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REV-11-1200-UM-00

Copyright © 2016 REV Robotics, LLC

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SPARK OVERVIEW

The REV Robotics SPARK Motor Controller is 12V 60A PWM-controlled brushed DC motor controller designed for

FIRST®

Robotics Competition robots.

The Spark features 60A continuous current with passive cooling, bi-directional limit switch inputs for smart mechanism
control, an RGB LED status indicator, and a button-activated brake/coast mode.

Figure 1-1 SPARK Motor Controller

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Summary of Contents for SPARK

Page 1: ...REV 11 1200 UM 00 Copyright 2016 REV Robotics LLC fg SPARK MOTOR CONTROLLER USER S MANUAL ...

Page 2: ...2 1 4 CONNECTING MOTOR AND POWER WIRES 8 2 2 SPEED AND DIRECTION CONTROL 9 2 2 1 SERVO PWM CONNECTION 9 2 2 2 CONTROLLING MOTOR SPEED AND DIRECTION 9 2 3 HEAT MANAGEMENT 10 2 4 LIMIT SWITCH INPUTS 11 2 4 1 LIMIT SWITCH OPERATION 11 2 4 2 LIMIT SWITCH WIRING 11 2 5 OPERATING MODES 12 2 5 1 BRAKE COAST MODE 12 2 5 2 CALIBRATION 13 2 5 3 FACTORY RESET 13 2 6 STATUS LED 14 APPENDIX A DIMENSIONS 15 APP...

Page 3: ...on 9 Figure 2 3 Heat Sink 10 Figure 2 4 Limit Switch Inputs 11 Figure 2 5 Mode Button 12 Figure 2 6 LED Status Codes 14 LIST OF TABLES Table 1 1 Electrical Specifications 6 Table 1 2 Servo PWM Input Specifications 6 Table 1 3 Limit Switch Input Specifications 6 Table 1 4 Mechanical Specifications 6 Table 2 1 Compatible Crimp terminal Sizes 7 Table 2 2 Input Pulse Mapping 9 ...

Page 4: ...A PWM controlled brushed DC motor controller designed for FIRST Robotics Competition robots The Spark features 60A continuous current with passive cooling bi directional limit switch inputs for smart mechanism control an RGB LED status indicator and a button activated brake coast mode Figure 1 1 SPARK Motor Controller ...

Page 5: ...se motion automatically o No programming required Brake Coast modes Calibration o Factory calibrated to 1ms 2ms input signal o User calibratable Integrated cable retention for PWM port Clamping screw terminals o Better contact area and retention o Compatible with 6 and 8 yellow ring terminals RGB Status LED o Detailed mode and operation feedback 1 2 KIT CONTENTS The following items are included wi...

Page 6: ...utral input pulse b 1500 µs Default full forward input pulse c 2000 µs Input pulse width range 500 2500 µs Input frequency 16 50 200 Hz Input timeout d 65 5 ms Input deadband e 40 µs Digital high level input current 7 25 mA a Full reverse corresponds to negative output voltage VIN b Neutral corresponds to zero output voltage 0V and is either braking or coasting depending on the current mode c Full...

Page 7: ...are made through the two sets of screw terminals built into the SPARK Figure 2 1 shows these connections in detail Figure 2 1 Power and Motor Connections 2 1 1 SCREW TERMINALS The SPARK has four M3 sized screw terminals two each for power and motor connections Each screw has a clamping washer that improves the contact area and clamping force compared to plain screw heads Table 2 1 lists the recomm...

Page 8: ...voltage drops below 5 5V the SPARK will brown out resulting in a power loss to the motor It is also recommended to incorporate a fuse or auto resetting circuit breaker in series with the SPARK between it and the power source to prevent exceeding the maximum current rating 2 1 4 CONNECTING MOTOR AND POWER WIRES Using an appropriate wire gauge for the expected current draw tightly crimp either a rin...

