Dual Channel High Power Digital Motor Controller
AX3500
User’s Manual
AX3500 Motor Controller User’s Manual
Version 1.9b. June 1
Revision History
Revision History
Date
Version
AX3500 Motor Controller User’s Manual
Version 1.9b. June 1
Revision History
General Operation
SECTION
SECTION
SECTION
SECTION
SECTION
SECTION
Programming using built-in Switches and Display
AX3500 Motor Controller User’s Manual
Version 1.9b. June 1
Important Safety
Avoid Shorts when Mounting Board against Chassis
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
Locating the Switches and Connectors
AX3500
Quick Start
What you will need
AX3500 Quick Start
AX3500 Motor Controller User’s Manual
Connecting to the Batteries and Motors
Connecting to the Batteries and Motors
AX3500 Motor Controller User’s Manual
Connecting to the 15-pin Connector
Important Warning
Signal
RC Mode
Connecting the R/C Radio
Powering On the Controller
Connecting the R/C Radio
Important Warning
Button Operation
AX3500 Quick Start
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
Exploring further
= Software version 1.9b
AX3500 Quick Start
AX3500 Motor Controller User’s Manual
SECTION 3AX3500 Motor Controller Overview
Product Description
AX3500 Motor Controller User’s Manual
Technical features
Multiple Command Modes
Automatic Joystick Command Corrections
AX3500 Motor Controller Overview
Technical features
Low Power Consumption
High Efficiency Motor Power Outputs
Optical Encoder Inputs
Advanced Safety Features
AX3500 Motor Controller Overview
Data Logging Capabilities
Compact Open Frame PCB Design
Connecting Power and Motors to the Controller
Power Connections
Power Connections
Important Warning
Controller Power
Connecting Power and Motors to the Controller
AX3500 Motor Controller User’s Manual
Controller Power
Power Control input is
And Main Battery
mended Off Configuration
Controller Powering Schemes
Powering the Controller from a single Battery
Connecting Power and Motors to the Controller
Power Control input is
Powering the Controller Using a Main and Backup Battery
Controller Powering Schemes
Important Warning
AX3500 Motor Controller User’s Manual
Connecting the Motors
Connecting Power and Motors to the Controller
Important Warning
Important Warning
Single Channel Operation
Converting the AX3500 to Single Channel
Single Channel Operation
AX3500 Motor Controller User’s Manual
Power Fuses
Connecting Power and Motors to the Controller
Important Warning
AX3500 Motor Controller User’s Manual
Wire Length Limits
Power Regeneration Considerations
Electrical Noise Reduction Techniques
Wire Length Limits
Overvoltage Protection
Undervoltage 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
Input Command Modes
General Operation
Basic Operation
Basic Operation
Selecting the Motor Control Modes
Open Loop, Separate Speed Control
Open Loop, Mixed Speed Control
General Operation
Closed Loop Speed Control
Close Loop Position Control
Selecting the Motor Control Modes
AX3500 Motor Controller User’s Manual
User Selected Current Limit Settings
Temperature-Based Current Limitation
Position Feedback Position Sensor Gear box
Setting
Battery Current vs. Motor Current
Battery Current vs. Motor Current
Temperature
Motor Current = Battery Current / PWM ratio
Regeneration Current Limiting
Motor Current = Battery Current / PWM Ratio
Important Warning
General Operation
Programmable Acceleration
Setting Using
Setting Using
Switches
Command Control Curves
Setting Using
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 Shut Down Using Controller Switches
Emergency Stop using External Switch
Activating Brake Release or Separate Motor Excitation
Speed Adjustment
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
Inverted Operation
Self-Test Mode
Self-Test Mode
= Software version 1.9b
AX3500 Motor Controller User’s Manual
Important Warning
General Operation
Encoder Speed or Position
AX3500 Motor Controller User’s Manual
Connecting Sensors and Actuators to Input/Outputs
AX3500 Connections
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
Signal
AX3500’s Inputs and Outputs
I/O type
Activated
Pin1
I/O List and Pin Assignment
Connecting Sensors and Actuators to Input/Outputs
Signal depending
Connecting devices to Output C
Connecting devices to Output C
