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