RoboteQ AX3500 User manual

AX3500
Dual Channel
High Power
Digital Motor
Controller
User’s Manual
v1.7, February 1, 2005
visit www.roboteq.com to download the latest revision of this manual
©Copyright 2003-2005 Roboteq, Inc.

2AX3500 Motor Controller User’s Manual Version 1.7. February 1, 2005
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.
Revision History
Date Version Changes
February 1, 2005 1.7 Initial Release. Based on v.16 of AX2550/2850 manual

AX3500 Motor Controller User’s Manual 3
Revision History 2
SECTION 1 AX3500
Quick Start 11
What you will need 11
Locating Switches, Wires and Connectors 12
Connecting to the Batteries and Motors 13
Using the Power Control Wire 14
Connecting the R/C Radio 14
Powering On the Controller 15
Button Operation 16
Default Controller Configuration 17
Checking and Changing Configurations 17
Connecting the controller to your PC using Roborun 18
Obtaining the Controller’s Software Revision Number 19
Exploring further 20
SECTION 2 AX3500 Motor Controller Overview 21
Product Description 21
Technical features 22
SECTION 3 Connecting Power and Motors to the Controller 25
Connecting Power 25
Controller Power 26
Powering the Controller using the Motor Batteries 28
Using a Backup Battery 29
Power Fuses 30
Wire Length Limits 30
Electrical Noise Reduction Techniques 31
Power Regeneration Considerations 31
Overvoltage Protection 32
Undervoltage Protection 32
Using the Controller with a Power Supply 32
SECTION 4 General Operation 35
Basic Operation 35
Input Command Modes 35
Selecting the Motor Control Modes 36
Open Loop, Separate Speed Control 36
Open Loop, Mixed Speed Control 36
Closed Loop Speed Control 37
Close Loop Position Control 37

4AX3500 Motor Controller User’s Manual Version 1.7. February 1, 2005
Current Limit Settings 38
Continuous and Extended Current Limitation 38
Temperature-Based Current Limitation 39
Surge Current Protection 40
Regeneration Current Limiting 40
Programmable Acceleration 40
Command Control Curves 42
Left / Right Tuning Adjustment 43
Emergency Shut Down Using Controller Switches 45
Emergency Stop using External Switch 45
Inverted Operation 46
Special Use of Accessory Digital Inputs 46
Using the Inputs to Activate the Buffered Output 46
Using the Inputs to turn Off/On the Power MOSFET
transistors 46
Self-Test Mode 47
SECTION 5 Connecting Sensors and Actuators to Input/Outputs 49
AX3500 Connections 49
AX3500’s Inputs and Outputs 51
I/O List and Pin Assignment 52
Connecting devices to Output C 53
Connecting devices to Output D 54
Connecting Switches or Devices to Input E 55
Connecting Switches or Devices to Input F 55
Connecting Switches or Devices to EStop/Invert Input 56
Connecting Position Potentiometers to Analog Inputs 57
Connecting Tachometer to Analog Inputs 58
Connecting External Thermistor to Analog Inputs 59
Using the Analog Inputs to Monitor External Voltages 60
Connecting User Devices to Analog Inputs 61
Internal Voltage Monitoring Sensors 62
Internal Heatsink Temperature Sensors 62
Temperature Conversion C Source Code 63
SECTION 6 Normal and
Fault Condition LED Messages 65
Use of the LED Display 65
Motor Direction Status 66
Fault Messages 67
No Control 67
Emergency Stop 68

