HBL23xx Motor Controller Datasheet

HBL23xx Motor Controller Datasheet
FBL2360
Advanced Features
2 x 60A or 1 x 120A
Brushless DC
Motor Controller
with USB and CAN
Roboteq’s FBL2360 is a features-packed, high-current, dual or
single channel controller for brushless DC motors. The controller can operate in one of several modes in order to sense the
rotor position and sequence power on the motors’ 3 windings
in order to generate smooth continuous rotation. The controller
also uses the Hall sensor and/or Encoder information to compute speed and measure travelled distance inside a 32-bit counter. The motors may be operated in open or closed loop speed
mode, position mode or in torque mode. The FBL2360 features
several Analog, Pulse and Digital I/Os which can be remapped
as command or feedback inputs, limit switches, or many other
functions. The FBL2360 accepts commands received from an
RC radio, Analog Joystick, wireless modem, or microcomputer.
For mobile robot applications, the controller’s two motor channels can either be operated independently or mixed to move
and steer a vehicle. Using CAN bus, up to 127 controllers can
be networked at up to 1Mbit/s on a single twisted pair.
Numerous safety features are incorporated into the controller
to ensure reliable and safe operation. The controller's operation
can be extensively automated and customized using Basic Language scripts. The controller can be configured, monitored and
tuned in realtime using a Roboteq’s free PC utility. The controller can also be reprogrammed in the field with the latest features by downloading new operating software from Roboteq.
Applications
•
•
•
•
•
•
•
•
Automatic Guided Vehicles
Small Electric Vehicles, Electric Bikes
Key Features
•
USB, Serial, 0-5V Analog, or Pulse (RC radio) command
modes
•
•
One serial port
•
•
Hazardous Material Handling Robots
Balancing Robots
Telepresence Systems
Animatronics
FBL2360 Motor Controller Datasheet
RS485 interface
Auto switch between Serial, USB, CAN, Analog, or Pulse
based on user-defined priority
•
Built-in dual 3-phase high-power drivers for two brushless
DC motor at up to 60A
•
Output channels can be paralleled in order to drive a single
motor at up to 120A
•
Multiple Motor Operating mode
- Trapezoidal with Hall Sensors
- Trapezoidal Sensorless (Q3/15)
- Sinusoidal with Encoders
- Sinusoidal with Hall Sensors
•
Support for absolute angle encoders
- sin/cos analog
- SPI digital
•
•
Field Oriented Control in Sinusoidal modes
•
•
Terrestrial and Underwater Robotic Vehicles
Police and Military Robots
CAN bus interface up to 1Mbit/s with multiple protocol
support
•
•
•
Full forward & reverse motor control. Four quadrant operation. Supports regeneration
Operates from a single 10V-60V power source
Programmable current limit up to 60A (120A on single
channel version) per motor for protecting controller, motor,
wiring and battery.
Separate connector for Hall Sensors
Accurate speed and Odometry measurement using Hall
Sensor or Encoder data
Up to 8 Analog Inputs for use as command and/or feedback
1
•
Up to 8 Pulse Length, Duty Cycle or Frequency Inputs
for use as command and/or feedback
•
Separate Programmable acceleration and deceleration
for each motor
•
Up to 10 Digital Inputs for use as Deadman Switch, Limit
Switch, Emergency stop or user inputs
•
Ultra-efficient 2.5 mOhm ON resistance MOSFETs (1.25
mOhm on Single Channel)
•
•
Inputs for up to 3 Quadrature Encoders
•
Stall detection and selectable triggered action if Amps is
outside user-selected range
•
•
•
Short circuit protection
4 general purpose 24V, 1.5A output for brake release or
accessories
•
Selectable min, max, center and deadband in Pulse and
Analog modes
•
Selectable exponentiation factors for each command
inputs
•
Trigger action if Analog, Pulse or Hall counter capture are
outside user selectable range (soft limit switches)
•
•
Open loop or closed loop speed control operation
•
•
•
•
Closed loop position control with encoder, hall sensors,
analog or pulse/frequency feedback
Torque mode
PID control loop
Built-in Battery Voltage and Temperature sensors
Optional 12V backup power input for powering safely the
controller if the main motor batteries are discharged
•
Power Control wire for turning On or Off the controller
from external microcomputer or switch
•
•
No consumption by output stage when motors stopped
•
•
•
•
•
•
•
•
•
•
•
Regulated 5V output for powering RC radio, RF Modem,
sensors or microcomputer
Overvoltage and Undervoltage protection
Watchdog for automatic motor shutdown in case of
command loss
Overtemperature protection
Diagnostic LED
ABS plastic enclosure with heat conducting bottom plate
Efficient heat sinking. Operates without a fan in most
applications.
