When docked with a SPARK Flex the NEO Vortex's phase and sensor connections are kept securely together. This eliminates intermediate wiring that can fail if not secured properly.

Docking Materials

Docking the NEO Vortex with the SPARK Flex is simple and only requires the following materials and tools:

• NEO Vortex Brushless Motor

• SPARK Flex Motor Controller

• Docking Hardware

  • 4 - M3 x 25 mm Socket Head Screws (included with SPARK Flex)

• 2.5 mm Hex Key

Docking Procedure

Follow these steps to ensure a secure and proper docking:

1. Ensure that power is disconnected from the SPARK Flex.

2. Align the motor phase bullets between the NEO Vortex and SPARK Flex.

3. Allowing the bullets to guide the two together, press the NEO Vortex and SPARK Flex together until their bodies meet. There may be a small gap between the motor and the controller opposite the bullets. This is normal.

4. Insert the included docking screws into the counterbored Docking Screw Clearance Holes on the SPARK Flex.

5. Using the 2.5 mm Hex Key, tighten the four screws evenly in a crisscross pattern until the screws are tight and secure. The screw heads should be sub-flush from the mounting face of she SPARK Flex. If you have a torque wrench, the ideal torque is 11.5 ±0.9 in-lb (1.3 ±0.1 Nm).

Undocking Procedure

Follow these steps to undock the NEO Vortex and SPARK Flex:

1. Ensure that power is disconnected from the SPARK Flex.

2. Completely remove the four docking screws from the assembly.

3. Gently pull the NEO Vortex and SPARK Flex apart until the bullets release. Try to maintain their relative orientation to each other while pulling them apart.

NEO Vortex Overview

Features

• High-resolution encoder

• Integrated motor parameter and calibration memory

• Through-hex bore with taper for numerous quick-change shafts

• No motor wires - reliable and robust docking connections for motor phases and sensor

• Dual sensor, direct contact winding temperature sensing

• 560KV (RPM per volt)

• 640 Watts (375 @ 40A)

• #10-32 threaded holes on a 2in bolt circle

• The motor and motor controller's silhouette fits behind a standard 2in rectangular tube

• 1/2in hex through-bore rotor compatible with any length hex shaft or application-specific Vortex Shafts:

  • 8mm keyed

  • Falcon compatible spline

  • MAXSwerve with integrated key

  • 7-tooth 20DP gear

  • MAXPlanetary input

  • Others to be announced

NEO Vortex Anatomy

Motor Specifications

Mechanical Specifications

NEO Vortex Motor Curve

DC Motors consist of two major parts, the part that rotates, or the “rotor”, and the part that is stationary, or the “stator”. A DC motor uses these parts to convert electrical energy into rotational mechanical energy using electricity and permanent magnets. Two types of DC motors are used in FIRST Robotics Competition: Brushed DC Motors and Brushless DC motors. Both types are useful in various robot applications, and both have their trade-offs.

Brushless vs. Brushed Motor Basics

Operating a brushed DC motor is simple; provide DC electrical power and the motor spins. In a brushed motor, the rotor consists of electrical winding wires and the stator consists of permanent magnets. Since the electrical part is spinning, there needs to be a way to connect the external power wires to the spinning rotor. This is accomplished through conductive “brushes” that make contact with the stator, automatically sequencing the power to make the rotor spin. Brushes make it easy on us, but they produce extra friction which reduces the efficiency of the motor.

Brushless DC motors don’t have brushes. They still have both electrical winding wires and permanent magnets, but the locations are flipped. The stator now consists of the electrical parts, and the spinning rotor consists of the magnets. This means there is no more brush friction within the motor, making a brushless motor more power-efficient. However, you can’t just give it DC power and expect it to spin. Without the brushes doing the sequencing for us, you must use a specialized motor controller that is designed for brushless motors to properly sequence the power and get the rotor spinning.

The REV NEO Brushless Motor runs an 8mm keyed output shaft which allows for an easy transition from CIM-style brushed motors into brushless.

Swap a set of NEO Brushless Motors into your drivetrain or use one in an elevator to save weight and maintain peak performance. When paired with the SPARK MAX, you can use the integrated hall-effect sensors to calculate incremental position or speed from the NEO.

Key Terms

General Application Information

In order to ensure that an electric motor lasts as long as possible a few rules of thumb should be kept in mind:

1. Smooth loading - large torque spikes or sudden changes in direction can cause excess wear and premature failure of gearbox components. This is only an issue when the torque spike exceeds the rated stall torque of the motor. When shock loading is necessary, it is best to utilize mechanical braking or a hard stop that absorbs the impact instead of the motor.

2. Overheating - when a motor is loaded at near its maximum operating torque it will produce more waste heat than when operating at a lower operating torque. If this heat this allowed to build up the motor can wear out prematurely or fail spontaneously.

3. Poorly supported output shaft, most motor output shafts are not designed to take large thrust forces or forces normal to the shaft. Bearings need to be used to support the axle when loads in these directions are expected.

The Brushless Revolution

In the fall of 2018, the NEO Brushless Motor and SPARK MAX Motor Controller became the first brushless motor and compatible ESC (Electronic Speed Controller) designed to meet the unique demands of the FRC community. Since then, REV Robotics has been working to continue the Brushless Revolution by releasing products and software features based on our customer's most popular feedback.

