RoboteQ Revision History, Date, Version, Changes, AX3500 Motor Controller User’s Manual

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Revision History

Revision History

Revision History

Date	Version	Changes

June 1, 2007	1.9b	Added Output C active when Motors On
		Fixed Encoder Limit Switches
		Protection in case of Encoder failure in Closed Loop Speed
		Added Short Circuit Protection (with supporting hardware)
		Added Analog 3 and 4 Inputs (with supporting hardware)
		Added Operating Mode Change on-the-fly
		Changeable PWM frequency
		Selectable polarity for Dead Man Switch
		Modified Flashing Pattern
		Separate PID Gains for Ch1 and C2, changeable on-the-fly
		Miscellaneous additions and correction
		Added Amps Calibration option

January 10, 2007	1.9	Changed Amps Limit Algorithm
		Miscellaneous additions and correction
		Console Mode in Roborun

March 7, 2005	1.7b	Updated Encoder section.

February 1, 2005	1.7	Added Position mode support with Optical Encoder
		Miscellaneous additions and corrections

April 17, 2004	1.6	Added Optical Encoder support

March 15, 2004	1.5	Added finer Amps limit settings
		Enhanced Roborun utility

August 25, 2003	1.3	Added Closed Loop Speed mode
		Added Data Logging support
		Removed RC monitoring

August 15, 2003	1.2	Modified to cover AX3500 controller design
		Changed Power Connection section

April 15, 2003	1.1	Added analog mode section
		Added position mode section
		Added RCRC monitoring feature
		Updated Roborun utility section
		Modified RS232 watchdog

March 15, 2003	1.0	Initial Release

The information contained in this manual is believed to be accurate and reliable. However, it may contain errors that were not noticed at time of publication. User’s are expected to perform their own product validation and not rely solely on data contained in this manual.