Signal depending
on Mode
Connecting Switches or Devices to Input F
Important warning
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
Connecting Position Potentiometers to Analog Inputs
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
Connecting Sensors and Actuators to Input/Outputs
Operating Mode
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
Connecting User Devices to Analog Inputs
Internal Heatsink Temperature Sensors
Internal Voltage Monitoring Sensors
Connecting User Devices to Analog Inputs
Temperature Conversion C Source Code
Connecting Sensors and Actuators to Input/Outputs
AX3500 Motor Controller User’s Manual
Value
Internal Heatsink Temperature Sensors
AX3500 Motor Controller User’s Manual
else
LoTemp = i * 5
Connecting Sensors and Actuators to Input/Outputs
AX3500 Motor Controller User’s Manual
Version 1.9b. June 1
RC Pulses Output
RC Pulse Output Overview
RC Pulse Output Overview
AX3500 Motor Controller User’s Manual
Connector Location and Pinout
Connecting Servos to Controllers
Servo Connection to RevA Controllers
RC Pulses Output
Connecting to Slave Controllers
Servo Connection to RevB Controllers
Connecting to Slave Controllers
AX3500 Motor Controller User’s Manual
Pulse Timing Information
Command Value
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
Connecting and Using the Encoder Function
Optical Incremental Encoders Overview
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
Cable Length and Noise Considerations
Motor - Encoder Polarity Matching
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
Wiring Optional Limit Switches
Connecting and Using the Encoder Function
Important Warning
AX3500 Motor Controller User’s Manual
Wiring Limit Switches Without Encoders
Effect of Limit Switches
Wiring Limit Switches Without Encoders
Motor 1 Fwd
Using the Encoder Module to Measure Distance
Using the Encoder to Measure Speed
Connecting and Using the Encoder Function
Motor 2 Fwd
Using the Encoder to Track Position
Important Notice
Using the Encoder to Track Position
AX3500 Motor Controller User’s Manual
Connecting and Using the Encoder Function
Important Notice
The actual formula is as follows
Distance = Destination - Counter value / Divider
Encoder Testing and Setting Using the PC Utility
RS232 Communication with the Encoder Module
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
Closed Loop Position Mode
Mode Description
Selecting the Position Mode
Mode Description
Position Sensor Selection
Sensor Mounting
Closed Loop Position Mode
Position Feedback Position Sensor Gear box
Feedback Potentiometer wiring
Feedback Potentiometer wiring in RC or RS232 Mode
Feedback Potentiometer wiring
Important Notice
Feedback Potentiometer wiring in Analog Mode
Closed Loop Position Mode
Important Notice
AX3500 Motor Controller User’s Manual
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
Important Notice
Using Optical Encoders in Position Mode
Sensor and Motor Polarity
Closed Loop Position Mode
Important Warning
Important Safety Warning
Encoder Error Detection and Protection
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
Using Current Limiting as Protection
Control Loop Description
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
Closed Loop Speed Mode
Selecting the Speed Mode
Mode Description
Mode Description
Using Optical Encoder for Speed FeedbackDigital Optical Encod
Tachometer wiring
Tachometer or Encoder Mounting
Closed Loop Speed Mode
Speed Sensor and Motor Polarity
Important Warning
Speed Sensor and Motor Polarity
AX3500 Motor Controller User’s Manual
Adjust Offset and Max Speed
Closed Loop Speed Mode
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
Normal and Fault Condition LED Messages
Use of the LED Display
Use of the LED Display
AX3500 Motor Controller User’s Manual
Motor Direction Status
Normal and Fault Condition LED Messages
Possible Display
Motor
Fault Messages
No Control
Fault Messages
Possible Display
Temporary Faults
Permanent 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
SECTION 12 R/C Operation
Mode Description
Mode Description
AX3500 Motor Controller User’s Manual
Selecting the R/C Input Mode
Connector I/O Pin Assignment R/C Mode
Signal
Pin1
R/C Input Circuit Description
Supplied Cable Description
Signal
R/C Input Circuit Description
