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