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

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

Supply and through 45cm long high-quality wires. Twisted Control wires also feature to make wiring the SPARK Flex easy for PWM or CAN control.

Status LED Indicator

Displays the , ensuring easy troubleshooting and real-time monitoring

• 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

The SPARK Flex can be controlled by three different interfaces: servo-style PWM, Controller Area Network (CAN), and USB. The following sections describe the operation and protocols of these interfaces. For more details on the physical connections, see Control Connections.

PWM Interface

The SPARK Flex can accept a standard servo-style PWM signal as a control for the output duty cycle. Even though the PWM port is shared with the CAN port, SPARK Flex will automatically detect the incoming signal type and respond accordingly. For details on how to connect a PWM cable to the SPARK Flex, see CAN/PWM Connections.

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.

The mode button can be used to activate basic operating modes within the SPARK Flex. For information on those modes, please see the Operating Modes section.

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):

The SPARK Flex can be controlled by three different interfaces: servo-style PWM, Controller Area Network (CAN), and USB. The following sections describe the physical connections to these interfaces. For details on the operation and protocols of the PWM, CAN, or USB interfaces, please see Control Interfaces.

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.

When daisy-chaining or extending the connections, use the included to secure the two mating connectors together to prevent unintended disconnections.

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 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.

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 breaks out the default pin functions of the SPARK Flex Data Port into commonly used connectors for external sensors.

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

The breaks out the SPARK Flex Data Port to individual unterminated wires and is useful for connecting custom circuits or sensors without a standard connector. It features the keyed and locking Data Port connector to ensure a secure and aligned fit when plugged into the SPARK Flex Motor Controller. Each wire is uniquely color-coded for easy identification.

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

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

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.

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.

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.