The Next Generation of Motors and Controllers

NEO Vortex Brushless Motor

The NEO Vortex Brushless Motor is a high-power, high-performance, and high-resolution sensored brushless motor from REV Robotics. It features a dockable controller interface that can be mounted directly to a SPARK Flex Motor Controller or a NEO Vortex Solo Adapter allowing control from any brushless motor controller, like the SPARK MAX. Its through-bore rotor is the heart of its unique interchangeable shaft system, facilitating easy integration with various robot mechanisms.

SPARK Flex Motor Controller

The SPARK Flex Motor Controller is a new smart motor controller from REV Robotics. Its dockable form factor allows direct mounting onto a NEO Vortex to simplify wiring and maintain flexibility. Improving upon the foundation of the SPARK MAX, new features of the SPARK Flex Motor Controller include 3-phase current sensing, reverse polarity protection, and an expanded data port with additional interfaces. When docked to an adapter, the SPARK Flex can control any existing NEO or compatible brushless/brushed DC motor.

Incredible Power Density and Integrated USB Control

SPARK MAX Motor Controller

The SPARK MAX Motor Controller is your first step for getting advanced brushed and brushless DC motor control in a small, easy-to-use package. SPARK MAX is a true all-in-one controller that will push the envelope for FRC teams. Test prototypes and tune parameters without needing the full control system, only using a computer running the REV Hardware Client and a USB C Cable!

NEO V1.1 Brushless Motor

The NEO V1.1 Brushless Motor offers an incredible power density due to its compact size and reduced weight. As it is designed to have similar performance characteristics and matching mounting features, NEO V1.1 can be a drop-in replacement for CIM-style motors. This motor is perfect for your FRC Robot, Industrial platform or Warehouse robot, Electric skateboards, and more! The NEO V1.1 has been optimized to work with the SPARK MAX Motor Controller to deliver best-in-class performance and feedback.

NEO 550 Brushless Motor

The NEO 550 Brushless Motor is the smallest member of the NEO family of brushless motors. Its output power and small size are designed to make NEO 550 the perfect motor for intakes and other non-drivetrain robot mechanisms. Mounting holes and pilot match a standard 550 series motor, making it natively compatible with many existing off-the-shelf gearboxes.

NEO Vortex Shaft Features

Vortex shafts feature a 1/2 in hex section for transferring torque, and a locating taper section for effortless self-centering. When the shaft is secured with a #10-32 Shaft End Screw, the taper keeps your shaft perfectly centered as it's drawn in and locked into place within the NEO Vortex Spindle.

NEO Vortex Shaft Anatomy

NEO Vortex Shaft Options

NEO Vortex

What are some best practices for using the NEO Vortex in a build?

What Smart Current Limit should I set for my NEO Vortex?

SPARK Flex

Are there any quick tips for getting the most from a SPARK Flex?

SPARK MAX

What is your best advice for using a SPARK MAX?

How do I run an encoder with the SPARK MAX?

My SPARK MAX isn't working, where do I start?

What does the LED on my SPARK MAX indicate?

Should I change the factory default setting for Smart Current Limit?

Can I run a NEO Vortex with a SPARK MAX?

Why don't the settings save on my SPARK MAX?

NEO V1.1

What are general best practices for the NEO V1.1?

What Smart Current Limit should I set for my NEO V1.1?

How do I make a NEO V1.1 compatible with the new SPARK FLEX Motor Controllers?

Can I run a NEO V1.1 on 24V?

NEO 550 FAQ

What are general best practices for the NEO 550?

What Smart Current Limit should I set for my NEO 550?

SPARK Motor Controllers

NEO Brushless Motors

Shaft Installation Materials

Installing a Vortex Shaft is simple and requires the following materials and tools:

• NEO Vortex (docked or undocked)

• Desired Vortex Shaft

• #10-32 Shaft End Screw

• 5/32 in Hex Key

Shaft Installation Procedure

Follow these steps to ensure a secure shaft installation:

1. Insert the shank of the desired shaft into the Vortex Spindle from the front mounting face of the motor.

2. While inserting, you may need to rotate the shaft or rotor slightly to align the hexagonal portion of the shank with the hexagonal bore of the spindle.

3. Once the shaft is fully inserted, install the Shaft End Screw through the back side of the spindle and thread into the shank.

4. Tighten the Shaft End Screw with the 5/32 in hex key to draw the taper into a locked and centered position. If you have a torque wrench, the ideal torque is 25 ±5 in-lb (2.8 ±0.6 Nm).

Shaft Removal Procedure

1. Remove the Shaft End Screw with the 5/32 in hex key.

2. Remove the Vortex Shaft from the motor.

NEO V1 Overview

The REV NEO Brushless Motor (REV-21-1650) is the first brushless motor designed to meet the unique demands of the FRC community. Offering an incredible power to weight ratio along with it's compact size it's designed to be a drop-in replacement for CIM-style motors as well as an easy install with mounting options.

Features

• Drop-in replacement for CIM-style motors

• Shielded out-runner construction

• Front and rear ball bearings

• High-temperature neodymium magnets

• High-flex silicone motor wires

• Integrated motor sensor

  • 3-phase hall sensors

  • Motor temperature sensor

Wiring Connections

Motor Specifications

Mechanical Specifications

NEO V1 Motor Curve

All of our motor testing was performed on our in-house dynamometer.