AX3500 Motor Controller User’s Manual 5
Self-Test Display 68
SECTION 7 R/C Operation 69
Mode Description 69
Selecting the R/C Input Mode 70
Typical Wiring 70
Connector I/O Pin Assignment (R/C Mode) 71
R/C Input Circuit Description 72
Supplied Cable Description 73
Cabling to R/C Receiver using Full Opto-Isolation 74
Cabling to R/C Receiver with Partial Opto-Isolation 75
Powering the Radio from the controller 76
Operating the Controller in R/C mode 78
Reception Watchdog 79
R/C Transmitter/Receiver Quality Considerations 79
Joystick Deadband Programming 80
Command Control Curves 81
Left/Right Tuning Adjustment 81
Joystick Calibration 81
Automatic Joystick Calibration 82
Activating the Accessory Outputs 83
Data Logging in R/C Mode 84
SECTION 8 Serial (RS-232) Controls and Operation 87
Use and benefits of RS232 87
Connector I/O Pin Assignment (RS232 Mode) 88
Cable configuration 89
Extending the RS232 Cable 89
Communication Settings 90
Establishing Manual Communication with a PC 90
Entering RS232 from R/C or Analog mode 91
Data Logging String in R/C or Analog mode 91
RS232 Mode if default 92
RS232 Commands Set 92
Set Motor Command Value 92
Set Accessory Outputs 93
Query Power Applied to Motors 93
Query Amps Consumed by Motors 94
Query Analog Inputs 94
Query Heatsink Temperatures 95
Query Battery Voltages 95
Query Digital Inputs 95
Read and Modify Controller Settings 96

6AX3500 Motor Controller User’s Manual Version 1.7. February 1, 2005
Apply Parameter Changes 97
Reset Controller 97
Optical Encoder Commands 97
Commands Acknowledge and Error Messages 97
Character Echo 97
Command Acknowledgement 98
Command Error 98
Watchdog time-out 98
RS-232 Watchdog 98
RS232 Accessible Parameter Table 99
Automatic Switching from RS232 to RC Mode 101
Analog and R/C Modes Data Logging String Format 102
Data Logging Cables 103
Decimal to Hexadecimal Conversion Table 104
SECTION 9 Analog Control and Operation 107
Mode Description 107
Connector I/O Pin Assignment (Analog Mode) 108
Connecting to a Voltage Source 109
Connecting a Potentiometer 109
Selecting the Potentiometer Value 110
Analog Deadband Adjustment 111
Power-On Safety 112
Under Voltage Safety 112
Data Logging in Analog Mode 112
SECTION 10 Closed Loop Position Mode 11 5
Mode Description 115
Selecting the Position Mode 115
Position Sensor Selection 116
Sensor Mounting 11 6
Potentiometer wiring 117
Using Optical Encoders in Position Mode 117
Sensor and Motor Polarity 117
Adding Safety Limit Switches 119
Using Current Limiting as Protection 120
Control Loop Description 120
PID tuning in Position Mode 122
SECTION 11 Closed Loop Speed Mode 123
Mode Description 123
Selecting the Speed Mode 123

AX3500 Motor Controller User’s Manual 7
Using Optical Encoder for Speed Feedback (AX2850 only) 124
Tachometer or Encoder Mounting 124
Tachometer wiring 124
Speed Sensor and Motor Polarity 125
Adjust Offset and Max Speed 126
Control Loop Description 127
PID tuning in Speed Mode 128
SECTION 12 Installing, Connecting and Using the Encoder Module 131
Optical Incremental Encoders Overview 131
Recommended Encoder Types 132
Installing the Encoder Module 133
Connecting the Encoder 135
Motor - Encoder Polarity Matching 136
Voltage Levels, Thresholds and Limit Switches 136
Wiring Optional Limit Switches 137
Using the Encoder Module to Measure Distance 138
Using the Encoder to Measure Speed 139
Using the Encoder to Track Position 140
RS232 Communication with the Encoder Module 141
RS232 Encoder Command Set 142
Read Encoder Counter 142
Set/Reset Encoder Counters and Destination Registers 143
Read Speed 143
Read Distance 144
Read Speed/Distance 144
Read Encoder Limit Switch Status 144
Read / Modify Encoder Module Registers and Parameters 145
Register Description 147
Encoder Hardware ID code 147
Switch Status 148
Speed or Distance 1 or 2 148
Counter Read/Write Mailbox 148
Counter 1 and 2 148
Destination Register 1 and 2 148
Distance 1 and 2 148
Speed 1 and 2 149
Time Base 1 and 2 149
Encoder Threshold 149
Counter Read Data Format 149
Encoder Testing and Setting Using the PC Utility 150
Encoder Module Parameters Setting 151
Exercising the Motors 152

