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RoboteQ AX3500 user manual Important Safety, Warnings, Read this Section First

Models: AX3500

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Important Safety

	Important Safety
SECTION 1	Important Safety
	Warnings

Read this Section First

The AX3500 is a high power electronics device. Serious damage, including fire, may occur to the unit, motors, wiring and batteries as a result of its misuse. Transistors may explode and require the use of safety glasses when operated in direct view. Please review the User’s Manual for added precautions prior to applying full battery or full load power.

This product is intended for use with rechargeable batteries

Unless special precautions are taken, damage to the controller and/or power supply may occur if operated with a power supply alone. See“Power Regeneration Consid- erations” on page 37 of the Users Manual. Always keep the controller connected to the Battery. Use the Power Control input to turn On/Off.

Avoid Shorts when Mounting Board against Chassis

Use precautions to avoid short circuits when mounting the board against a metallic chassis with the heat sink on or removed. See “Attaching the Controller Directly to a Chassis” on page 205.

Do not Connect to a RC Radio with a Battery Attached

Without proper protection, a battery attached to an RC Radio may inject its voltage directly inside the controller’s sensitive electronics. See

Beware of Motor Runaway in Improperly Closed Loop

Wiring or polarity errors between the feedback device and motor in position or closed loop position mode may cause the controller to runaway with no possibility to stop it until power is turned off.

AX3500 Motor Controller User’s Manual

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RoboteQ AX3500 Important Safety, Warnings, Read this Section First, Avoid Shorts when Mounting Board against Chassis