NEO V1.1 Pinion Pressing Guide

Needed Materials

• NEO V1.1 (REV-21-1650)

• 1 - 10-32 x 3/8in long Socket Head Screw

• Press Fit Pinion

• Arbor Press

Steps

NEO V1.0 Pinion Pressing Guide

Needed Materials

• NEO V1.0 (REV-21-1650)

• A high-quality 1.5mm Allen Key (i.e. WERA Tools, Bondhus)

• Loctite 242

• Arbor Press

Steps

The NEO Vortex Solo Adapter (REV-11-2828), allows teams to seamlessly integrate the NEO Vortex Brushless Motor with a SPARK MAX. This adapter breaks out the motor sensor connector and phase wire connections for simple backward compatibility.

Specifications

Kit Contents

The following items are included with each NEO Vortex Solo Adapter

Docking a NEO Vortex Solo Adapter

When docked with a NEO Vortex Solo Adapter a NEO Vortex can be controlled with a SPARK MAX.

Docking Materials

Docking the NEO Vortex with the SPARK Flex is simple and only requires the following materials and tools:

• NEO Vortex Brushless Motor

• NEO Vortex Solo Adapter

• Docking Hardware

  • 4 - M3 x 25 mm Socket Head Screws (included with SPARK Flex)

• 2.5 mm Hex Key

Docking Procedure

Follow these steps to ensure a secure and proper docking:

1. Ensure that power is disconnected from the NEO Vortex Solo Adapter.

2. Align the motor phase bullets between the NEO Vortex and NEO Vortex Solo Adapter.

3. Allowing the bullets to guide the two together, press the NEO Vortex and NEO Vortex Solo Adapter together until their bodies meet. There may be a small gap between the motor and the controller opposite the bullets. This is normal.

4. Insert the included docking screws into the counterbored Docking Screw Clearance Holes on the NEO Vortex Solo Adapter.

5. Using the 2.5 mm Hex Key, tighten the four screws evenly in a crisscross pattern until the screws are tight and secure. The screw heads should be sub-flush from the mounting face of she NEO Vortex Solo Adapter. If you have a torque wrench, the ideal torque is 11.5 ±0.9 in-lb (1.3 ±0.1 Nm).

Undocking Procedure

Follow these steps to undock the NEO Vortex and NEO Vortex Solo Adapter:

1. Ensure that power is disconnected from the NEO Vortex Solo Adapter.

2. Completely remove the four docking screws from the assembly.

3. Gently pull the NEO Vortex and NEO Vortex Solo Adapter apart until the bullets release. Try to maintain their relative orientation to each other while pulling them apart.

NEO V1.1 Overview

Features

• Drop-in replacement for CIM-style motors

• Shielded out-runner construction

• Front and rear ball bearings

• High-temperature neodymium magnets

• High-flex silicone motor wires

• Integrated motor sensor

  • 3-phase hall sensors

  • Motor temperature sensor

New to NEO V1.1

• A tapped #10-32 hole on the end of the shaft, allowing teams to retain pinions on the shaft without using external retaining rings

• A tapped #10-32 hole on the back housing of the motor, making it no longer necessary to remove the motor housing to press pinions

• Additional holes on the front face of the motor for added mounting flexibility

Wiring Connections

Motor Specifications

Mechanical Specifications

NEO V1.1 Motor Curve

SPARK Flex Dock Overview

When connected to a SPARK Flex Dock (REV-11-2858) the SPARK Flex can control any existing NEO or compatible brushless/brushed DC motor.

SPARK Flex Dock Features & Specifications

NEO 550 Overview

The REV NEO 550 Brushless Motor runs a 0.12in output shaft which, when combined with its 550-style mounting features, allows for easy installation in many off-the-shelf gearboxes.

Its small size and weight make it easy to put power where you need it, whether that is on intakes, end-effectors, or other weight-sensitive mechanisms. However, keep in mind that this motor has a lower thermal mass than a NEO, CIM, or Mini CIM, and thus it may not be ideal for some drivetrain applications.

Wiring Connections

Features

• Mounting features match other 550 series DC motors

• Front and rear ball bearings

• High-temperature neodymium magnets

• High-flex silicone motor wires

• Integrated motor sensor (3-phase hall sensors)

• Motor temperature sensor

Motor Specifications

Mechanical Specifications

NEO 550 Motor Curve

Dynamometer Characterization

The data for Motor Curves provided in our documentation is generated with an inertia-type dynamometer, or dyno, and then further analyzed by our engineers.

Parts of a Dynamometer

The dynamometer REV Robotics uses consists of the following major components mounted directly to the main shaft:

• Flywheel - A weighted flywheel supported by ball bearings

• Encoder - An encoder that collects data during the test

• Motor Mount - An adjustable system where the motor is equipped with a coupling so its output lines up with the rotational axis of the dynamometer

• Motor and ESC - The motor and ESC (Electronic Speed Controller or Motor Controller) are always tested as a unit. Some examples of this are the SPARK MAX and NEO or the Falcon 500 Motor and Talon FX ESC

• Power Supply - A high current power supply system capable of supplying 12V at 200A with minimal voltage sag while handling voltage spikes and braking conditions.

Testing Process

A test starts at rest and consists of applying a constant throttle setting to the motor and motor controller. Generally, this value is 100%, but any value can be used. The motor is allowed to accelerate the flywheel while data is recorded with timestamps.

