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

Models: AX3500

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

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 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 ManualWarnings Important SafetyAvoid Shorts when Mounting Board against Chassis Do not Connect to a RC Radio with a Battery AttachedImportant Safety Warnings AX3500 Motor Controller User’s ManualVersion 1.9b. June 1 What you will need Locating the Switches and ConnectorsAX3500 Quick StartAX3500 Motor Controller User’s Manual AX3500 Quick StartConnecting to the Batteries and Motors Connecting to the Batteries and MotorsAX3500 Motor Controller User’s Manual RC Mode Connecting to the 15-pin ConnectorImportant Warning SignalImportant Warning Connecting the R/C RadioPowering On the Controller Connecting the R/C RadioFunction Button OperationAX3500 Quick Start Prog and Set button statusProg and Set button status Default Controller ConfigurationDefault Controller Configuration Default ValuesConnecting the controller to your PC using Roborun AX3500 Quick StartAX3500 Motor Controller User’s Manual Obtaining the Controller’s Software Revision Number Obtaining the Controller’s Software Revision NumberAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Exploring further= Software version 1.9b AX3500 Quick StartSECTION 3AX3500 Motor Controller Overview Product DescriptionAX3500 Motor Controller User’s Manual AX3500 Motor Controller Overview Technical featuresMultiple Command Modes Automatic Joystick Command CorrectionsOptical Encoder Inputs Technical featuresLow Power Consumption High Efficiency Motor Power OutputsCompact Open Frame PCB Design Advanced Safety FeaturesAX3500 Motor Controller Overview Data Logging CapabilitiesImportant Warning Connecting Power and Motors to the ControllerPower Connections Power ConnectionsController Power Connecting Power and Motors to the ControllerAX3500 Motor Controller User’s Manual mended Off Configuration Controller PowerPower Control input is And Main BatteryPower Control input is Controller Powering SchemesPowering the Controller from a single Battery Connecting Power and Motors to the ControllerAX3500 Motor Controller User’s Manual Powering the Controller Using a Main and Backup BatteryController Powering Schemes Important WarningImportant Warning Connecting the MotorsConnecting Power and Motors to the Controller Important WarningAX3500 Motor Controller User’s Manual Single Channel OperationConverting the AX3500 to Single Channel Single Channel OperationAX3500 Motor Controller User’s Manual Power FusesConnecting Power and Motors to the Controller Important WarningWire Length Limits Wire Length LimitsPower Regeneration Considerations Electrical Noise Reduction TechniquesImportant Warning Overvoltage ProtectionUndervoltage Protection Connecting Power and Motors to the ControllerUsing the Controller with a Power Supply Using the Controller with a Power SupplyAX3500 Motor Controller User’s Manual Connecting Power and Motors to the Controller AX3500 Motor Controller User’s ManualVersion 1.9b. June 1 Basic Operation Input Command ModesGeneral Operation Basic OperationGeneral Operation Selecting the Motor Control ModesOpen Loop, Separate Speed Control Open Loop, Mixed Speed ControlAX3500 Motor Controller User’s Manual Closed Loop Speed ControlClose Loop Position Control Selecting the Motor Control ModesSetting User Selected Current Limit SettingsTemperature-Based Current Limitation Position Feedback Position Sensor Gear boxMotor Current = Battery Current / PWM ratio Battery Current vs. Motor CurrentBattery Current vs. Motor Current TemperatureGeneral Operation Regeneration Current LimitingMotor Current = Battery Current / PWM Ratio Important WarningSwitches Programmable AccelerationSetting Using Setting UsingSwitches Command Control CurvesSetting Using Setting UsingSelected Curve Left / Right Tuning AdjustmentLeft / Right Tuning Adjustment