motors
2- Motor Power setting
1- Run/Stop Button
3- Measurement
4- Real-Time Strip Chart Recorder
6- Input Status and Output Setting
5- Transmit and Receive Data
8- Joystick Enable
Logging Data to Disk
7- Data Logging and Timer
4- Reset Timer button
Data type/range
Connecting a Joystick
Parameter Header
Measured Parameter
Using the Console
2- Command Entry
1- Terminal Screen
4- Send Reset String
Viewing and Logging Data in Analog and R/C Modes
Loading and Saving Profiles to Disk
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
Creating Customized Object Files
Updating the Encoder Software
Creating Customized Object Files
Using the Roborun Configuration Utility
Mechanical Specifications
Mechanical Dimensions
Mechanical Dimensions
Mounting Considerations
Thermal Considerations
Mechanical Specifications
Attaching the Controller Directly to a Chassis
Attaching the Controller Directly to a Chassis
Precautions to observe
Wire Dimensions
Weight
Wire Dimensions
Mechanical Specifications
AX3500 Motor Controller User’s Manual
Version 1.9b. June 1