The data recorded during testing includes:

• The speed and position of the flywheel encoder

• The DC current at the input of the ESC

• The bus voltage at the input of the ESC

• Any data provided by the ESC, this may vary from controller to controller

  • This is generally collected over CAN

Data Analysis

Using the speed and position data, the acceleration of the flywheel can be calculated throughout the timespan of the test. The moment of inertia of the rotating portion of the dyno is known to a high degree of precision. This includes the flywheel, shaft, hub, motor rotor, couplings, etc. Using the acceleration and moment of inertia, the torque produced by the motor can be calculated.

Calibration

At thousands of RPM, the flywheel and shaft system can generate enough drag to affect the results of the test significantly. To determine the drag in the system from air movement and viscous friction, the dyno is spun up to a very high speed and allowed to freely rotate until it comes to a stop. During this process, speed and position data are recorded and then used to calculate the drag torque. The drag torque is added to the motor torque calculated from each acceleration measurement during a motor test so that our results are calibrated for our specific dyno setup.

Current Limiting

At low speeds, a motor will typically draw more current than the set current limit on its ESC. Current limiting may affect the duty cycle and commutating of the motor, causing the data to deviate from “raw” motor performance. Current limiting processes within an ESC's software can also cause excess noise in current, voltage, and acceleration data collected by the dyno. For these reasons, the low-speed section where current limiting is in effect is usually removed from the data set before characterizing the motor.

Data Characterization

Characterization is accomplished by correlating torque and current with velocity. These relationships are usually extremely linear and a best fit can be used to approximate and extrapolate the motor’s performance outside of the test region. Additional processing can be applied to compensate for voltage drop in the power supply lines at high currents.

REV's in-house Dynamometer

REV Robotics has designed a dynamometer that we are working to make open source and available to the public. In creating this dynamometer, we have focused on using as many off-the-shelf components as possible in an effort to make this design easy for members of the community to build.

Below are some photos of our progress!

NEO 550 Pinion Pressing Guide

Needed Materials:

• Press Fit Pinion

• Arbor Press

Steps

NEO Vortex - Quick Comparison

NEO V1.1 - Quick Comparison

Interpreting this Data

Values of motor data may vary from manufacturer to manufacturer because of variances in the dynamometer used to test each motor and how that data is analyzed. With each motor shown on this page, REV Robotics performed the same dynamometer testing and analysis of the data collected.

Absolute vs. Relative Data

• Absolute Values for a specification are determined independently of each similar motor made by other manufacturers. Each of the specifications are determined by a manufacturer's individual testing procedures and methods of analyzing test data.

• Relative Values for a specification are found by running the same test and analysis on a motor. While the values provided may not match a motor's listed Absolute Values for a given specification, this kind of data helps us compare the motors as fairly as possible.

Motor Curves

NEO Vortex - REV Robotics

NEO V1.1 - REV Robotics

Kraken X60 - WestCoast Products

Falcon 500 V2 - VEX Robotics

Feature Highlights:

• Docking interface for motor phases and sensors

• USB type C configuration and control

• PWM and CAN communication

• Fully integrated power and control wires

• Enhanced data port with more power, latching connector, and additional serial interfaces

• Advanced motor control modes include:

  • Velocity

  • Position

  • Current

  • New modes with future firmware updates

• #10-32 threaded holes on a 2in bolt circle

• Motor and motor controller's silhouette fits behind a standard 2in rectangular tube

SPARK Flex Resources

General Resources

Software Resources

The following tables provide the operating and mechanical specifications for the SPARK Flex Motor Controller.

Main Electrical Specifications

PWM Input Specifications

Data Port Specifications

Mechanical Specifications

SPARK Flex is designed to drive 12V brushed and brushless DC motors at current up to 60A continuously. It features a unique Docking Interface that ensures secure and reliable motor phase and sensor connections, reducing the chance of intermittent or poor connections affecting the commutation of the attached motor.

Power Input

Power input wires are labeled as + and - with red and black wires, respectively, and consist of two 12 AWG ultra-flexible silicone-coated wires extending 45 cm from the motor controller case.

SPARK Flex is intended to operate in a 12 V DC robot system, however it is compatible with any DC power source between 4.5 V and 24 V.

When used in high power applications, it is recommended to use a power source that is capable of handling large surge currents, e.g. a 12V lead-acid battery. If the supply voltage drops below 4.5 V the SPARK Flex will brown out, which can result in unexpected behavior. It is also highly recommended to add a fuse or circuit breaker in between your SPARK Flex and its power source to prevent exceeding the maximum current rating.

Docking Interface

SPARK Flex is specifically designed to dock with the NEO Vortex Brushless Motor. Docking eliminates the extra connections between the motor and motor controller that are prone to fail due to assembly issues and rough environments.

When docked into a SPARK Flex Dock (coming soon), the motor controller can also drive virtually any 12 V brushed DC motor and the existing NEO & NEO 550 brushless motors.

Instruction on how to dock a SPARK Flex can be found within the documentation of the applicable device:

• SPARK Flex Dock Instructions - Coming Soon

CAN/PWM Connections

CAN and PWM control connections share a set of four integrated 26 AWG twisted wires extending 45 cm from the case of the motor controller. Each wire is color coded according to its function:

The wires are terminated with two 1 x 3, 0.1 in pitch, rectangular connectors, both excluding the center pin. One connector is pinned and the other socketed to facilitate daisy-chaining between multiple CAN devices on the bus when using the CAN interface.

When using the PWM interface, only one of the two connectors should be used. In most systems this will be the socketed connector. Therefore, it is best practice to secure the unused wires and protect the exposed pins by covering them with electrical tape.