Powering the Radio from the controller
FIGURE 74. RC Cable wiring diagram
R/C Operation
FIGURE 75. RC connection cable
Powering the Radio from the controller
3 Channel 1 Command Pulses 4 Channel 2 Command Pulses
6 Radio battery - Ground 7 Radio battery + 8 Channel 3 Command Pulses
Wire loop bringing power from controller to RC radio
Connecting to a Separately Powered Radio
Operating the Controller in R/C mode
R/C Operation
AX3500 Motor Controller User’s Manual
Reception Watchdog
Reception Watchdog
AX3500 Motor Controller User’s Manual
Important Notice about PCM Radios
R/C Transmitter/Receiver Quality Considerations
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
Left/Right Tuning Adjustment
Joystick Calibration
Command Control Curves
R/C Operation
Automatic Joystick Calibration
Automatic Joystick Calibration
AX3500 Motor Controller User’s Manual
Data Logging in R/C Mode
Important Notice
R/C Operation
On before entering joystick calibration
Data Logging in R/C Mode
AX3500 Motor Controller User’s Manual
DB15 Male
To Controller
R/C Operation
AX3500 Motor Controller User’s Manual
Version 1.9b. June 1
Analog Control and Operation
Mode Description
Mode Description
Important Notice
Connector I/O Pin Assignment Analog Mode
Signal
Pin1
Analog Control and Operation
Connecting to a Voltage Source
Connecting a Potentiometer
Connecting to a Voltage Source
AX3500 Motor Controller User’s Manual
Selecting the Potentiometer Value
Important Notice
Analog Deadband Adjustment
Power-On Safety
Under Voltage Safety
Data Logging in Analog Mode
Motor Power at 0%
Data Logging in Analog Mode
AX3500 Motor Controller User’s Manual
Analog Control and Operation
AX3500 Motor Controller User’s Manual
Version 1.9b. June 1
Serial RS-232 Controls and Operation
Use and benefits of RS232
Use and benefits of RS232
AX3500 Motor Controller User’s Manual
Connector I/O Pin Assignment RS232 Mode
Signal
Pin1
Serial RS-232 Controls and Operation
Cable configuration
Extending the RS232 Cable
Cable configuration
AX3500 Motor Controller User’s Manual
Communication Settings
9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity
Establishing Manual Communication with a PC
Serial RS-232 Controls and Operation
RS232 Communication with the Encoder Module
Establishing Manual Communication with a PC
Roboteq v1.9b 06/01/07 s
AX3500 Motor Controller User’s Manual
Entering RS232 from R/C or Analog mode
Data Logging String in R/C or Analog mode
Serial RS-232 Controls and Operation
AX3500 Motor Controller User’s Manual
Commands Acknowledge and Error Messages
RS232 Mode if default
Command Acknowledgement
Command Error
Controller Commands and Queries
RS-232 Watchdog
Command
Serial RS-232 Controls and Operation
Set Motor Command Value
Set Accessory Output
Query Power Applied to Motors
Controller Commands and Queries
Query Amps from Battery to each Motor Channel
Important Notice
Important Notice
Serial RS-232 Controls and Operation
Query Heatsink Temperatures
Query Analog Inputs
Controller Commands and Queries
?r or ?R
Query Battery Voltages
Reset Controller
Query Digital Inputs
Serial RS-232 Controls and Operation
Accessing & Changing Configuration Parameter in Flash
Apply Parameter Changes
Accessing & Changing Configuration Parameter in Flash
Read parameter
Flash Configuration Parameters List
Serial RS-232 Controls and Operation
Location
Description
Input Control Mode
Motor Control Mode
Accessing & Changing Configuration Parameter in Flash
Access
Amps Limit
Acceleration
Access
After Reset or FF
Input Switches Function
Accessing & Changing Configuration Parameter in Flash
Access
After Reset or FF
Left/Right Adjust
RC Joystick or Analog Deadband
Exponentiation on Channel 1 and Channel
Access
Default Encoder Time Base 1 and
Default Encoder Distance Divider
Accessing & Changing Configuration Parameter in Flash
Access
Default PID Gains
Joystick Min, Max and Center Values
Access
After Reset or FF
Reading & Changing Operating Parameters at Runtime
Reading & Changing Operating Parameters at Runtime
Definition
See pages
Operating Modes Registers
Read/Change PID Values
Access
Access Read/Write Effective Instantly
PWM Frequency Register
Controller Status Register
Address Access Read/Write Effective Instantly
Access
Controller Identification Register