Dustproof and weather resistant. IP51 NEMA rating
Power wiring 0.25" Faston tabs
5.5” (139.7mm) L, 5.5” W (139.7mm), 1.0” (25mm) H
-40o to +85o C operating environment
0.5 lbs (250g)
Easy configuration, tuning and monitory using provided
PC utility
Field upgradeable software for installing latest features
via the internet
Orderable Product References
2
Reference
Number of Channels
Amps/Channel
Volts
FBL2360
2
60
60
FBL2360S
1
120
60
FBL2360 Motor Controller Datasheet
Version 1.0. June 09, 2015
Power Wires Identifications and Connection
Important Safety Disclaimer
Dangerous uncontrolled motor runaway condition can occur for a number of reasons, including, but not
limited to: command or feedback wiring failure, configuration error, faulty firmware, errors in user script or
user program, or controller hardware failure.
The user must assume that such failures can occur and must make his/her system safe in all conditions.
Roboteq will not be liable in case of damage or injury as a result of product misuse or failure.
Power Wires Identifications and Connection
Power connections are made by means of faston tabs located at the back of the controller.
Hall Sensors
Connector
I/O Connector
LEDs USB
Connector
FIGURE 1. FBL2360 front view
Power Supply and Motor Connections
FIGURE 2. FBL2360 rear view
The diagram below shows how to wire the controller in a dual motor configuration, and how to turn power On and
Off.
FBL2360 Motor Controller Datasheet
3
F2
1A
SW1 Main
On/Off Switch 1A
PwrCtrl
Note 1
U1
U1
Ground
Motor1
Backup
Battery
V1
Diode
>20A
W1
W1
Resistor
1K, 0.5W
Note 3
V1
Hall
Sensors1
Note 2
VMot
F1
Note 4
HA1/HB1/HC1
GND/+5V
HA2/HB2/HC2
Hall
Sensors2
Hall sensor
Connector
SW2
Emergency
Contactor or
Cut-off Switch
W2
V2
V2
Ground
+
W2
Motor2
I/O Connector
U2
Main
Battery
U2
Note 6
Do not Connect!
Note 5
FIGURE 3. Powering the controller. Thick lines identify MANDATORY connections
Important Warning
Carefully follow the wiring instructions provided in the Power Connection section of the User Manual. The
information on this datasheet is only a summary.
Mandatory Connections
It is imperative that the controller is connected as shown in the above diagram in order to ensure a safe and trouble-free operation. All connections shown as thick black lines line are mandatory. The controller must be powered
On/Off using switch SW1on the Pwr Ctrl tab. Use a suitable high-current fuse F1 as a safety measure to prevent
damage to the wiring in case of major controller malfunction.
Emergency Switch or Contactor
The battery must be connected in permanence to the controller’s VMot tabs via a high-power emergency switch
or contactor SW2 as additional safety measure. The user must be able to deactivate the switch or contactor at
any time, independently of the controller state.
Precautions and Optional Connections
Note 1: Backup battery to ensure motor operation with weak or discharged batteries, connect a second battery to
the Power Control wire/terminal via the SW1 switch.
Note 2: Use precharge 1K, 0.5W Resistor to prevent switch arcing.
Note 3: Insert a high-current diode to ensure a return path to the battery during regeneration in case the fuse is
blown.
Note 4: Optionally ground the VMot tabs when the controller is Off if there is any concern that the motors could
be made to spin and generate voltage in excess of 60V.
