Data Sheet

ManualsBrandsRoboteQ ManualsR/C DC ControllersFBL2360E 60V 2x60A Brushless DC Motor Controller (Supports Ethernet)

FBL2360 Brushless DC Motor Controller Datasheet 1

FBL2360

Roboteq’s FBL2360 is a features-packed, high-current, dual

or single channel controller for brushless DC motors. The

control ler 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 com pute speed and measure travelled distance

inside a 32-bit coun ter. 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 chan nels 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 Lan guage scripts. The controller

can be conﬁgured, monitored and tuned in realtime

using a Roboteq’s free PC utility. The control ler can also

be reprogrammed in the ﬁeld with the latest fea tures by

downloading new operating software from Roboteq.

Applications

• Automatic Guided Vehicles

• Small Electric Vehicles, Electric Bikes

• Terrestrial and Underwater Robotic Vehicles

• Police and Military Robots

• Hazardous Material Handling Robots

• Balancing Robots

• Telepresence Systems

• Animatronics

Key Features

• USB, Serial, 0-5V Analog, or Pulse (RC radio) command

modes

• One serial port

• CAN bus interface up to 1Mbit/s with multiple protocol

support

• RS485 Optional Ethernet 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

- Sinusoidal with Encoders

- Sinusoidal with Hall Sensors

• Support for absolute angle encoders

- sin/cos analog

- SPI or SSI (A-version)

- Resolver (A-version)

• Field Oriented Control in Sinusoidal modes

• Full forward & reverse motor control. Four quadrant

opera tion. 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 feed back

• Up to 8 Pulse Length, Duty Cycle or Frequency Inputs for

use as command and/or feedback

Advanced Features

2 x 60A or 1 x 120A

Brushless DC

Motor Controller

with USB and CAN

Summary of content (17 pages)

PAGE 1
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.
PAGE 2
• • • • • • • • • • • • • • • Up to 10 Digital Inputs for use as Deadman Switch, Limit Switch, Emergency stop or user inputs Inputs for up to 3 Quadrature Encoders 4 general purpose 24V, 1.
PAGE 3
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.
PAGE 4
VMot Ground Ground Power Control Controller Power F2 1A SW1 Main On/Off Switch 1A PwrCtrl Note 1 U1 U1 Ground Motor1 Backup Battery V1 Diode >20A 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 + - W1 W1 Resistor 1K, 0.5W Note 3 V1 Ground Note 6 Do not Connect! W2 Motor2 I/O Connector Main Battery V2 U2 U2 Note 5 FIGURE 3. Powering the controller.
PAGE 5
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.
PAGE 6
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 to +40V Max VMot Digital Out I/O Connector + - Ground Main Battery FIGURE 5.
PAGE 7
Connection to SPI Absolute Encoder 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.
PAGE 8
TABLE 2. Pin Number 1 2 3 4 5 Row 1 5V NC NC Sel GND Row 2 5V Clock Data 2 Data 1 GND Connection to SSI Absolute Encoder In Sinusoidal Mode, the controller can use motors equipped with absolute angle sensors with SSI interface. When enabled, the SSI signals are found on the 10-pin Molex connector that is otherwise used for the Hall Sensors. The controller issues a differencial clock signal and expects a 12-bit differencial data signal from the encoder.
PAGE 9
Commands and I/O Connections Secondary 1 ASIN1 Primary Channel 1 Secondary 2 ACOS1 EXC Secondary 1 ASIN2 Primary Channel 2 Secondary 2 ACOS2 GND The table below shows the signals assignment on the 25-pin connector. TABLE 5.
PAGE 10
TABLE 6.
PAGE 11
RS485 Communication FIGURE 10. Factory default pins assignment 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.
PAGE 12
Ethernet Communication Ethernet communication is currently only available on the E versions of applicable Roboteq product. There is a connection port on the top of the unit for easy and rapid access. While the TCP and Modbus TCP protocols are supported, Serial is the preferred method to access all native commands. 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 two second interval.
PAGE 13
Electrical Specifications Measured and Calculated Amps Including Amps sensors on the wires allows for fast and efficient gathering of information. Motor amps are be measured in real time which allows precise calculation of battery amps. Secure Connection to AMP FASTON™ Tabs Power Motor and Battery connections are made via standard 250mils (6.35mm) AMP FASTON Tabs. FASTON connectors provide a high current and very secure connection, proven over decades of use in the automotive industry.
PAGE 14
Power Stage Electrical Specifications (at 25ºC ambient) TABLE 8.
PAGE 15
Electrical Specifications TABLE 8. Continuous Max Current per channel Measure point Model Min Typ Max Units 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.
PAGE 16
TABLE 10. Parameter Measure Point Min RS232 Watchdog timeout Rx pin 1 (2) Typ Max Units 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 11.
PAGE 17
Power Wires Identifications and Connection GND 0.98" (25mm) M3- M3+ M2- M2+ M1- M1+ VMOT Pwr Ctrl 0.25" (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 FIGURE 1.