Exponentiation Parameter ValueParameter Value Speed AdjustmentSpeed Adjustment General OperationSpeed Adjustment 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 transistorsAX3500 Motor Controller User’s Manual Self-Test ModeSelf-Test Mode = Software version 1.9bAX3500 Motor Controller User’s Manual Important WarningGeneral Operation Encoder Speed or PositionAX3500 Motor Controller User’s Manual Connecting Sensors and Actuators to Input/OutputsAX3500 Connections AX3500 ConnectionsAX3500’s Inputs and Outputs Connecting Sensors and Actuators to Input/OutputsAX3500 Motor Controller User’s Manual Activated SignalAX3500’s Inputs and Outputs I/O typeSignal depending Pin1I/O List and Pin Assignment Connecting Sensors and Actuators to Input/Outputson Mode Connecting devices to Output CConnecting devices to Output C Signal dependingAX3500 Motor Controller User’s Manual Connecting Switches or Devices to Input FImportant warning Connecting Sensors and Actuators to Input/OutputsConnecting Switches or Devices to EStop/Invert Input Connecting Switches or Devices to EStop/Invert InputAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Connecting Position Potentiometers to Analog InputsAnalog Inputs Connecting Sensors and Actuators to Input/OutputsImportant Warning Connecting Tachometer to Analog InputsConnecting Tachometer to Analog Inputs Operating ModeAna 1 p11 Connecting Sensors and Actuators to Input/OutputsOperating Mode Important WarningResistance kOhm Connecting External Thermistor to Analog InputsConnecting External Thermistor to Analog Inputs Temp oCUsing the Analog Inputs to Monitor External Voltages Connecting Sensors and Actuators to Input/OutputsAX3500 Motor Controller User’s Manual Connecting User Devices to Analog Inputs Connecting User Devices to Analog InputsInternal Heatsink Temperature Sensors Internal Voltage Monitoring SensorsValue Temperature Conversion C Source CodeConnecting Sensors and Actuators to Input/Outputs AX3500 Motor Controller User’s ManualLoTemp = i * 5 Internal Heatsink Temperature SensorsAX3500 Motor Controller User’s Manual elseConnecting Sensors and Actuators to Input/Outputs AX3500 Motor Controller User’s ManualVersion 1.9b. June 1 AX3500 Motor Controller User’s Manual RC Pulses OutputRC Pulse Output Overview RC Pulse Output OverviewRC Pulses Output Connector Location and PinoutConnecting Servos to Controllers Servo Connection to RevA ControllersAX3500 Motor Controller User’s Manual Connecting to Slave ControllersServo Connection to RevB Controllers Connecting to Slave Controllers1.50ms Pulse Timing InformationCommand Value Pulse Width 1.00msAX3500 Motor Controller User’s Manual RC Channel Testing Using the PC UtilityRC Channel Testing Using the PC Utility Important WarningRC Pulses Output AX3500 Motor Controller User’s ManualVersion 1.9b. June 1 AX3500 Motor Controller User’s Manual Connecting and Using the Encoder FunctionOptical Incremental Encoders Overview Optical Incremental Encoders OverviewRecommended Encoder Types Connecting and Using the Encoder FunctionAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Connecting the EncoderConnecting the Encoder Pulse Frequency in Hz = RPM / 60 * PPRImportant Warning Cable Length and Noise ConsiderationsMotor - Encoder Polarity Matching Connecting and Using the Encoder FunctionVoltage Levels, Thresholds and Limit Switches Voltage Levels, Thresholds and Limit SwitchesAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Wiring Optional Limit SwitchesConnecting and Using the Encoder Function Important WarningMotor 1 Fwd Wiring Limit Switches Without EncodersEffect of Limit Switches Wiring Limit Switches Without EncodersMotor 2 Fwd Using the Encoder Module to Measure DistanceUsing the Encoder to Measure Speed Connecting and Using the Encoder FunctionAX3500 Motor Controller User’s Manual Using the Encoder to Track PositionImportant Notice Using the Encoder to Track PositionDistance = Destination - Counter value / Divider