Current Amps Limit Registers
Access
Access
RS232 Encoder Command Set
Set/Reset Encoder Counters and Destination Registers
Read Encoder Counter
RS232 Encoder Command Set
Read Speed
q or !Q n
Syntax
AX3500 Motor Controller User’s Manual
Read Encoder Limit Switch Status
Read Distance
Read Speed/Distance
RS232 Encoder Command Set
Important Note
Read / Modify Encoder Module Registers and Parameters
Switch
Switch
RS232 Encoder Command Set
Access
Modify parameter
Address
Switch Status
Register Description
Encoder Hardware ID code
Access
Speed or Distance 1 or
Counter Read/Write Mailbox
Counter 1 and
Destination Register 1 and
Distance 1 and
Speed 1 and
Time Base 1 and
Encoder Threshold
Counter Read Data Format
RC Pulse Outputs Activation
Default Value
Access
Encoder Testing and Setting Using the PC Utility
Decimal
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
00 11 22 33 44 55 66 77 88 99 AA BB CC
Analog and R/C Modes Data Logging String Format
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
Decimal to Hexadecimal Conversion Table
AX3500 Motor Controller User’s Manual
AX3500 Motor Controller User’s Manual
Version 1.9b. June 1
SECTION 15 Configuring the Controller using the Switches
Programming using built-in Switches and Display
Programming Methods
AX3500 Motor Controller User’s Manual
Entering Programming Mode
Configuring the Controller using the Switches
Program
AX3500 Motor Controller User’s Manual
Changing parameters
The Special Case of Joystick Calibration
Programming using built-in Switches and Display
Important Warning
Restoring factory defaults
Exiting the Parameter Setting Mode
Programmable Parameters List
Configuring the Controller using the Switches
Possible Values default
For safety reasons, the modes below
cannot be selected using the switches
Programmable Parameters List
Configuring the Controller using the Switches
Possible Values default
Order
Letter
SECTION 16 Using the Roborun Configuration Utility
Downloading and Installing the 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
Getting On-Screen Help
Using the Roborun Configuration Utility
3- Parameter Selection and Setting and Special Functions
4- File and Program Management Commands
Control Settings
Loading, Changing Controller Parameters
2- Motor Control Mode
Loading, Changing Controller Parameters
Power Settings
Using the Roborun Configuration Utility
3- Input Command Adjustment
4- Emergency Stop or Invert Switch Select
Analog or R/C Specific Settings
Loading, Changing Controller Parameters 2- Left/Right Adjust
3- Acceleration Setting
1- Deadband
Encoder Setting and Testing
Closed Loop Parameters
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
RC Output Testing
Exercising the Motors
Viewing Encoder Data
Using the Roborun Configuration Utility
Running the Motors
Running the Motors
AX3500 Motor Controller User’s Manual
Using the Roborun Configuration Utility
2- Motor Power setting
1- Run/Stop Button
3- Measurement
4- Real-Time Strip Chart Recorder
6- Input Status and Output Setting
Running the Motors
5- Transmit and Receive Data
Logging Data to Disk
Using the Roborun Configuration Utility
7- Data Logging and Timer
8- Joystick Enable
Connecting a Joystick
Running the Motors
Parameter Header
Data type/range
Using the Console
Using the Roborun Configuration Utility
2- Command Entry
1- Terminal Screen
Viewing and Logging Data in Analog and R/C Modes
Loading and Saving Profiles to Disk
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
Updating the Controller’s Software
Important Warning
Updating the Controller’s Software
AX3500 Motor Controller User’s Manual
Creating Customized Object Files
Updating the Encoder Software
Using the Roborun Configuration Utility
Important Warning
Creating Customized Object Files
AX3500 Motor Controller User’s Manual
Using the Roborun Configuration Utility
AX3500 Motor Controller User’s Manual
Version 1.9b. June 1
Mechanical Specifications
Mechanical Dimensions
Mechanical Dimensions
AX3500 Motor Controller User’s Manual
Mounting Considerations
Thermal 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
Wire Dimensions
Weight
Wire Dimensions
AX3500 Motor Controller User’s Manual
Mechanical Specifications
AX3500 Motor Controller User’s Manual
Version 1.9b. June 1