Page 9: ...ally white but may also be yellow or orange Figure 2 2 Servo PWM Connection The plastic surrounding the PWM port was designed provide cable retention by exerting pressure on the housing of a standard 3 wire cable housing Retention effectiveness may vary depending on the cable being used 2 2 2 CONTROLLING MOTOR SPEED AND DIRECTION The SPARK responds to a factory default pulse range of 1000µs to 200...

Page 10: ... output in order to minimize the heat generated by its H bridge Some heating is unavoidable so an aluminum heat sink passively dissipates heat into the surrounding atmosphere Figure 2 3 Heat Sink As seen in Figure 2 3 the heat sink is located at the center of the SPARK For most applications a cooling fan isn t necessary however airflow should be kept in mind when using the SPARK in high load appli...

Page 11: ... overriding the input command See section 2 6 STATUS LED for more information For example if the Forward Limit Switch is triggered a forward command from the PWM input is overridden and the output is forced into its neutral state However reverse commands are still accepted and sent to the output 2 4 2 LIMIT SWITCH WIRING The SPARK has two 3 pin connectors that can accept standard 3 wire sensor cab...

Page 12: ...all implement to press the Mode Button The following sections describe each operating mode in detail 2 5 1 BRAKE COAST MODE When not driving the motor the SPARK will short the motor terminals to dissipate electrical energy effectively braking the motor Alternatively the SPARK can be put in a Coast Mode which allows the motor to spin down at its own rate Press and release the MODE button to toggle ...

Page 13: ... several seconds while the SPARK immediately begins responding to the new signal range If the calibration routine was unsuccessful the Status LED will blink white and red and the previous values are restored Check that the signal didn t violate the timing constraints and or the neutral value wasn t too close to the full forward or full reverse values See section 2 6 STATUS LED for more information...

Page 14: ... Figure 2 6 shows the status codes associated with each operating state of the SPARK LED Status Code Time Scale 1 second 1 second State Normal Operation No Signal Brake Coast Full Forward Proportional Forward Neutral Brake Coast Proportional Reverse Full Reverse Forward Limit Tripped Reverse Limit Tripped Calibration Calibration Mode Successful Calibration Failed Calibration Factory Reset Mode but...

Page 15: ...REV 11 1100 UM 00 Copyright 2016 REV Robotics LLC 15 APPENDIX A DIMENSIONS All dimensions are in inches ...

Page 16: ...REV 11 1100 UM 00 Copyright 2016 REV Robotics LLC 16 APPENDIX B THERMAL DATA ...

Page 17: ... REV Robotics LLC 17 APPENDIX C LINEARITY DATA The following data was taken with a free spinning CIM motor and a 12V power source The flat zone in the middle represents the 40µs input deadband on either side of the neutral pulse width ...

Page 18: ...REV 11 1200 UM 00 Copyright 2016 REV Robotics LLC 18 APPENDIX D SCHEMATIC Appendix D shows the schematic for the REV Robotics SPARK Motor Controller ...

Page 19: ...2 AGND 12 VBB 8 CA 9 GHA 10 SA 11 GLA 3 GLB 4 SB 5 GHB 6 CB 14 CP1 13 CP2 2 GND 15 GND 16 GND 25 PAD U2 A4940 5 1 2 3 4 Q1 5 1 2 3 4 Q2 5 1 2 3 4 Q3 5 1 2 3 4 Q4 RV1 RV2 R1 27 R2 27 R3 27 R4 27 C1 1 0uF C2 1 0uF C4 0 1uF C3 1 0uF R5 82 0K R6 10K C6 0 1uF C5 10uF 1 ANODE 3 CATHODE 4 GND 5 VO 6 VCC U3 OPTO ISO TLP118 C7 0 1uF R7 1K R8 150 1 3 2 4 S1 SW TACT PTS645SM43SMTR92 R11 10K 1 T1 1 T2 1 T3 1 ...

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