4
FBL2360 Motor Controller Datasheet
Version 1.0. June 09, 2015
Single Channel Wiring
Note 5: Connect the controller’s bottom plate to a wire connected to the Earth while the charger is plugged in the
AC main, or if the controller is powered by an AC power supply.
Note 6: Beware not to create a path from the ground pins on the I/O connector and the battery minus terminal.
Single Channel Wiring
On the Single Channel FBL2360S, the each of the motor wire must be connected to both output tabs of the same
letter as shown in the figure below. Use the Encoders and/or Hall sensors of Channel 1 for operation.
U1
V1
W1
V
U2
V2
W2
W
U
FIGURE 4. Single Channel wiring diagram
Important Warning
This wiring must be done only on the single channel version of the controller. Paralleling the wires on a dual
channel product will cause permanent damage. Verify that your controller is an FBL2360S before you wire
in this manner.
FBL2360 Motor Controller Datasheet
5
Use of Safety Contactor for Critical Applications
An external safety contactor must be used in any application where damage to property or injury to person can
occur because of uncontrolled motor operation resulting from failure in the controller’s power output stage.
F2
1A
SW1 Main
On/Off Switch 1A
PwrCtrl
Ground
Resistor
1K, 0.5W
Diode
>20A
F1
VMot
Digital Out
to +40V Max
I/O Connector
+
Ground
Main
Battery
FIGURE 5. Contactor wiring diagram
The contactor coil must be connected to a digital output configured to activate when “No MOSFET Failure”. The
controller will automatically deactivate the coil if the output is expected to be off and battery current of 1A or
more is measured for more than 0.5s. This circuit will not protect against other sources of failure such as those
described in the “Important Safety Disclaimer” on page 3.
Controller Mounting
During motor operation, the controller will generate heat that must be evacuated. The published amps rating can
only be fully achieved if adequate cooling is provided. Good conduction cooling can be achieved by having the bottom edges of the case making contact with a metallic surface (chassis, cabinet).
Hall Sensors Connection
Connection to the Hall Sensors is done using a special connector on the front side of the controller. The Hall sensor connector is a 10-pin Molex Microfit 3.0, ref. 43025-1000. Pin assignment is in the table below.
Row Ch1
Row Ch2
Row Ch1
5
Row Ch2
1
5
1
FIGURE 6. Hall Sensors connector
6
FBL2360 Motor Controller Datasheet
Version 1.0. June 09, 2015
Hall Sensor vs Motor Output sequencing
TABLE 1.
Pin Number
1
2
3
4
5
Row Ch1
5V
Hall1 C
Hall1 B
Hall1 A
Ground
Row Ch2
5V
Hall2 C
Hall2 B
Hall2 A
Ground
Hall Sensor vs Motor Output sequencing
The controller requires the Hall sensors inside the motor to be 120 degrees apart. The controller’s 3-phase bridge
will activate each of the motor winding according to the sequence shown in the figure below.
1
2
3
4
5
6
1
2
3
4
5
6
Hall A
U
Hall B
3
1
Hall C
U
+
V
W
6
4
+
-
-
-
+
+
-
+
-
+ +
+
-
-
+
-
+
-
+
5
W
-
V
2
+
FIGURE 7. Hall Sensors sequence
Connection to SPI Absolute Encoder
In Sinusoidal Mode, the controller can use motors equipped with absolute angle sensors with SPI interface, such
as found on the BL167 or BL90 motors from Micromotor. When enabled, the SPI signals are found on the 10-pin
Molex connector that is otherwise used for the Hall Sensors. The controller issues a clock and select signal.
When two motors are used, these signals must be connected to both sensors. Serial data from each sensor is
captured on separate input pins.
Row 1
Row 2
Row 1
5
Row 2
1
5
1
FIGURE 8. Hall Sensor connector used for SPI encoders
FBL2360 Motor Controller Datasheet
7
TABLE 1.
Pin Number
1
2
3
4
5
Row 1
5V
NC
NC
Sel
GND
Row 2
5V
Clock
Data 1
Data 2
GND
Connection to Analog Sin/Cos Absolute Encoder
The FBL2360 has 4 high-speed analog inputs that can be used to capture absolute angle position from resolvers
or magnetic sensors with sin/cos voltage outputs. The signal must be 0-5V max with the 0 at 2.500V. The table
below shows the signals assignment on the 25-pin connector.
