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