8AX3500 Motor Controller User’s Manual Version 1.7. February 1, 2005
Viewing Encoder Data 152
Updating the Encoder Software 152
SECTION 13 RC Pulses Output 153
RC Pulse Output Overview 153
Connector Location and Pinout 154
Connecting Servos and Slave Controllers 154
Pulse Timing Information 155
RS232 Commands 156
RC Channel Testing Using the PC Utility 157
SECTION 14 Configuring the Controller using the Switches 159
Programming Methods 159
Programming using built-in Switches and Display 159
Entering Programming Mode 160
Changing parameters 161
The Special Case of Joystick Calibration 161
Restoring factory defaults 161
Exiting the Parameter Setting Mode 162
Programmable Parameters List 162
SECTION 15 Using the Roborun Configuration Utility 165
System Requirements 165
Downloading and Installing the Utility 165
Connecting the Controller to the PC 166
Roborun Frame, Tab and Menu Descriptions 167
Getting On-Screen Help 168
Loading, Changing Controller Parameters 168
Controls Settings 169
Power Settings 170
Analog or R/C Specific Settings 171
Closed Loop Parameters 172
Viewing the Parameters Summary 172
Optical Encoder Operation 173
Running the Motors 173
Logging Data to Disk 176
Connecting a Joystick 177
Viewing and Logging Data in Analog and R/C Modes 178
Loading and Saving Profiles to Disk 178
Operating the AX3500 over a Wired or Wireless LAN 178
Updating the Controller’s Software 180
Creating Customized Object Files 180

AX3500 Motor Controller User’s Manual 9
SECTION 16 Mechanical Specifications 183
Mechanical Dimensions 183
Mounting Considerations 184
Thermal Considerations 184
Wire Dimensions 185
Weight 185

10 AX3500 Motor Controller User’s Manual Version 1.7. February 1, 2005

AX3500 Motor Controller User’s Manual 11
SECTION 1 AX3500
Quick Start
This section will give you the basic information needed to quickly install, setup and run your AX3500
controller in a minimal configuration.
Important Safety Warnings
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 Regener-
ation Considerations” on page 31 of the Users Manual.
What you will need
For a minimal installation, gather the following components
•One AX3500 Controller and its provided cables
•12V to 40V high capacity, high current battery
•One or two brushed DC motors
•One R/C to DB15 connector (provided)
•Miscellaneous wires, connectors, fuses and switch

AX3500 Quick Start
12 AX3500 Motor Controller User’s Manual Version 1.7. February 1, 2005
Locating Switches and Connectors
Take a moment to familiarize yourself with the controller’s switches and connector.
The front side (shown in Figure 1) contains the buttons and display needed to operate and
monitor the controller. The 15-pin connector provides the connection to the R/C or micro-
computer, as well as connections to optional switches and sensors.
At the back of the controller (shown in the figure below) are located all the Fast-on tabs
that must be connected to the batteries and the motors.
Connector to Receiver/Controls
and sensors
Operating Status
and Program LED Display
Controller Configuration
buttons
FIGURE 1. Controller Front View
Connector to
Optical Encoders
RC Outputs
connectors
VMot
Motor 2 Motor 1
M2+ M1+ M1- VMotM2- 3 x Gnd
Pwr
Ctrl
FIGURE 2. Controller Rear View
Note:
Both VMot tabs are con-
nected to each other in
the board and must be
wired to the same volt-
age.