TABLE 2.
Signal
Pin Number
Pin Name
Sin1
9
ASIN1
Cos1
10
ACOS1
Sin2
24
ANA7/ASIN2
Cos2
12
ANA8/ACOS2
Commands and I/O Connections
Connection to RC Radio, Microcomputer, Joystick and other low current sensors and actuators is done via the 25
connector. The functions of many pins vary depending on controller model and user configuration. Pin assignment
is found in the table below.
14
25
1
13
FIGURE 9. Main Connector pin locations
TABLE 3.
Connector Pin
1
14
Power
Dout
Com
Ana
Dinput
Enc
Default Config
GND
5VOut
2
RS TxD
15
3
4
17
5
18
6
RS232Tx
RC1
ANA1
DIN1
RCRadio1
RC2
ANA2
DIN2
RCRadio2
RC3
ANA3
DIN3
AnaCmd1 (1)
RC4
ANA4
DIN4
AnaCmd2 (1)
RS RxD
16
8
Pulse
RS232Rx
GND
DOUT1
Motor Brake 1
DOUT2
Motor Brake 2
FBL2360 Motor Controller Datasheet
Version 1.0. June 09, 2015
Commands and I/O Connections
TABLE 3.
Connector Pin
Power
19
7
Dout
Com
Pulse
Ana
Dinput
Enc
DOUT3
Contactor
DOUT4
Unused
20
CANH
8
Unused
CANL
21
Unused
RC5
9
22
RC6
10
23
11
ANA5
DIN5
ASIN1
DIN9
ANA6
DIN6
ACOS1
DIN10
ENC2A
Unused
Unused
ENC2B
Unused
Unused
TTL TxD
Unused
TTL RxD
Unused
24
12
25
Default Config
RC7
ANA7/
ASIN2
DIN7
ENC1A
Unused
RC8
ANA8/
ACOS2
DIN8
ENC1B
Unused
5VOut
13
GND
Note 1: Analog command is disabled in factory default configuration.
Default I/O Configuration
While the controller can be configured so that practically any Digital, Analog and RC pin can be used for any purpose, the controller’s factory default configuration provides an assignment that is suitable for most applications.
The figure below shows how to wire the controller to two analog potentiometers, an RC radio, and the RS232
port. It also shows how to connect two outputs to motor brake solenoids and another output to an external status
LED. You may omit any connection that is not required in your application. The controller automatically arbitrates
the command priorities depending on the presence of a valid command signal in the following order: 1-RS232, 2RC Pulse, 3-None. If needed, use the Roborun+ PC Utility to change the pin assignments and the command priority order.
RC Ch1
RC Ch2
1
Pot 1
2
14
1
RS232
TxOut
RxIn
Ground
Pot 2
25
13
Contactor
Motor Brake 2
Motor Brake 1
FIGURE 10. Factory default pins assignment
FBL2360 Motor Controller Datasheet
9
Enabling Analog Commands
For safety reasons, the Analog command mode is disabled by default. To enable the Analog mode, use the PC
utility and set Analog in Command Priority 2 or 3 (leave Serial as priority 1). Note that by default the additional
securities are enabled and will prevent the motor from starting unless the potentiometer is centered, or if the
voltage is below 0.25V or above 4.75V. The drawing shows suggested assignment of Pot 1 to ANA1 and Pot 2 to
ANA4. Use the PC utility to enable and assign analog inputs.
USB communication
Use USB only for configuration, monitoring and troubleshooting. USB is not a reliable communication method
when used in a electrically noisy environments and communication will not always recover after it is lost without
unplugging and replugging the connector, or restarting the controller. Always prefer RS232 communication when
interfacing to a computer. USB and CAN can operate at the same time on the FBL2360. Plugging USB to a computer will not disable the CAN interface.
Status LED Flashing Patterns
After the controller is powered on, the Power LED will tun on, indicating that the controller is On. The Status LED
will be flashing at a 2 seconds interval. The flashing pattern and color provides operating or exception status information.