USB-C Port

The USB-C Port is located above the CAN/PWM wires of the SPARK Flex. It supports USB 2.0 and can provide 5 V power for the SPARK Flex's internal microcontroller.

More information about what can be configured and operated through the USB port can be found in the USB Interface section.

The SPARK Flex Motor Controller is a fully featured smart motor controller designed to be robust and easy to use yet fully capable of advanced motion control. The following sections describe each feature in detail.

SPARK Flex Connections

Allows for seamless firmware updates and code uploads, facilitating quick and efficient software management through the REV Hardware Client

Allows for integration of additional sensors such as the Through Bore Encoder, analog sensors, absolute encoders, and limit switches.

Ultra-flexible, and Silicone-coated Wires

Status LED Indicator

• Precisely engineered clearance holes for docking screws provide stable and secure attachment of the SPARK Flex and NEO Vortex to your Mechanism

• High-current Bullet Connectors facilitate quick and secure connections to the NEO Vortex's phases, ideal for high-performance and high-power applications

• Robust Motor Interface Connector mates to the NEO Vortex's control systems to ensure efficient, secure, and reliable electrical connections and communication

• The SPARK Flex features six #10-32 threaded mounting holes on a 2 in bolt circle

Located next to the SPARK Flex's power and control input wires, the Data Port allows for extra sensor input and future feature expansion. Connector details can be found below.

Data Port Pinout

SPARK Flex Data Port Break Out Cable

The keyed and locking Data Port connector ensures a secure and aligned fit when plugged into the SPARK Flex Motor Controller. Its JST-PH 6-pin connector is designed to plug directly into the REV Through Bore Encoder, connecting both the quadrature and absolute encoder outputs to the appropriate SPARK Flex Data Port pins. Additional inputs, like Limit Switch and Analog inputs, are broken out to shrouded, 1 x 3 pinned, 0.1in pitch, PWM-style connectors that provide both power and ground in addition to the input signal.

SPARK Flex Data Port Pigtail Cable

Data Port Connector Information

The SPARK Flex Data Port is a 0.05 in pitch, 2 x 5 pin, keyed and locking connector. Custom cables can be made with the following parts:

Data Port Pigtail - Electrical Specifications

Data Port Breakout Cable - Electrical Specifications

• 1 x JST PH, 6-pin connector

• 4 x Servo Connector 0.1" Pitch, 3-pin Male Shrouded

The mounting face of the SPARK Flex features six #10-32 threaded mounting holes on a 2 in bolt circle. Each hole has an absolute maximum depth of 0.25 in.

Depth gauges are laser-etched into each side of the SPARK Flex body to make it easy to check that the chosen screw length will not violate the maximum depth.

Simply check the screw length against the intended stack-up of structure and motor controller, and verify that it does not violate the maximum depth.

Pressing the SPARK Flex Mode Button

The Mode Button is specifically designed to be difficult to press inadvertently. Therefore, please follow the steps below to press the mode button successfully.

Using a small and blunt tool, like a straightened paper clip, gently press the Mode Button. You should feel and hear a soft click. If you are in a noisy environment, you may only be able to feel the click through the tool.

If you do not feel the click, ensure the tool is aligned with the button.

Some early batches of SPARK Flex Motor Controllers have variances in the alignment of the Mode Button and the case hole. Misaligned buttons can still be pressed and the alignment does not affect the functionality of the SPARK Flex Motor Controller as a whole.

If your button is misaligned, please pay close attention and avoid the gap between the button and the printed circuit board (PCB):

SPARK Flex Anatomy

Side View

Outside

Inside

The SPARK Flex is a motor controller with many features allowing it to control a host of brushless and brushed motor controllers. Out of the box, the Flex can be docked directly with a NEO Vortex Brushless Motor and drive it with the Flex's PWM interface. This Getting Started guide will assume that you are driving NEO Vortex and includes steps to get the motor spinning using the REV Hardware Client as well as information on how to configure your SPARK Flex. Driving other motors requires the SPARK Flex Dock (coming soon) and will be covered in its own separate guides.

Before You Start

Before following this guide, the REV Hardware Client should be installed before continuing. It is the best way to verify that the device up to date and configured correctly. Configuration through the Hardware Client is required before using the CAN interface.

PWM Interface

The SPARK Flex responds to a factory default pulse range of 1000 µs to 2000 µs. These pulses correspond to full-reverse and full-forward rotation, respectively, with 1500 µs (±5% default input deadband) as the neutral position, i.e. no rotation. The input deadband is configurable with the REV Hardware Client or the CAN interface. The table below describes how the default pulse range maps to the output behavior.

CAN Interface

The SPARK Flex can be connected to a robot CAN network. CAN is a bi-directional communications bus that enables advanced features within the SPARK Flex.

Even though the CAN port is shared with the PWM port, SPARK Flex will automatically detect the incoming signal type and respond accordingly.

Each device on the CAN bus must be assigned a unique CAN ID number. Out of the box, SPARK Flex is assigned a device ID of 0. This ID is considered "unconfigured" and must be assigned to a unique number from 1 to 62. CAN IDs can be changed by connecting the SPARK Flex to a Windows computer and using the REV Hardware Client.

Additional information about the CAN accessible features and how to access them can be found in the SPARK Flex API Information section.

USB Interface

The SPARK Flex can be configured and controlled through a USB connection to a computer running the REV Hardware Client.

Brushed/Brushless Mode - Motor Type

This mode is only compatible with the SPARK Flex Dock (coming soon). More information about this mode will be available once the dock is available.