AX3500 Motor Controller User’s Manual 13
Connecting to the Batteries and Motors
Connecting to the Batteries and Motors
Connection to the batteries and motors is shown in the figure below and is done by con-
necting wires to the Fast-on tabs on the controller.
1- Connect two of the three Ground tabsto the minus (-) terminal of the battery that will be
used to power the motors. Connect the two VMot tabsto the plus (+) terminal of the bat-
tery. The motor battery may be of 12 to 40 Volts. There is no need to insert a switch on
Motor Power cables, although one is suggested.
The two VMot tabs are connected to each other inside the controller. The same is
true for the Ground tabs. You should wire each pair together as shown in the dia-
gram above.
2- You may leave the Power control tab unconnected, or you may connect it to a power
switch.
Refer to the chapter “Connecting Power and Motors to the Controller”on page 25 for
more information about batteries and other connection options.
3- Connect each motor to one of the two output tabs pair. Make sure to respect the polar-
ity, otherwise the motor(s) may spin in the opposite direction than expected
Important Warning
12V to 40V
Motor Battery
Optional
Power on/off
switch
Motor
Cables
Battery
Power Cables
Power Control
Wire
-
-
+
+
Motor1
Motor2
Controller
Fuse
Notes:
- The Battery Power connection are doubled in order to provide the maximum current to the controller. If
only one motor is used, only one set of motor power cables needs to be connected
- Typically, 1, 2 or 3 x 12V batteries are connected in series to reach 12, 24 or 36V respectively
- The Power Control wire may be used to turn On and Off the controller, or to provide a separate and sta-
ble supply to the controller’s logic (See discussion below)
FIGURE 3. Electrical Power Wiring Diagram

AX3500 Quick Start
14 AX3500 Motor Controller User’s Manual Version 1.7. February 1, 2005
The controller includes large capacitors. When connecting the Motor Power Cables,
a spark will be generated at the connection point. This is a normal occurrence and
should be expected.
Using the Power Control Tab
The AX3500 includes a DC/DC converter that will generate a 12V internal supply from the
main +12 to +40V battery. As a result, the controller will turn On as soon as the Vmot and
Ground tabs are connected to the battery.
In order to turn On and Off the controller without the need for a bulky and expensive
switch or relay on the high current wires, the AX3500 uses a Power Control input to enable
or disable the internal DC/DC converter. When left unconnected, the DC/DC converter is
On. When grounded, the DC/DC converter is Off.
The Power Control tab can also be used to feed a separate supply to the controller so that
it will continue to operate if and when the main batteries’voltage dips below 12V. The table
below shows the various functions of the Power Control input. See “Connecting Power”
on page 25 for more details on the use and operation of the Power Control signal.
Connecting the R/C Radio
Connect the R/C adapter cables to the controller on one side and to two or three channels
on the R/C receiver on the other side. The third channel is for activating the accessory out-
puts and is optional. Note: the channel 3 RC input is not yet implemented in the AX3500.
When operating the controller in “Separate”mode, the wire labelled Ch1 controls Motor1,
and the wire labelled Ch2 controls Motor2.
When operating the controller in “Mixed”mode, Ch1 is used to set the robot’s speed and
direction, while Ch2 is used for steering.
See “R/C Operation”on page 69 of the User’s Manual for a more complete discussion on
R/C commands, calibration and other options.
TABLE 1. Use of Power Control wire
Power Control input connected to Action
Floating Controller is On
Ground Controller is Off
Separate 12V to 40V supply Controller is On. Controller will draw power from
the Power Control tab if main battery voltage dips
below 12V.

