Data Sheet

ManualsBrandsRoboteQ ManualsBrushless DC Motor ControllersFBL2360S 60V 1x75A Brushless DC Motor Controller

FBL2360 Motor Controller Datasheet 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 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 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

• 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

Summary of content (14 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 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.
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
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.
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 VMot Digital Out to +40V Max I/O Connector + Ground Main Battery FIGURE 5.
PAGE 7
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.
PAGE 8
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.
PAGE 9
Commands and I/O Connections TABLE 3.
PAGE 10
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.
PAGE 11
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.
PAGE 12
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.
PAGE 13
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.
PAGE 14
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.