Brake/Coast Mode - Idle Behavior

When the SPARK Flex is receiving a neutral command the idle behavior of the motor can be handled in two different ways: Braking or Coasting.

When in Brake Mode, the SPARK Flex will effectively short all motor wires together. This quickly dissipates any electrical energy within the motor and brings it to a quick stop.

When in Coast Mode, the SPARK Flex will effectively disconnect all motor wires. This allows the motor to spin down at its own rate.

The Idle Mode can be configured using the Mode Button, CAN, and USB interfaces.

Mode Button Configuration

Follow the steps below to switch the Idle Mode between Brake and Coast with the Mode Button.

1. Connect the SPARK Flex to main power, not just USB Power.

2. The Status LED will indicate which Idle Mode is currently configured by blinking blue or cyan for Brake and yellow or magenta for Coast depending on the motor type.

3. Press and release the Mode Button

4. You should see the Status LED change to indicate the selected Idle Mode.

USB Configuration

Follow the steps below to switch the Idle Mode between Brake and Coast with the USB and the REV Hardware Client application. Be sure to download and install the REV Hardware Client application before continuing.

1. Connect the SPARK Flex to your computer using a USB-C cable.

2. Open the REV Hardware Client application and verify that the application is connected to your SPARK Flex.

3. On the Basic tab, select the desired mode with the Idle Mode switch.

4. Click Update Configuration and confirm the change.

CAN Configuration

Please see the API Information for information on how to configure the SPARK Flex using the CAN interface.

Recovery Mode

In the rare case where a firmware update has been interrupted or corrupted, it may be necessary to boot the SPARK Flex into Recovery Mode. This can be done by following the steps below. Have a computer running the REV Hardware Client and a USB cable ready in order to reload the device firmware once the device is in Recovery Mode.

1. Start with all power disconnected from the SPARK Flex.

2. Press and hold the Mode Button.

3. While still holding the Mode Button, connect power by either turning on main power or connecting the USB cable between the SPARK Flex and the computer.

4. Once powered, you may release the Mode Button. The LED should stay dark. The SPARK Flex is now in Recovery Mode.

If the firmware is not booting properly, it may not be easy to know if the device has entered Recovery Mode since the LED will be dark in both cases. To confirm that the SPARK Flex is in Recovery Mode:

1. Connect the USB cable between the SPARK Flex and computer if not already connected.

2. In the REV Hardware Client, the SPARK Flex should show up as a Recovery Mode Device when scanning for devices.

If the device doesn't show up, please repeat the process, ensuring that the power and button holding sequence is followed exactly. If the device still doesn't show up, please contact REV Support.

Required Materials

• 12 V battery

• 120 A circuit breaker

• Power Distribution Hub

• SPARK Flex

• NEO Vortex

• Associated wiring and a "test bed" described below

• USB type-C cable

• A Computer Running the REV Hardware Client

Prepare the Components

Test Bed

Motor Connections and Mounting

Mount the docked SPARK Flex and NEO Vortex assembly to a piece of structure to keep it secured when it spins up. The motor has a lot of inertia and upon spin-up it can jump off the table.

The SPARK Flex's mounting face includes six #10-32 threaded mounting holes that are on a 2 in bolt circle. This bolt pattern is compatible with many structure types available, including REV ION System. However, two 0.196 - 0.201 in holes, spaced 2 in apart can easily be drilled into a piece of wood to rigidly mount the assembly.

Power Connections

The power wires are permanently connected to the SPARK Flex and are not replaceable. Take care not to cut these wires too short. It is highly recommended to install connectors on these wires to allow for reconfiguration as you experiment and design your robot. WAGO 221 Inline Splicing Connectors (REV-19-2491-PK50) and Anderson Power Pole connectors are commonly used for this purpose.

Connect the integrated SPARK Flex power leads labeled + (red) and - (black) to an available channel on the Power Distribution Hub. If you need to extend the length of the integrated wires, it is recommended to use 12 AWG wire or larger (a lower gauge number).

Power On

Connect to the SPARK Flex

Plug in the USB cable and start the REV Hardware Client. Select the SPARK Flex from the Connected Hardware

Basic Setup and Configuration

Before any parameters can be changed, you must first assign a unique CAN ID to the device. This can be any number between 1 and 63. After setting a unique CAN ID, the user interface will refresh and allow you to change other parameters.

Set the Motor Type

If you are using a NEO Vortex, NEO, or NEO 550, verify that the motor type is set to REV NEO Brushless, Sensor Type is Hall Effect, and the LED is blinking Magenta or Cyan.

Suggested Current Limits

Your ideal current limit may vary based on your specific application, but these values can be used as a starting point to reduce the chance of an overload on your motor as you begin tuning your specific mechanism's Smart Current Limit.

Save the Settings

The settings must be saved for the SPARK Flex to remember its new configuration through a power cycle. To do this, press the Burn Flash button at the bottom of the page. It will take a few seconds to save, indicated by the loading symbol on the button.

Any settings saved this way will be remembered when the device is powered back on. You can always restore the factory defaults if you need to reset the device.

Spin the Motor

To spin the motor, go to the Run tab, keep all of the default settings and press Run Motor. The setpoint is 0 by default, meaning that the motor is being commanded to idle (0% power). When you press Run you should see the LED go from slow blinking to solid, indicating that the motor is idling.