Connecting and Using the Encoder FunctionImportant Notice The actual formula is as followsAX3500 Motor Controller User’s Manual Encoder Testing and Setting Using the PC UtilityRS232 Communication with the Encoder Module RS232 Communication with the Encoder ModuleConnecting and Using the Encoder Function AX3500 Motor Controller User’s ManualVersion 1.9b. June 1 Mode Description Closed Loop Position ModeMode Description Selecting the Position ModePosition Feedback Position Sensor Gear box Position Sensor SelectionSensor Mounting Closed Loop Position ModeImportant Notice Feedback Potentiometer wiringFeedback Potentiometer wiring in RC or RS232 Mode Feedback Potentiometer wiringAX3500 Motor Controller User’s Manual Feedback Potentiometer wiring in Analog ModeClosed Loop Position Mode Important NoticeImportant Notice Feedback Wiring in RC or RS232 Mode on Single Channel ControllersFeedback Wiring in Analog Mode on Single Channel Controllers Analog Feedback on Single Channel ControllersImportant Warning Using Optical Encoders in Position ModeSensor and Motor Polarity Closed Loop Position ModeEncoder Error Detection and Protection Important Safety WarningEncoder Error Detection and Protection Adding Safety Limit SwitchesClosed Loop Position Mode FIGURE 62. Safety limit switches interrupting power to motorsAX3500 Motor Controller User’s Manual Important Warning Using Current Limiting as ProtectionControl Loop Description Using Current Limiting as ProtectionPID tuning in Position Mode Closed Loop Position ModeAX3500 Motor Controller User’s Manual PID tuning in Position Mode Applied Power = Command Value - Actual Position * Proportional GainAX3500 Motor Controller User’s Manual Closed Loop Position Mode AX3500 Motor Controller User’s ManualVersion 1.9b. June 1 Mode Description Closed Loop Speed ModeSelecting the Speed Mode Mode DescriptionClosed Loop Speed Mode Using Optical Encoder for Speed FeedbackDigital Optical EncodTachometer wiring Tachometer or Encoder MountingAX3500 Motor Controller User’s Manual Speed Sensor and Motor PolarityImportant Warning Speed Sensor and Motor PolarityControl Loop Description Adjust Offset and Max SpeedClosed Loop Speed Mode Important WarningPID tuning in Speed Mode PID tuning in Speed ModeAX3500 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 stabilityAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Normal and Fault Condition LED MessagesUse of the LED Display Use of the LED DisplayMotor Motor Direction StatusNormal and Fault Condition LED Messages Possible DisplayPossible Display Fault MessagesNo Control Fault MessagesNormal and Fault Condition LED Messages Temporary FaultsPermanent Faults Self-Test Display= Software version 1.9b Self-Test DisplayAX3500 Motor Controller User’s Manual Normal and Fault Condition LED Messages AX3500 Motor Controller User’s ManualVersion 1.9b. June 1 AX3500 Motor Controller User’s Manual SECTION 12 R/C OperationMode Description Mode DescriptionPin1 Selecting the R/C Input ModeConnector I/O Pin Assignment R/C Mode SignalR/C Input Circuit Description R/C Input Circuit DescriptionSupplied Cable Description SignalFIGURE 75. RC connection cable Powering the Radio from the controllerFIGURE 74. RC Cable wiring diagram R/C OperationWire loop bringing power from controller to RC radio Powering the Radio from the controller3 Channel 1 Command Pulses 4 Channel 2 Command Pulses 6 Radio battery - Ground 7 Radio battery + 8 Channel 3 Command PulsesAX3500 Motor Controller User’s Manual Connecting to a Separately Powered RadioOperating the Controller in R/C mode R/C OperationReception Watchdog Reception WatchdogAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Important Notice about PCM RadiosR/C Transmitter/Receiver Quality Considerations R/C OperationDeadband as Percent of full Joystick Travel Joystick Deadband ProgrammingJoystick Deadband Programming Deadband Parameter ValueR/C Operation Left/Right Tuning AdjustmentJoystick Calibration Command