Contents

AX3500 Dual Channel High Power Digital Motor ControllerUser’s Manual Version 1.9b. June 1 AX3500 Motor Controller User’s ManualRevision History Revision HistoryDate VersionVersion 1.9b. June 1 AX3500 Motor Controller User’s ManualRevision History General Operation SECTION SECTIONSECTION SECTION SECTION SECTION Programming using built-in Switches and Display Version 1.9b. June 1 AX3500 Motor Controller User’s ManualAvoid Shorts when Mounting Board against Chassis Important SafetyDo not Connect to a RC Radio with a Battery Attached WarningsAX3500 Motor Controller User’s Manual Important Safety WarningsVersion 1.9b. June 1 AX3500 Locating the Switches and ConnectorsQuick Start What you will needAX3500 Motor Controller User’s Manual AX3500 Quick StartConnecting to the Batteries and Motors Connecting to the Batteries and MotorsAX3500 Motor Controller User’s Manual Important Warning Connecting to the 15-pin ConnectorSignal RC ModePowering On the Controller Connecting the R/C RadioConnecting the R/C Radio Important WarningAX3500 Quick Start Button OperationProg and Set button status FunctionDefault Controller Configuration Default Controller ConfigurationDefault Values Prog and Set button statusAX3500 Quick Start Connecting the controller to your PC using RoborunAX3500 Motor Controller User’s Manual Obtaining the Controller’s Software Revision Number Obtaining the Controller’s Software Revision NumberAX3500 Motor Controller User’s Manual = Software version 1.9b Exploring furtherAX3500 Quick Start AX3500 Motor Controller User’s ManualProduct Description SECTION 3AX3500 Motor Controller OverviewAX3500 Motor Controller User’s Manual Multiple Command Modes Technical featuresAutomatic Joystick Command Corrections AX3500 Motor Controller OverviewLow Power Consumption Technical featuresHigh Efficiency Motor Power Outputs Optical Encoder InputsAX3500 Motor Controller Overview Advanced Safety FeaturesData Logging Capabilities Compact Open Frame PCB DesignPower Connections Connecting Power and Motors to the ControllerPower Connections Important WarningConnecting Power and Motors to the Controller Controller PowerAX3500 Motor Controller User’s Manual Power Control input is Controller PowerAnd Main Battery mended Off ConfigurationPowering the Controller from a single Battery Controller Powering SchemesConnecting Power and Motors to the Controller Power Control input isController Powering Schemes Powering the Controller Using a Main and Backup BatteryImportant Warning AX3500 Motor Controller User’s ManualConnecting Power and Motors to the Controller Connecting the MotorsImportant Warning Important WarningConverting the AX3500 to Single Channel Single Channel OperationSingle Channel Operation AX3500 Motor Controller User’s ManualConnecting Power and Motors to the Controller Power FusesImportant Warning AX3500 Motor Controller User’s ManualPower Regeneration Considerations Wire Length LimitsElectrical Noise Reduction Techniques Wire Length LimitsUndervoltage Protection Overvoltage ProtectionConnecting Power and Motors to the Controller Important WarningUsing the Controller with a Power Supply Using the Controller with a Power SupplyAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Connecting Power and Motors to the ControllerVersion 1.9b. June 1 General Operation Input Command ModesBasic Operation Basic OperationOpen Loop, Separate Speed Control Selecting the Motor Control ModesOpen Loop, Mixed Speed Control General OperationClose Loop Position Control Closed Loop Speed ControlSelecting the Motor Control Modes AX3500 Motor Controller User’s ManualTemperature-Based Current Limitation User Selected Current Limit SettingsPosition Feedback Position Sensor Gear box SettingBattery Current vs. Motor Current Battery Current vs. Motor CurrentTemperature Motor Current = Battery Current / PWM ratioMotor Current = Battery Current / PWM Ratio Regeneration Current LimitingImportant Warning General OperationSetting Using Programmable AccelerationSetting Using SwitchesSetting Using Command Control CurvesSetting Using SwitchesLeft / Right Tuning Adjustment Left / Right Tuning AdjustmentExponentiation Parameter Value Selected CurveSpeed Adjustment Speed AdjustmentGeneral Operation Parameter ValueEmergency Stop using External Switch Emergency Shut Down Using Controller SwitchesActivating Brake Release or Separate Motor Excitation Speed AdjustmentUsing the Inputs to Activate the Buffered Output Special Use of Accessory Digital InputsUsing the Inputs to turn Off/On the Power MOSFET transistors Inverted OperationSelf-Test Mode Self-Test Mode= Software version 1.9b AX3500 Motor Controller User’s ManualGeneral Operation Important WarningEncoder Speed or Position AX3500 Motor Controller User’s ManualAX3500 Connections Connecting Sensors and Actuators to Input/OutputsAX3500 Connections AX3500 Motor Controller User’s ManualConnecting Sensors and Actuators to Input/Outputs AX3500’s Inputs and OutputsAX3500 Motor Controller User’s Manual AX3500’s Inputs and Outputs SignalI/O type ActivatedI/O List and Pin Assignment Pin1Connecting Sensors and Actuators to Input/Outputs Signal dependingConnecting devices to Output C Connecting devices to Output CSignal depending on ModeImportant