Slowly ramp the setpoint slider up. The motor should start to spin and you should see a green blink pattern proportional to the speed you have set to the motor. Slowly ramp the slider down. The motor should spin in reverse, and you should see a red blink pattern proportional to the speed you have set to the motor.

Many issues can be solved by systematic troubleshooting without needing to contact REV Support. Take a look at the troubleshooting tips below for help in determining the cause of the issue you are seeing. Should you need to contact us, describing the steps you've taken in detail will help us get you up and running quickly.

General Troubleshooting Tips

The key to effective troubleshooting is isolating the issue. Many issues can show the same symptom, so eliminating failure points one at a time is critical to finding the root cause.

Rule Out Issues By Isolation

If possible, try to eliminate a section of the system when troubleshooting. For example:

• Rule out a code or control wiring issue:

  • Use the REV Hardware Client to run the SPARK Flex over USB.

    • Please be aware of the CAN lockout feature of the SPARK Flex. If it has been connected to the roboRIO's CAN bus, a safety feature within the SPARK Flex will lock out USB communication. Disconnecting from the CAN bus and power cycling the MAX will release the lock.
• Rule out a code issue:

  • Create a simple test program using our SPARK Flex Example Code.

• Rule out a mechanical issue:

  • Remove the motor from the mechanism or use a different, free-spinning motor.

Use the Driver Station

An extremely useful set of tools can be found on the Driver Station:

• • Look at the PDP channel current draw:

    • Higher than expected current on a channel can indicate both mechanical and electrical issues.

  • Look at the battery voltage:

    • Large dips in the battery voltage around the time of an issue can indicate battery health issues that cause brownouts.

• • Look at the CAN Bus Utilization.

  • Look at CAN Faults.

  • Look at Comms Faults:

    • Comms faults can affect the SPARK Flex. If it loses communication with the roboRIO, it will go to its safe disabled state. This can look like a momentary glitch in a motor spinning if the comms faults are infrequent and irregular.

Use the APIs

It is also very useful to log or plot operating values internal to the SPARK Flex. These values can be accessed using the SPARK Flex APIs. Useful values to log:

• getAppliedOutput()

  • This value will show what the SPARK Flex is actually applying to the motor output. This can illuminate issues with closed-loop control tuning.

• getOutputCurrent()

  • This value will show the output current going to the phases of the motor. Output current won't always be the same as the Input current measured by the PDP. Knowing the output current is useful to diagnose current-limit issues if motors are overheating.

• getBusVoltage()

  • A way to measure the input voltage right at the controller.

• getStickyFaults()

  • A sticky fault indicates if a fault has occurred since the last time the faults were reset. Checking these can provide a lot of insight into what the controller is experiencing.

CAN Troubleshooting

Recovery Mode

Sometimes, when updating the firmware on a SPARK Flex, it is possible for the process to be interrupted or for the firmware to be corrupted by a bad download or other type of interruption in data transfer. In this state, the Status LED will be dark or dim and the device will fail to operate. There is a built-in recovery mode that can force your device to accept new firmware even if the controller seems to be bricked and the procedure is outlined below:

Please note, that performing this procedure will erase all data and settings on the device. To perform the procedure a small tool, like a straightened paper clip, is necessary to press the Mode Button (located to the right of the Status LED), the orange USB-C cable that came with the unit (or a DATA capable USB-C cable), and a native Windows based computer with the REV Hardware Client installed:

1. With the SPARK Flex disconnected from power, press and hold the Mode Button.

2. While still holding the Mode Button, connect the Device to the computer using the USB-C cable - the Status LED will not illuminate - this is expected.

3. With the REV Hardware Client running on the computer, wait a few seconds for the audible tone or icon for the device to be recognized in recovery mode then release the Mode Button - no lights will be present on the SPARK Flex during this stage of the process, this is expected.

4. Select the SPARK Flex in Recovery Mode from the REV Hardware Client window.

5. From the "Choose a Device" type dropdown, choose - SPARK Flex.

6. Choose the latest version of the firmware from the dropdown and then click update.

7. Wait for the software update to complete.

8. Power cycle unit (unplug and plug in USB-C) click on the SPARK Flex icon, and clear any sticky faults - the recovery should be complete!

SPARK Flex has many operating modes that can be configured through its CAN and USB interfaces.

Brake/Coast Mode - Idle Behavior

When the SPARK Flex is receiving a neutral command the idle behavior of the motor can be handled in two different ways: Braking or Coasting.

When in Brake Mode, the SPARK Flex will effectively short all motor wires together. This quickly dissipates any electrical energy within the motor and brings it to a quick stop.

When in Coast Mode, the SPARK Flex will effectively disconnect all motor wires. This allows the motor to spin down at its own rate.

The Idle Mode can be configured using the Mode Button, CAN, and USB interfaces.

Mode Button Configuration

Follow the steps below to switch the Idle Mode between Brake and Coast with the Mode Button.

1. Connect the SPARK Flex to main power, not just USB Power.

2. The Status LED will indicate which Idle Mode is currently configured by blinking blue or cyan for Brake and yellow or magenta for Coast depending on the motor type.

3. Press and release the Mode Button.

4. You should see the Status LED change to indicate the selected Idle Mode.

USB Configuration

1. Connect the SPARK Flex to your computer using a USB-C cable.

2. Open the REV Hardware Client application and verify that the application is connected to your SPARK MAX.

3. On the Basic tab, select the desired mode with the Idle Mode switch.

4. Click Burn Flash and confirm the change.

CAN Configuration

SPARK Flex will indicate important status information on its multi-colored Status LED visible through the frosted plastic near the USB port. The following tables shows each state and the corresponding LED color pattern.