Idle - Waiting for Command
RS232/USB Mode
RC Pulse Mode
Analog Mode
FIGURE 11. Normal Operation Flashing Patterns
Short Detected
Overheat
Under or Over Voltage
Power Stage Off
FIGURE 12. Exception or Fault Flashing Patterns
Additional status information may be obtained by monitoring the controller with the PC utility.
10
FBL2360 Motor Controller Datasheet
Version 1.0. June 09, 2015
Electrical Specifications
Electrical Specifications
Absolute Maximum Values
The values in the table below should never be exceeded, permanent damage to the controller may result.
TABLE 4.
Parameter
Measure point
Battery Leads Voltage
Ground to VBat
Reverse Voltage on Battery Leads
Ground to VBat
Power Control Voltage
Ground to Pwr Control wire
63
Volts
Motor Leads Voltage
Ground to U, V, W wires
63 (1)
Volts
Digital Output Voltage
Ground to Output pins
30
Volts
Analog and Digital Inputs Voltage
Ground to any signal pin on 15-pin &
Hall inputs
15
Volts
RS232 I/O pins Voltage
External voltage applied to Rx/Tx
pins
15
Volts
Case Temperature
Case
Humidity
Case
Min
Typ
Max
Units
63
Volts
-1
Volts
-40
85
oC
100 (2)
%
Note 1: Maximum regeneration voltage in normal operation. Never inject a DC voltage from a battery or other fixed source
Note 2: Non-condensing
Power Stage Electrical Specifications (at 25oC ambient)
TABLE 5.
Continuous Max Current
per channel
Measure point
Model
Min
Battery Leads Voltage
Ground to VBat
All
0 (1)
Typ
Max
Units
63
Volts
Motor Leads Voltage
Ground to U, V, W wires
All
0 (1)
63 (2)
Volts
Power Control Voltage
Ground to Power Control wire
All
0 (1)
65
Volts
Minimum Operating Voltage
VBat or Pwr Ctrl wires
All
9 (3)
Over Voltage protection range
Ground to VBat
All
5
60 (4)
Under Voltage protection range
Ground to VBat
All
0
Idle Current Consumption
VBat or Pwr Ctrl wires
All
50
ON Resistance (Excluding wire
resistance)
VBat to U, V or W. Ground to U,
V or W
FBL2360
2.5
mOhm
FBL2360S
1.25
mOhm
Max Current for 30s
Motor current
FBL2360
60
Amps
FBL2360S
120
Amps
FBL2360
40 (6)
Amps
FBL2360S
80 (6)
Amps
Continuous Max Current per
channel
Motor current
Current Limit range
Motor current
Stall Detection Amps range
Stall Detection timeout range
FBL2360 Motor Controller Datasheet
Motor current
Motor current
Volts
63
Volts
5 (4)
63
Volts
100 (5)
150
mA
FBL2360
10
50 (7)
60
Amps
FBL2360S
20
100 (7)
120
Amps
FBL2360
10
60 (7)
60
Amps
FBL2360S
20
120 (7)
120
Amps
All
1
500 (8)
65000
milliseconds
11
TABLE 5.
Continuous Max Current
per channel
Measure point
Model
Short Circuit Detection
threshold (9)
Between Motor wires or
Between Motor wires and Ground
FBL2360
Short Circuit Detection
threshold
Between Motor wires and VBat
All
No Protection. Permanent damage will
result
Motor Acceleration/
Deceleration range
Motor Output
All
100
Min
Typ
FBL2360S
500 (11)
Max
Units
500 (10)
Amps
1000 (10)
Amps
65000
milliseconds
Note 1: Negative voltage will cause a large surge current. Protection fuse needed if battery polarity inversion is possible
Note 2: Maximum regeneration voltage in normal operation. Never inject a DC voltage from a battery or other fixed source
Note 3: Minimum voltage must be present on VBat or Power Control wire
Note 4: Factory default value. Adjustable in 0.1V increments
Note 5: Current consumption is lower when higher voltage is applied to the controller’s VBat or PwrCtrl wires
Note 6: Estimate. Limited by case temperature. Current may be higher with better cooling
Note 7: Factory default value. Adjustable in 0.1A increments
Note 8: Factory default value. Time in ms that Stall current must be exceeded for detection
Note 9: Controller will stop until restarted in case of short circuit detection
Note 10: Approximate value
Note 11: Factory default value. Time in ms for power to go from 0 to 100%
Command, I/O and Sensor Signals Specifications
TABLE 6.