warning Connecting Switches or Devices to Input FConnecting Sensors and Actuators to Input/Outputs AX3500 Motor Controller User’s ManualConnecting Switches or Devices to EStop/Invert Input Connecting Switches or Devices to EStop/Invert InputAX3500 Motor Controller User’s Manual Analog Inputs Connecting Position Potentiometers to Analog InputsConnecting Sensors and Actuators to Input/Outputs AX3500 Motor Controller User’s ManualConnecting Tachometer to Analog Inputs Connecting Tachometer to Analog InputsOperating Mode Important WarningOperating Mode Connecting Sensors and Actuators to Input/OutputsImportant Warning Ana 1 p11Connecting External Thermistor to Analog Inputs Connecting External Thermistor to Analog InputsTemp oC Resistance kOhmConnecting Sensors and Actuators to Input/Outputs Using the Analog Inputs to Monitor External VoltagesAX3500 Motor Controller User’s Manual Internal Heatsink Temperature Sensors Connecting User Devices to Analog InputsInternal Voltage Monitoring Sensors Connecting User Devices to Analog InputsConnecting Sensors and Actuators to Input/Outputs Temperature Conversion C Source CodeAX3500 Motor Controller User’s Manual ValueAX3500 Motor Controller User’s Manual Internal Heatsink Temperature Sensorselse LoTemp = i * 5AX3500 Motor Controller User’s Manual Connecting Sensors and Actuators to Input/OutputsVersion 1.9b. June 1 RC Pulse Output Overview RC Pulses OutputRC Pulse Output Overview AX3500 Motor Controller User’s ManualConnecting Servos to Controllers Connector Location and PinoutServo Connection to RevA Controllers RC Pulses OutputServo Connection to RevB Controllers Connecting to Slave ControllersConnecting to Slave Controllers AX3500 Motor Controller User’s ManualCommand Value Pulse Timing InformationPulse Width 1.00ms 1.50msRC Channel Testing Using the PC Utility RC Channel Testing Using the PC UtilityImportant Warning AX3500 Motor Controller User’s ManualAX3500 Motor Controller User’s Manual RC Pulses OutputVersion 1.9b. June 1 Optical Incremental Encoders Overview Connecting and Using the Encoder FunctionOptical Incremental Encoders Overview AX3500 Motor Controller User’s ManualConnecting and Using the Encoder Function Recommended Encoder TypesAX3500 Motor Controller User’s Manual Connecting the Encoder Connecting the EncoderPulse Frequency in Hz = RPM / 60 * PPR AX3500 Motor Controller User’s ManualMotor - Encoder Polarity Matching Cable Length and Noise ConsiderationsConnecting and Using the Encoder Function Important WarningVoltage Levels, Thresholds and Limit Switches Voltage Levels, Thresholds and Limit SwitchesAX3500 Motor Controller User’s Manual Connecting and Using the Encoder Function Wiring Optional Limit SwitchesImportant Warning AX3500 Motor Controller User’s ManualEffect of Limit Switches Wiring Limit Switches Without EncodersWiring Limit Switches Without Encoders Motor 1 FwdUsing the Encoder to Measure Speed Using the Encoder Module to Measure DistanceConnecting and Using the Encoder Function Motor 2 FwdImportant Notice Using the Encoder to Track PositionUsing the Encoder to Track Position AX3500 Motor Controller User’s ManualImportant Notice Connecting and Using the Encoder FunctionThe actual formula is as follows Distance = Destination - Counter value / DividerRS232 Communication with the Encoder Module Encoder Testing and Setting Using the PC UtilityRS232 Communication with the Encoder Module AX3500 Motor Controller User’s ManualAX3500 Motor Controller User’s Manual Connecting and Using the Encoder FunctionVersion 1.9b. June 1 Mode Description Closed Loop Position ModeSelecting the Position Mode Mode DescriptionSensor Mounting Position Sensor SelectionClosed Loop Position Mode Position Feedback Position Sensor Gear boxFeedback Potentiometer wiring in RC or RS232 Mode Feedback Potentiometer wiringFeedback Potentiometer wiring Important NoticeClosed Loop Position Mode Feedback Potentiometer wiring in Analog ModeImportant Notice AX3500 Motor Controller User’s ManualFeedback Wiring in Analog Mode on Single Channel Controllers Feedback Wiring in RC or RS232 Mode on Single Channel ControllersAnalog Feedback on Single Channel Controllers Important NoticeSensor and Motor Polarity Using Optical Encoders in Position ModeClosed Loop Position Mode Important WarningEncoder Error Detection and Protection Important Safety WarningAdding Safety Limit Switches Encoder Error Detection and ProtectionFIGURE 62. Safety limit switches interrupting power to motors Closed Loop Position ModeAX3500 Motor Controller User’s Manual Control Loop Description Using Current Limiting as ProtectionUsing Current Limiting as Protection Important WarningClosed Loop Position Mode PID tuning in Position ModeAX3500 Motor Controller User’s Manual Applied Power = Command Value - Actual Position * Proportional Gain PID tuning in Position ModeAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Closed Loop Position ModeVersion 1.9b. June 1 Selecting the Speed Mode Closed Loop Speed ModeMode Description Mode DescriptionTachometer wiring Using Optical Encoder for Speed FeedbackDigital Optical EncodTachometer or Encoder Mounting Closed Loop Speed ModeImportant Warning Speed Sensor and Motor PolaritySpeed Sensor and Motor Polarity