Standard Operation

Identification, Updating, and Recovery

Fault Conditions

Feature Summary

• Brushed and sensored-brushless motor control

• PWM, CAN, and USB control interfaces

  • PWM/CAN - Locking and keyed 4-pin JST-PH

  • USB - USB type C

• USB configuration and control

  • Rapid configuration with a PC

• Smart control modes

  • Closed-loop velocity control

  • Closed-loop position control

  • Follower mode

• Encoder port

  • Locking and keyed 6-pin JST-PH

  • 3-phase hall-sensor encoder input

  • Motor temperature sensor input

• Data port

  • Limit switch input

  • Quadrature encoder input with index

  • Multi-function pin

• Mode button

  • On-board motor type and idle behavior configuration

• RGB status LED

  • Detailed mode and operation feedback

• Integrated power and motor wires

  • 12 AWG ultra-flexible silicone wire

• Passive cooling

Kit Contents

The following items are included with each SPARK MAX Motor Controller

• 1 - SPARK MAX Motor Controller

• 1 - USB-A male to USB-C cable

• 1 - 4-pin JST-PH to CAN cable

• 1 - 4-pin JST-PH to single PWM cable

• 1 - PWM/CAN cable retention clip

• 1 - Data port protection cap

Special Thanks

SPARK MAX is designed to drive 12V brushed and brushless DC motors at currents up to 60A continuously. Power and motor connections are made through the two sets of wires built into the SPARK MAX. The wires are 12AWG ultra-flexible silicone-coated wire. Each wire runs approximately 15cm from the end faces of the controller. Be sure to take care when cutting and stripping the wires as not to cut them too short. The figure below shows these connections in detail.

Motor Output

Motor output wires are labeled as A, B, and C with red, black, and white wires. Brushed motors must be connected to the A and B wires, while brushless motors must be connected to all three. It is critical that the order of the brushless motor wires match the SPARK MAX or the motor will not spin and could be damaged. Additional details are below.

Motor Connections

Power Input

Power input wires are labeled as V+ and V- with red and black wires. The SPARK MAX is intended to operate in a 12 V DC robot system, however, it is compatible with any DC power source between 5.5 V and 24 V.

When using high-current motors, it is recommended to use a power source that is capable of handling large surge currents, e.g. a 12V lead-acid battery. If the supply voltage drops below 5.5V the SPARK MAX will brown out, resulting in unexpected behavior. It is also highly recommended to incorporate a fuse or circuit breaker in series with the SPARK MAX between it and the power source to prevent exceeding the maximum current rating.

CAN/PWM Port

The CAN/PWM Port is located on the power input side of the SPARK MAX. This port can be connected to either a servo-style PWM signal or a CAN bus with other devices. Connector details can be found below.

CAN/PWM Port Connector Information

Mating Connector Information

Identical-function pins are electrically connected inside the SPARK MAX, therefore the CAN daisy-chain is completed internally and any two signal and ground pairs can be used for PWM.

USB-C Port

The USB-C Port is located on the power input side of the SPARK MAX. It supports USB 2.0 and 5V power for the SPARK MAX's internal microcontroller. While you can configure the SPARK MAX without main power, you will not be able to spin a motor.

Encoder Port Connector Information

Mating Connector Information

SPARK MAX Data Port Pinout

Located on the top of the SPARK MAX, the Data Port allows for extra sensor input and future feature development. The connector details can be found below.

SPARK MAX Data Port Features

Limit Switch Inputs

SPARK MAX has two limit switch inputs that, when triggered, can independently prevent motion in both the forward and reverse directions. By default, when the pin for the corresponding direction is grounded, SPARK MAX will override any input commands for that direction and force the output into the neutral state. Input commands for the opposite direction will still be processed unless the corresponding limit signal is also triggered.

The default polarity is compatible with Normally Open (NO) style limit switches, whose contacts are shorted together when the switch is pressed. The Limit Switch Inputs can be configured for the opposite polarity using the USB or CAN interfaces. When configured for the opposite polarity, Normally Closed (NC), the limit will be triggered when the pin is left disconnected from ground. In other words, connecting the pin to ground will release the limit. The following table shows these configurations in detail:

Limit Switch Operation

Quadrature Encoder Input

When in Brushed Mode, an external encoder can be connected through either the Data Port or the Encoder Port.

The SPARK MAX encoder signals are not pulled high internally. This is to ensure the maximum compatibility with different types of encoders.

Analog Input

The Analog Port on the SPARK MAX can measure voltages up to 3.3V with 12-bit resolution. The SPARK MAX Data Port Breakout includes a 5V to 3.3V amplifier circuit so that 5V signals can be sensed with the Analog Input pin.

Analog input is supported on firmware versions 1.4.0 and newer.

Multi-function Pin

This pin is reconfigured when the SPARK MAX is configured in Alternate Encoder Mode.

Power Rails

SPARK MAX Data Port Accessories

Alternate Encoder Adapter

Features

• JST PH 6-pin connector

• Pinout compatible with REV Through Bore Encoder

• Index Signal/Absolute PWM Pulse selection switch

• Selects which signal is connected to pin 4 of the Data Port

• Solder pads

• Analog Input

• 3.3V and 5.0V Power

• Ground