Control CurvesAutomatic Joystick Calibration Automatic Joystick CalibrationAX3500 Motor Controller User’s Manual On before entering joystick calibration Data Logging in R/C ModeImportant Notice R/C OperationTo Controller Data Logging in R/C ModeAX3500 Motor Controller User’s Manual DB15 MaleR/C Operation AX3500 Motor Controller User’s ManualVersion 1.9b. June 1 Important Notice Analog Control and OperationMode Description Mode DescriptionAnalog Control and Operation Connector I/O Pin Assignment Analog ModeSignal Pin1AX3500 Motor Controller User’s Manual Connecting to a Voltage SourceConnecting a Potentiometer Connecting to a Voltage SourceImportant Notice Selecting the Potentiometer ValueAnalog Deadband Adjustment Motor Power at 0% Power-On SafetyUnder Voltage Safety Data Logging in Analog ModeAX3500 Motor Controller User’s Manual Data Logging in Analog ModeAnalog Control and Operation AX3500 Motor Controller User’s ManualVersion 1.9b. June 1 AX3500 Motor Controller User’s Manual Serial RS-232 Controls and OperationUse and benefits of RS232 Use and benefits of RS232Serial RS-232 Controls and Operation Connector I/O Pin Assignment RS232 ModeSignal Pin1AX3500 Motor Controller User’s Manual Cable configurationExtending the RS232 Cable Cable configurationSerial RS-232 Controls and Operation Communication Settings9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Establishing Manual Communication with a PCAX3500 Motor Controller User’s Manual RS232 Communication with the Encoder ModuleEstablishing Manual Communication with a PC Roboteq v1.9b 06/01/07 sAX3500 Motor Controller User’s Manual Entering RS232 from R/C or Analog modeData Logging String in R/C or Analog mode Serial RS-232 Controls and OperationCommand Error Commands Acknowledge and Error MessagesRS232 Mode if default Command AcknowledgementSerial RS-232 Controls and Operation Controller Commands and QueriesRS-232 Watchdog CommandController Commands and Queries Set Motor Command ValueSet Accessory Output Query Power Applied to MotorsSerial RS-232 Controls and Operation Query Amps from Battery to each Motor ChannelImportant Notice Important Notice?r or ?R Query Heatsink TemperaturesQuery Analog Inputs Controller Commands and QueriesSerial RS-232 Controls and Operation Query Battery VoltagesReset Controller Query Digital InputsRead parameter Accessing & Changing Configuration Parameter in FlashApply Parameter Changes Accessing & Changing Configuration Parameter in FlashDescription Flash Configuration Parameters ListSerial RS-232 Controls and Operation LocationAccess Input Control ModeMotor Control Mode Accessing & Changing Configuration Parameter in FlashAfter Reset or FF Amps LimitAcceleration AccessAfter Reset or FF Input Switches FunctionAccessing & Changing Configuration Parameter in Flash AccessAccess Left/Right AdjustRC Joystick or Analog Deadband Exponentiation on Channel 1 and ChannelAccess Default Encoder Time Base 1 andDefault Encoder Distance Divider Accessing & Changing Configuration Parameter in FlashAfter Reset or FF Default PID GainsJoystick Min, Max and Center Values AccessSee pages Reading & Changing Operating Parameters at RuntimeReading & Changing Operating Parameters at Runtime DefinitionAccess Read/Write Effective Instantly Operating Modes RegistersRead/Change PID Values AccessAccess PWM Frequency RegisterController Status Register Address Access Read/Write Effective InstantlyAccess Controller Identification RegisterCurrent Amps Limit Registers AccessRS232 Encoder Command Set RS232 Encoder Command SetSet/Reset Encoder Counters and Destination Registers Read Encoder CounterAX3500 Motor Controller User’s Manual Read Speedq or !Q n SyntaxRS232 Encoder Command Set Read Encoder Limit Switch StatusRead Distance Read Speed/DistanceSwitch Important NoteRead / Modify Encoder Module Registers and Parameters SwitchAddress RS232 Encoder Command SetAccess Modify parameterAccess 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 