AX3500 Motor Controller User’s ManualClosed Loop Speed Mode Adjust Offset and Max SpeedImportant Warning Control Loop DescriptionPID tuning in Speed Mode PID tuning in Speed ModeAX3500 Motor Controller User’s Manual 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 Closed Loop Speed ModeAX3500 Motor Controller User’s Manual Use of the LED Display Normal and Fault Condition LED MessagesUse of the LED Display AX3500 Motor Controller User’s ManualNormal and Fault Condition LED Messages Motor Direction StatusPossible Display MotorNo Control Fault MessagesFault Messages Possible DisplayPermanent Faults Temporary FaultsSelf-Test Display Normal and Fault Condition LED MessagesSelf-Test Display = Software version 1.9bAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Normal and Fault Condition LED MessagesVersion 1.9b. June 1 Mode Description SECTION 12 R/C OperationMode Description AX3500 Motor Controller User’s ManualConnector I/O Pin Assignment R/C Mode Selecting the R/C Input ModeSignal Pin1Supplied Cable Description R/C Input Circuit DescriptionSignal R/C Input Circuit DescriptionFIGURE 74. RC Cable wiring diagram Powering the Radio from the controllerR/C Operation FIGURE 75. RC connection cable3 Channel 1 Command Pulses 4 Channel 2 Command Pulses Powering the Radio from the controller6 Radio battery - Ground 7 Radio battery + 8 Channel 3 Command Pulses Wire loop bringing power from controller to RC radioOperating the Controller in R/C mode Connecting to a Separately Powered RadioR/C Operation AX3500 Motor Controller User’s ManualReception Watchdog Reception WatchdogAX3500 Motor Controller User’s Manual R/C Transmitter/Receiver Quality Considerations Important Notice about PCM RadiosR/C Operation AX3500 Motor Controller User’s ManualJoystick Deadband Programming Joystick Deadband ProgrammingDeadband Parameter Value Deadband as Percent of full Joystick TravelJoystick Calibration Left/Right Tuning AdjustmentCommand Control Curves R/C OperationAutomatic Joystick Calibration Automatic Joystick CalibrationAX3500 Motor Controller User’s Manual Important Notice Data Logging in R/C ModeR/C Operation On before entering joystick calibrationAX3500 Motor Controller User’s Manual Data Logging in R/C ModeDB15 Male To ControllerAX3500 Motor Controller User’s Manual R/C OperationVersion 1.9b. June 1 Mode Description Analog Control and OperationMode Description Important NoticeSignal Connector I/O Pin Assignment Analog ModePin1 Analog Control and OperationConnecting a Potentiometer Connecting to a Voltage SourceConnecting to a Voltage Source AX3500 Motor Controller User’s ManualImportant Notice Selecting the Potentiometer ValueAnalog Deadband Adjustment Under Voltage Safety Power-On SafetyData Logging in Analog Mode Motor Power at 0%AX3500 Motor Controller User’s Manual Data Logging in Analog ModeAX3500 Motor Controller User’s Manual Analog Control and OperationVersion 1.9b. June 1 Use and benefits of RS232 Serial RS-232 Controls and OperationUse and benefits of RS232 AX3500 Motor Controller User’s ManualSignal Connector I/O Pin Assignment RS232 ModePin1 Serial RS-232 Controls and OperationExtending the RS232 Cable Cable configurationCable configuration AX3500 Motor Controller User’s Manual9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Communication SettingsEstablishing Manual Communication with a PC Serial RS-232 Controls and OperationEstablishing Manual Communication with a PC RS232 Communication with the Encoder ModuleRoboteq v1.9b 06/01/07 s AX3500 Motor Controller User’s ManualData Logging String in R/C or Analog mode Entering RS232 from R/C or Analog modeSerial RS-232 Controls and Operation AX3500 Motor Controller User’s ManualRS232 Mode if default Commands Acknowledge and Error MessagesCommand Acknowledgement Command ErrorRS-232 Watchdog Controller Commands and QueriesCommand Serial RS-232 Controls and OperationSet Accessory Output Set Motor Command ValueQuery Power Applied to Motors Controller Commands and QueriesImportant Notice Query Amps from Battery to each Motor ChannelImportant Notice Serial RS-232 Controls and OperationQuery Analog Inputs Query Heatsink TemperaturesController Commands and Queries ?r or ?RReset Controller Query Battery VoltagesQuery Digital Inputs Serial RS-232 Controls and OperationApply Parameter Changes Accessing & Changing Configuration Parameter in FlashAccessing & Changing Configuration Parameter in Flash Read parameterSerial RS-232 Controls and Operation Flash Configuration Parameters ListLocation DescriptionMotor Control Mode Input Control ModeAccessing & Changing Configuration Parameter in Flash AccessAcceleration Amps LimitAccess After Reset or FFAccessing & Changing Configuration Parameter in Flash Input Switches FunctionAccess After Reset or FFRC Joystick or Analog Deadband Left/Right AdjustExponentiation on Channel 1 and Channel AccessDefault Encoder Distance Divider Default Encoder Time Base 1 andAccessing & Changing Configuration Parameter in Flash AccessJoystick Min, Max and Center Values Default PID GainsAccess After Reset or FFReading & Changing Operating Parameters at Runtime Reading & Changing Operating Parameters at RuntimeDefinition See pagesRead/Change PID Values Operating Modes RegistersAccess