AX3500 Motor Controller User’s Manual 15
Powering On the Controller
This wiring - with the wire loop uncut - assumes hat the R/C radio will be powered by the
AX3500 controller. Other wiring options are described in “R/C Operation”on page 69 of
the User’s Manual.
Important Warning
Do not connect a battery to the radio when the wire loop is uncut. The RC battery
voltage will flow directly into the controller and cause permanent damage if its volt-
age is higher than 5.5V.
Powering On the Controller
Important reminder: There is no On-Off switch on the controller. You must insert a switch
on the controller’s power tab as described in section“Connecting to the Batteries and
Motors”on page 13.
To power the controller, center the joystick and trims on the R/C transmitter. Then turn on
the switch that you have placed on the Battery Power wire or on the Power Control wire.
If the R/C transmitter and/or receiver is powered off, the display on the controller will alter-
nate the letters spelling “no ctrl”to indicate that it is On but is not receiving a control sig-
nal.
8
9
15
Pin 1
Channel 1
Wire loop bringing power from
controller to RC radio and
to optical isolators
Channel 2 3: Channel 1 Command Pulses
4: Channel 2 Command Pulses
6: Radio battery (-) Ground
7: Radio battery (+)
8: Channel 3 Command Pulses
Channel 3
FIGURE 4. R/C connector wiring for 3 channels and battery elimination (BEC)

AX3500 Quick Start
16 AX3500 Motor Controller User’s Manual Version 1.7. February 1, 2005
Turn the R/C transmitter On. The “no ctrl”scrolling message will disappear and the display
will show steady patterns depending on the motors’selected direction.
Move the joystick on the transmitter to activate the motors to the desired speed and direc-
tion.
See “R/C Operation”on page 69 of the User’s Manual for a detailed description of the
many features and options available in the R/C mode.
Button Operation
The AX3500 has three buttons: Set, Program and Reset. These buttons are not needed
for normal operation, as the controller is immediately operational upon power up.
The Reset button will restart the controller. This button is recessed and you will need a
paper clip to press it. Reset is also accomplished by turning the controller’s power Off and
back On.
The Set and Program buttons have the following functions depending how and when they
are pressed:
TABLE 2. AX3500 Buttons Function
Prog and Set button status Function
Press and hold Program alone during reset or power up Enter the Programming Mode.
Press and hold Set alone during reset of power up Enter Self-Test mode. See “Self-Test
Mode”on page 47 of the User’s Manual
Press and hold Program and Set together during reset or
power up
Reset configuration parameters to factory
default
Press Program while Programming Mode Accept previous parameter change and
select next parameter
Press Set while in Programming mode Change value of selected parameter
Press Program pressed alone during normal operation No effect
Press Set alone during normal operation No effect
Press Program and Set together during normal operation Emergency stop
FIGURE 5. “no control”scroll message indicates no valid R/C signal is present

AX3500 Motor Controller User’s Manual 17
Default Controller Configuration
Default Controller Configuration
Version 1.7 of the AX3500 software is configured with the factory defaults shown in the
table below. Although Roboteq strives to keep the same parameters and values from one
version to the next, changes may occur from one revision to the next. Make sure that you
have the matching manual and software versions. These may be retrieved from the
Roboteq web site. See “Configuring the Controller using the Switches”on page 159 of the
User Manual for a complete configuration parameter list and their possible values.
Checking and Changing Configurations
Any one of the parameters listed in Table 3, and others not listed, can easily be changed
either using the controller’s buttons or your PC with the Roboteq Configuration Utility.
The example below shows how to use the buttons to select and change the Motor Control
mode from “separate”to “mixed”. See “Configuring the Controller using the Switches”on
page 159 of the User’s Manual for a complete list of all the AX3500’s parameters and their
meanings.
TABLE 3. AX3500 Default Settings
Parameter Default Values Letter
Input Command mode: (0) = R/C Radio mode I
Motor Control mode (0) = Separate A, B, speed control, open loop C
Amp limit (5) = 52.5A A
Acceleration (2) = medium-slow S
Input switch function (3) = no action U
Brake/Coast (0) = brake when idle b
Joystick Deadband (2) = 16% d
Exponentiation on channel 1 (0) = Linear (no exponentiation) E
Exponentiation on channel 2 (0) = Linear (no exponentiation) F
Left / Right Adjust (7) = no adjustment L
Restart
Press & hold Prog
Press and hold the Prog button for 10 seconds while
resetting or powering on the controller
After 10 seconds, the controller will enter the program-
ming mode and flash alternatively the current parame-
ter (I= Input Mode) and its value (0= R/C mode).
Program mode entered
after 10 seconds