andAccess Counter Read Data FormatRC Pulse Outputs Activation Default ValueController Output Encoder Testing and Setting Using the PC UtilityDecimal 32-bit HexAutomatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC ModeAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual 00 11 22 33 44 55 66 77 88 99 AA BB CCAnalog and R/C Modes Data Logging String Format Data Logging CablesDecimal 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 ManualAX3500 Motor Controller User’s Manual SECTION 15 Configuring the Controller using the SwitchesProgramming using built-in Switches and Display Programming MethodsAX3500 Motor Controller User’s Manual Entering Programming ModeConfiguring the Controller using the Switches ProgramImportant Warning Changing parametersThe Special Case of Joystick Calibration Programming using built-in Switches and DisplayConfiguring the Controller using the Switches 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 Configuring the Controller using the SwitchesPossible Values default OrderAX3500 Motor Controller User’s Manual SECTION 16 Using the Roborun Configuration UtilityDownloading and Installing the Utility System RequirementsConnecting the Controller to the PC Using the Roborun Configuration UtilityAX3500 Motor Controller User’s Manual 2- Controller and Communication Link Information Roborun Frame, Tab and Menu DescriptionsRoborun Frame, Tab and Menu Descriptions 1- Program Revision Number4- File and Program Management Commands Getting On-Screen HelpUsing the Roborun Configuration Utility 3- Parameter Selection and Setting and Special FunctionsLoading, Changing Controller Parameters Control SettingsLoading, Changing Controller Parameters 2- Motor Control Mode4- Emergency Stop or Invert Switch Select Power SettingsUsing the Roborun Configuration Utility 3- Input Command Adjustment1- Deadband Analog or R/C Specific SettingsLoading, Changing Controller Parameters 2- Left/Right Adjust 3- Acceleration SettingAX3500 Motor Controller User’s Manual Encoder Setting and TestingClosed Loop Parameters Using the Roborun Configuration UtilityEncoder Module Parameters Setting Encoder Setting and TestingAX3500 Motor Controller User’s Manual Using the Roborun Configuration Utility RC Output TestingExercising the Motors Viewing Encoder DataRunning the Motors Running the MotorsAX3500 Motor Controller User’s Manual 3- Measurement Using the Roborun Configuration Utility2- Motor Power setting 1- Run/Stop Button5- Transmit and Receive Data 4- Real-Time Strip Chart Recorder6- Input Status and Output Setting Running the Motors8- Joystick Enable Logging Data to DiskUsing the Roborun Configuration Utility 7- Data Logging and TimerData type/range Connecting a JoystickRunning the Motors Parameter Header1- Terminal Screen Using the ConsoleUsing the Roborun Configuration Utility 2- Command EntryViewing 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 Using the Roborun Configuration UtilityAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Updating the Controller’s SoftwareImportant Warning Updating the Controller’s SoftwareImportant Warning Creating Customized Object FilesUpdating the Encoder Software Using the Roborun Configuration UtilityAX3500 Motor Controller User’s Manual Creating Customized Object FilesUsing the Roborun Configuration Utility AX3500 Motor Controller User’s ManualVersion 1.9b. June 1 AX3500 Motor Controller User’s Manual Mechanical SpecificationsMechanical Dimensions Mechanical DimensionsAX3500 Motor Controller User’s Manual Mounting ConsiderationsThermal Considerations Mechanical SpecificationsAttaching the Controller Directly to a Chassis Attaching the Controller Directly to a ChassisAX3500 Motor Controller User’s Manual Precautions to observe Mechanical SpecificationsAX3500 Motor Controller User’s Manual AX3500 Motor Controller User’s Manual Wire DimensionsWeight Wire DimensionsMechanical Specifications AX3500 Motor Controller User’s ManualVersion 1.9b. June 1