Parameter
Measure point
Min
Typ
Main 5V Output Voltage
Ground to 5V pins on
4.6
4.75
4.9
Volts
5V Output Current
5V pins on RJ45 and DSub15
200 (1)
mA
Digital Output Voltage
Ground to Output pins
30
Volts
Output On resistance
Output pin to ground
0.5
Ohm
0.25
1.7
Max
Units
Output Short circuit threshold
Output pin
Digital Output Current
Output pins, sink current
3.5
Amps
1.5
Amps
Input Impedances (except
DIN11-19)
AIN/DIN Input to Ground
Digital Input 0 Level
Ground to Input pins
-1
1
Volts
Digital Input 1 Level
Ground to Input pins
3
15
Volts
Analog Input Range
Ground to Input pins
0
5.1
Volts
Analog Input Precision
Ground to Input pins
Analog Input Resolution
Ground to Input pins
Pulse durations
Pulse inputs
20000
10
us
Pulse repeat rate
Pulse inputs
50
250
Hz
Pulse Capture Resolution
Pulse inputs
Frequency Capture
Pulse inputs
53
kOhm
0.5
%
1
mV
1
100
us
10000
Hz
Note 1: Sum of all 5VOut outputs
12
FBL2360 Motor Controller Datasheet
Version 1.0. June 09, 2015
Electrical Specifications
Operating & Timing Specifications
TABLE 7.
Parameter
Measure Point
Min
Typ
Max
Units
Command Latency
Command to output change
0
0.5
1
ms
PWM Frequency
Motor Output
10
18
20
kHz
Closed Loop update rate
Internal
RS232 baud rate
Rx & Tx pins
RS232 Watchdog timeout
Rx pin
1000
Hz
115200 (1)
1 (2)
Bits/s
65000
ms
Note 1: 115200, 8-bit, no parity, 1 stop bit, no flow control
Note 2: May be disabled with value 0
Scripting
TABLE 8.
Parameter
Measure Point
Min
Typ
Max
Units
1500
Lines
Scripting Flash Memory
Internal
Max Basic Language programs
Internal
16384
Integer Variables
Internal
1024
Words (1)
Boolean Variables
Internal
1024
Symbols
Execution Speed
Internal
50 000
100 000
Lines/s
Parameter
Measure Point
Min
Typ
Case Temperature
Case
Thermal Protection range
Case
Power Dissipation
Case
Thermal resistance
Humidity
1000
Bytes
Note 1: 32-bit words
Thermal Specifications
TABLE 9.
Max
Units
-40
85 (1)
oC
80
90 (2)
oC
70
Watts
Power MOSFETs to case
0.6
oC/W
Case
100(3)
%
Max
Units
Note 1: Thermal protection will protect the controller power
Note 2: Max allowed power out starts lowering at minimum of range, down to 0 at max of range
Mechanical Specifications
TABLE 10.
Parameter
Measure Point
Weight
Board
250 (0,5)
g (lbs)
Power Connectors width
Terminal tab
0.25
Inches
FBL2360 Motor Controller Datasheet
Min
Typ
13
0.25"
0.98"
(25mm)
(6.3 mm)
0.57"
0.7" (17.8mm)
0.3"
(14.5mm)
(7.6 mm)
0.16" (4.0mm)
0.325" (8.3 mm)
FIGURE 13. FBL2360 side view and dimensions
5.50" (139.7mm)
5.00" (127.0mm)
5.50" (139 .7mm)
0.24" (6.0mm)
1.25" (31.8mm)
3.00" (76.2mm)
FIGURE 14. FBL2360 top view and dimensions
14
FBL2360 Motor Controller Datasheet
Version 1.0. June 09, 2015
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