Access Read/Write Effective InstantlyController Status Register PWM Frequency RegisterAddress Access Read/Write Effective Instantly AccessCurrent Amps Limit Registers Controller Identification RegisterAccess AccessSet/Reset Encoder Counters and Destination Registers RS232 Encoder Command SetRead Encoder Counter RS232 Encoder Command Setq or !Q n Read SpeedSyntax AX3500 Motor Controller User’s ManualRead Distance Read Encoder Limit Switch StatusRead Speed/Distance RS232 Encoder Command SetRead / Modify Encoder Module Registers and Parameters Important NoteSwitch SwitchAccess RS232 Encoder Command SetModify parameter AddressRegister Description Switch StatusEncoder Hardware ID code AccessCounter Read/Write Mailbox Speed or Distance 1 orCounter 1 and Destination Register 1 andSpeed 1 and Distance 1 andTime Base 1 and Encoder ThresholdRC Pulse Outputs Activation Counter Read Data FormatDefault Value AccessDecimal Encoder Testing and Setting Using the PC Utility32-bit Hex Controller OutputAutomatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC ModeAX3500 Motor Controller User’s Manual Analog and R/C Modes Data Logging String Format 00 11 22 33 44 55 66 77 88 99 AA BB CCData Logging Cables AX3500 Motor Controller User’s ManualDecimal to Hexadecimal Conversion Table Decimal to Hexadecimal Conversion TableAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Decimal to Hexadecimal Conversion TableVersion 1.9b. June 1 AX3500 Motor Controller User’s ManualProgramming using built-in Switches and Display SECTION 15 Configuring the Controller using the SwitchesProgramming Methods AX3500 Motor Controller User’s ManualConfiguring the Controller using the Switches Entering Programming ModeProgram AX3500 Motor Controller User’s ManualThe Special Case of Joystick Calibration Changing parametersProgramming using built-in Switches and Display Important WarningExiting the Parameter Setting Mode Restoring factory defaultsProgrammable Parameters List Configuring the Controller using the SwitchesFor safety reasons, the modes below Possible Values defaultcannot be selected using the switches Programmable Parameters ListPossible Values default Configuring the Controller using the SwitchesOrder LetterDownloading and Installing the Utility SECTION 16 Using the Roborun Configuration UtilitySystem Requirements AX3500 Motor Controller User’s ManualUsing the Roborun Configuration Utility Connecting the Controller to the PCAX3500 Motor Controller User’s Manual Roborun Frame, Tab and Menu Descriptions Roborun Frame, Tab and Menu Descriptions1- Program Revision Number 2- Controller and Communication Link InformationUsing the Roborun Configuration Utility Getting On-Screen Help3- Parameter Selection and Setting and Special Functions 4- File and Program Management CommandsLoading, Changing Controller Parameters Control Settings2- Motor Control Mode Loading, Changing Controller ParametersUsing the Roborun Configuration Utility Power Settings3- Input Command Adjustment 4- Emergency Stop or Invert Switch SelectLoading, Changing Controller Parameters 2- Left/Right Adjust Analog or R/C Specific Settings3- Acceleration Setting 1- DeadbandClosed Loop Parameters Encoder Setting and TestingUsing the Roborun Configuration Utility AX3500 Motor Controller User’s ManualEncoder Setting and Testing Encoder Module Parameters SettingAX3500 Motor Controller User’s Manual Exercising the Motors RC Output TestingViewing Encoder Data Using the Roborun Configuration UtilityRunning the Motors Running the MotorsAX3500 Motor Controller User’s Manual 2- Motor Power setting Using the Roborun Configuration Utility1- Run/Stop Button 3- Measurement6- Input Status and Output Setting 4- Real-Time Strip Chart RecorderRunning the Motors 5- Transmit and Receive DataUsing the Roborun Configuration Utility Logging Data to Disk7- Data Logging and Timer 8- Joystick EnableRunning the Motors Connecting a JoystickParameter Header Data type/rangeUsing the Roborun Configuration Utility Using the Console2- Command Entry 1- Terminal ScreenLoading 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 ModesUsing the Roborun Configuration Utility Operating the AX3500 over a Wired or Wireless LANAX3500 Motor Controller User’s Manual Important Warning Updating the Controller’s SoftwareUpdating the Controller’s Software AX3500 Motor Controller User’s ManualUpdating the Encoder Software Creating Customized Object FilesUsing the Roborun Configuration Utility Important WarningAX3500 Motor Controller User’s Manual Creating Customized Object FilesAX3500 Motor Controller User’s Manual Using the Roborun Configuration UtilityVersion 1.9b. June 1 Mechanical Dimensions Mechanical SpecificationsMechanical Dimensions AX3500 Motor Controller User’s ManualThermal Considerations Mounting ConsiderationsMechanical Specifications AX3500 Motor Controller User’s ManualAttaching the Controller Directly to a Chassis Attaching the Controller Directly to a ChassisAX3500 Motor Controller User’s Manual Mechanical Specifications Precautions to observeAX3500 Motor Controller User’s Manual Weight Wire DimensionsWire Dimensions AX3500 Motor Controller User’s ManualAX3500 Motor Controller User’s Manual Mechanical SpecificationsVersion 1.9b. June 1