AX3500 Motor Controller User’s Manual

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Contents Dual Channel High Power Digital Motor Controller AX3500User’s Manual Version 1.9b. June 1 AX3500 Motor Controller User’s ManualVersion Revision HistoryRevision History DateVersion 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 Warnings Important SafetyAvoid Shorts when Mounting Board against Chassis Do not Connect to a RC Radio with a Battery AttachedImportant Safety Warnings What you will need Locating the Switches and ConnectorsAX3500 Quick StartAX3500 Quick Start Connecting to the Batteries and Motors Connecting to the Batteries and MotorsRC Mode Connecting to the 15-pin ConnectorImportant Warning SignalConnecting the R/C Radio Powering On the ControllerConnecting the R/C Radio Button Operation Prog and Set button statusFunction Parameter Default Controller ConfigurationDefault Controller Configuration Default ValuesConnecting 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 furtherProduct Description SECTION 3AX3500 Motor Controller OverviewAX3500 Motor Controller Overview Technical featuresMultiple Command Modes Automatic Joystick Command CorrectionsOptical Encoder Inputs Technical featuresLow Power Consumption High Efficiency Motor Power OutputsAdvanced Safety Features Data Logging CapabilitiesCompact Open Frame PCB Design Connecting Power and Motors to the Controller Power ConnectionsPower Connections Connecting Power and Motors to the Controller Controller Powermended Off Configuration Controller PowerPower Control input is And Main BatteryPowering the Controller from a single Battery Controller Powering SchemesController Powering Schemes Powering the Controller Using a Main and Backup BatteryConnecting the Motors Single Channel Operation Converting the AX3500 to Single ChannelSingle Channel Operation Power Fuses Wire Length Limits Wire Length LimitsPower Regeneration Considerations Electrical Noise Reduction TechniquesUndervoltage Protection Overvoltage ProtectionUsing the Controller with a Power Supply Using the Controller with a Power SupplyConnecting Power and Motors to the Controller Basic Operation Input Command ModesGeneral Operation Basic OperationGeneral Operation Selecting the Motor Control ModesOpen Loop, Separate Speed Control Open Loop, Mixed Speed ControlClosed Loop Speed Control Close Loop Position ControlSelecting the Motor Control Modes Setting User Selected Current Limit SettingsTemperature-Based Current Limitation Position Feedback Position Sensor Gear boxTemperature Battery Current vs. Motor CurrentBattery Current vs. Motor Current Motor Current = Battery Current / PWM ratioMotor Current = Battery Current / PWM Ratio Regeneration Current LimitingProgrammable Acceleration Programmable AccelerationSetting Using Switches0.089 second Command Control Curves15 Hex 17.97%Selected Curve Left / Right Tuning AdjustmentLeft / Right Tuning Adjustment Exponentiation Parameter ValueParameter Value Speed AdjustmentActivating Brake Release or Separate Motor Excitation Emergency Shut Down Using Controller SwitchesEmergency Stop using External Switch Activating Brake Release or Separate Motor ExcitationInverted Operation Special Use of Accessory Digital InputsUsing the Inputs to Activate the Buffered Output Using the Inputs to turn Off/On the Power MOSFET transistorsSelf-Test Mode Self-Test ModeEncoder Speed or Position Connecting Sensors and Actuators to Input/Outputs AX3500 ConnectionsAX3500 Connections Connecting Sensors and Actuators to Input/Outputs AX3500’s Inputs and OutputsAX3500’s Inputs and Outputs I/O typeActivated Input or Pin1I/O List and Pin Assignment Signal dependingConnecting devices to Output C Connecting devices to Output CImportant warning Connecting Switches or Devices to Input FConnecting Switches or Devices to EStop/Invert Input Connecting Switches or Devices to EStop/Invert InputAnalog Inputs Connecting Position Potentiometers to Analog InputsOperating Mode Connecting Tachometer to Analog InputsConnecting Tachometer to Analog Inputs Ana2Ana 4 p8 Ana 1 p11Ana2 p10 Ana 3 p12Resistance kOhm Connecting External Thermistor to Analog InputsConnecting External Thermistor to Analog Inputs Temp oCUsing the Analog Inputs to Monitor External Voltages Connecting User Devices to Analog Inputs Connecting User Devices to Analog InputsInternal Voltage Monitoring Sensors Internal Heatsink Temperature SensorsTemperature Conversion C Source Code ValueAnalog HiTemp = LoTemp + 5 lobound = TempTablei hibound = TempTablei+1 Internal Heatsink Temperature Sensorselse LoTemp = i * 5Connecting Sensors and Actuators to Input/Outputs RC Pulses Output RC Pulse Output OverviewRC Pulse Output Overview RC Pulses Output Connector Location and PinoutConnecting Servos to Controllers Servo Connection to RevA ControllersConnecting to Slave Controllers Servo Connection to RevB ControllersConnecting to Slave Controllers 1.50ms Pulse Timing InformationCommand Value Pulse Width 1.00msRC Channel Testing Using the PC Utility RC Channel Testing