AX3500 Quick Start
18 AX3500 Motor Controller User’s Manual Version 1.7. February 1, 2005
Connecting the controller to your PC using Roborun
Connecting the controller to your PC is not necessary for basic R/C operation. However, it
is a very simple procedure that is useful for the following purposes:
•to Read and Set the programmable parameters with a user-friendly graphical inter-
face
•to obtain the controller’s software revision and date
•to send precise commands to the motors
•to read and plot real-time current consumption value
•Save captured parameters onto disk for later analysis
•to update the controller’s software
Press the Prog button to move to the next parameter
(C= Motor Control Mode) and its value (0= Separate)
Press Prog to select
next parameter
Press the Set button to change the parameter’s value
(1= Combined)
Press Set to select
next value for parameter
Press the Prog button record the change and move to
the next parameter (A= Amps limit) and it’s value (2=
75A)
Press the Reset button or power off/on the control to
restart the controller using the new parameters.
Press Prog to store change
and select next parameter
Reset controller
to exit

AX3500 Motor Controller User’s Manual 19
Obtaining the Controller’s Software Revision Number
To connect the controller to your PC, use the provided cable. Connect the 15-pin connector
to the controller. Connect the 9-pin connector to your PC’s available port (typically COM1).
Apply power to the controller to turn it on.
Load your CD or download the latest revision of Roborun software from
www.Roboteq.com, install it on your PC and launch the program. The software will auto-
matically establish communication with the controller, retrieve the software revision num-
ber and present a series of buttons and tabs to enable its various possibilities.
The intuitive Graphical User Interface will let you view and change any of the controller’s
parameters. The “Run”tab will present a number of buttons, dials and charts that are used
for operating and monitoring the motors.
Obtaining the Controller’s Software Revision Number
One of the unique features of the AX3500 is the ability to easily update the controller’s
operating software with new revisions downloaded from Roboteq’s web site at
www.roboteq.com. This is useful for adding features and/or improving existing ones.
FIGURE 6. Roborun Utility screen layout

AX3500 Quick Start
20 AX3500 Motor Controller User’s Manual Version 1.7. February 1, 2005
Each software version is identified with a unique number. Obtaining this number can be
done using the PC connection discussed previously.
It is also possible to get the controller to display the software version number by following
these simple steps
•Disconnect the power from the motor batteries
•Press and hold the Set button while powering or resetting the controller
The LED will display a sequence of two numerical digits and an optional letter separated by
dashes as shown in the examples below.
After these digits are displayed, the controller will attempt to power the motors as part of
the self test mode (see “Self-Test Mode”on page 47 of the User’s Manual for a more
detailed explanation). This is why the motor’s battery must be disconnected. After about
30 seconds, the software revision number will be displayed every 30 seconds.
You will need to reset, or power down and up, the controller to exit and resume normal
operations.
Now that you know your controller’s software version number, you will be able to see if a
new version is available for download and installation from Roboteq’s web site, and which
features have been added or improved.
Installing new software is a simple and secure procedure, fully described in “Operating the
AX3500 over a Wired or Wireless LAN”on page 178 of the User’s Manual.
Exploring further
By following this quick-start section, you should have managed to get your controller to
operate in its basic modes within minutes of unpacking.
Each of the features mentioned thus far has numerous options which are discussed further
in the complete User’s Manual, including:
•Self test mode
•Emergency stop condition
•Joystick calibration
•Using Inputs/Outputs
•Current limiting
•Closed Loop Operation
•Software updating
•and much more
= Software version 1.7
FIGURE 7. Press and hold “Set”to display version number and enter self-test