Using the PC UtilityRC Pulses Output Connecting and Using the Encoder Function Optical Incremental Encoders OverviewOptical Incremental Encoders Overview Connecting and Using the Encoder Function Recommended Encoder TypesConnecting the Encoder Connecting the EncoderPulse Frequency in Hz = RPM / 60 * PPR Cable Color Cable Length and Noise ConsiderationsMotor - Encoder Polarity Matching NameVoltage Levels, Thresholds and Limit Switches Voltage Levels, Thresholds and Limit SwitchesWiring Optional Limit Switches Motor 1 Fwd Wiring Limit Switches Without EncodersEffect of Limit Switches Wiring Limit Switches Without EncodersMotor 2 Rev Using the Encoder Module to Measure DistanceUsing the Encoder to Measure Speed Motor 2 FwdUsing the Encoder to Track Position Important NoticeUsing the Encoder to Track Position Distance = Destination - Counter value / Divider The actual formula is as followsEncoder Testing and Setting Using the PC Utility RS232 Communication with the Encoder ModuleRS232 Communication with the Encoder Module Connecting and Using the Encoder Function Mode Description Closed Loop Position ModeMode Description Selecting the Position ModeClosed Loop Position Mode Position Sensor SelectionSensor Mounting Position Feedback Position Sensor Gear boxFeedback Potentiometer wiring Feedback Potentiometer wiring in RC or RS232 ModeFeedback Potentiometer wiring Feedback Potentiometer wiring in Analog Mode Analog Feedback on Single Channel Controllers Feedback Wiring in RC or RS232 Mode on Single Channel ControllersFeedback Wiring in Analog Mode on Single Channel Controllers Analog Feedback on Single Channel ControllersSensor and Motor Polarity Using Optical Encoders in Position ModeEncoder Error Detection and Protection Important Safety WarningEncoder Error Detection and Protection Adding Safety Limit SwitchesFIGURE 62. Safety limit switches interrupting power to motors Using Current Limiting as Protection Control Loop DescriptionUsing Current Limiting as Protection PID tuning in Position Mode Applied Power = Command Value - Actual Position * Proportional Gain PID tuning in Position ModeClosed Loop Position Mode Selecting the Speed Mode Closed Loop Speed ModeClosed Loop Speed Mode Using Optical Encoder for Speed FeedbackDigital Optical EncodTachometer wiring Tachometer or Encoder MountingSpeed Sensor and Motor Polarity Speed Sensor and Motor PolarityAdjust Offset and Max Speed PID tuning in Speed Mode PID tuning in Speed ModeIn 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 DisplayUse of the LED Display Motor Motor Direction StatusNormal and Fault Condition LED Messages Possible DisplayRapidly Flashing Fault MessagesNo Control Fault MessagesTemporary Faults Permanent FaultsSelf-Test Display Self-Test Display = Software version 1.9bNormal and Fault Condition LED Messages SECTION 12 R/C Operation R/C Operation Connector I/O Pin Assignment R/C ModeSelecting the R/C Input Mode Pin1R/C Input Circuit Description Supplied Cable DescriptionR/C Input Circuit Description Powering the Radio from the controller FIGURE 74. RC Cable wiring diagramFIGURE 75. RC connection cable Powering the Radio from the controller Operating the Controller in R/C mode Connecting to a Separately Powered RadioReception Watchdog Reception WatchdogR/C Transmitter/Receiver Quality Considerations Important Notice about PCM RadiosDeadband as Percent of full Joystick Travel Joystick Deadband ProgrammingJoystick Deadband Programming Deadband Parameter ValueJoystick Calibration Left/Right Tuning AdjustmentAutomatic Joystick Calibration Automatic Joystick CalibrationOn before entering joystick calibration Data Logging in R/C ModeData Logging in R/C Mode DB15 MaleTo Controller R/C Operation Analog Control and Operation Analog Control and Operation Connector I/O Pin Assignment Analog ModeConnecting to a Voltage Source Connecting a PotentiometerConnecting to a Voltage Source Selecting the Potentiometer Value Analog Deadband Adjustment Motor Power at 0% Power-On SafetyUnder Voltage Safety Data Logging in Analog ModeData Logging in Analog Mode Analog Control and Operation Serial RS-232 Controls and Operation Use and benefits of RS232Use and benefits of RS232 Serial RS-232 Controls and Operation Connector I/O Pin Assignment RS232 ModeCable configuration Extending the RS232 CableCable configuration Communication Settings 9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even ParityEstablishing Manual Communication with a PC RS232 Communication with the Encoder Module Establishing Manual Communication with a PCRoboteq v1.9b 06/01/07 s Data Logging String in R/C or Analog mode Entering RS232 from R/C or Analog modeCommand Error Commands Acknowledge and Error MessagesRS232 Mode if default Command AcknowledgementType Controller Commands and QueriesRS-232 Watchdog CommandController Commands and Queries Set Motor Command ValueSet Accessory Output Query Power Applied to MotorsSyntax Query Amps from Battery to each Motor Channel?m or ?M Query Analog InputsQuery Heatsink Temperatures ?r or ?RExamples Query Battery VoltagesReset Controller Query Digital InputsRead parameter Accessing & Changing Configuration Parameter in FlashApply Parameter Changes Accessing & Changing Configuration Parameter in FlashFlash Configuration Parameters List LocationActive after After Reset Input Control ModeMotor Control Mode AccessAmps Limit AccelerationDefinition Input Switches Function 08 - Channel Left/Right AdjustRC Joystick or Analog Deadband Exponentiation on Channel 1 and Channel0C - Encoder Default Encoder Time Base 1 andDefault Encoder Distance Divider 0B - Encoder10 - Integral Gain Default PID GainsJoystick Min, Max and Center Values 0F - Proportional GainReading & Changing Operating Parameters at Runtime Reading & Changing Operating Parameters at Runtime80 - Channel Operating Modes RegistersRead/Change PID Values Access Read/Write Effective InstantlyFault Condition PWM Frequency RegisterController Status Register Address Access Read/Write Effective Instantly8B - Channel Controller Identification RegisterCurrent Amps Limit Registers Model or FunctionRS232 Encoder Command Set RS232 Encoder Command SetSet/Reset Encoder Counters and Destination Registers Read Encoder Counter8 Set Encoder 2 destination register with value in buffer Read Speedq or !Q n 7 Set Encoder 1 destination register with value in bufferRead Encoder Limit Switch Status Read DistanceRead Speed/Distance n Value Important NoteRead / Modify Encoder Module Registers and Parameters SwitchSize Parameter DescriptionAddress *84 Switch StatusRegister Description Encoder Hardware ID codeDestination Register 1 and Speed or Distance 1 orCounter Read/Write Mailbox Counter 1 andEncoder Threshold Distance 1 andSpeed 1 and Time Base 1 andCounter Read Data Format Counter Read Data FormatRC Pulse Outputs Activation Default ValueDecimal 32-bit HexController Output Automatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC Mode00 11 22 33 44 55 66 77 88 99 AA BB CC Analog and R/C Modes Data Logging String FormatData Logging Cables Decimal to Hexadecimal Conversion Table Decimal to Hexadecimal Conversion TableAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Decimal to Hexadecimal Conversion TableVersion 1.9b. June 1 SECTION 15 Configuring the Controller using the Switches Programming using built-in Switches and DisplayProgramming Methods Entering Programming Mode Configuring the Controller using the SwitchesProgram Changing parameters The Special Case of Joystick CalibrationProgramming using built-in Switches and Display This manual is for software version 1.9b Restoring factory defaultsExiting the Parameter Setting Mode Programmable Parameters ListProgrammable Parameters List Possible Values defaultFor safety reasons, the modes below cannot be selected using the switchesLetter SECTION 16 Using the Roborun Configuration Utility Downloading and Installing the UtilitySystem Requirements Using the Roborun Configuration Utility Connecting the Controller to the PC2- Controller and Communication Link Information Roborun Frame, Tab and Menu DescriptionsRoborun Frame, Tab and Menu Descriptions 1- Program Revision Number5- View Controller Connector Pinout Getting On-Screen Help3- Parameter Selection and Setting and Special Functions 4- File and Program Management Commands1- Controller Input Control SettingsLoading, Changing Controller Parameters Loading, Changing Controller Parameters5- Effect of Digital Inputs Power Settings3- Input Command Adjustment 4- Emergency Stop or Invert Switch Select1- Deadband Analog or R/C Specific SettingsLoading, Changing Controller Parameters 2- Left/Right Adjust 3- Acceleration SettingClosed Loop Parameters Encoder Setting and TestingEncoder Setting and Testing Encoder Module Parameters SettingRC Output Testing Exercising the MotorsViewing Encoder Data Running the Motors Running the Motors2- Motor Power setting 1- Run/Stop Button3- Measurement 4- Real-Time Strip Chart Recorder 6- Input Status and Output Setting5- Transmit and Receive Data 4- Reset Timer button Logging Data to Disk7- Data Logging and Timer 8- Joystick EnableMeasured Parameter Connecting a JoystickParameter Header Data type/rangeUsing the Console 2- Command Entry1- Terminal Screen Viewing and Logging Data in Analog and R/C Modes Viewing and Logging Data in Analog and R/C ModesLoading and Saving Profiles to Disk 4- Send Reset StringOperating the AX3500 over a Wired or Wireless LAN Updating the Controller’s Software Updating the Controller’s SoftwareUpdating the Encoder Software Creating Customized Object FilesCreating Customized Object Files Using the Roborun Configuration Utility Mechanical Specifications Mechanical DimensionsMechanical Dimensions Mounting Considerations Thermal ConsiderationsMechanical Specifications Attaching the Controller Directly to a Chassis Attaching the Controller Directly to a ChassisPrecautions to observe Wire Dimensions WeightWire Dimensions Mechanical Specifications AX3500 Motor Controller User’s ManualVersion 1.9b. June 1

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