Data Sheet

ManualsBrandsRoboteQ ManualsBrushless DC Motor ControllersRGBL1896 96V 1x200A Brushless DC Motor Controller

RGBL18xx Motor Controller Datasheet 1

RGBL18xx

Roboteq’s RGBL18xx is a very high-current, feature-packed mo-

tor controller for brushless DC motors. The controller can oper-

ate in one of several modes in order to sense the rotor position

and sequence power to the motors’ three windings so that it

generates a smooth continuous rotation. The controller also

uses the Hall sensor and/or Encoder information to compute

speed and measure traveled 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 RGBL18xx features

several Analog, Digital and Pulse I/Os which can be remapped

as command or feedback inputs, limit switches, or many other

functions. The RGBL18xx accepts commands received from

an RC radio, Analog potentiometer, wireless modem, PLC, or

microcomputer. Using CAN bus, as many as 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 RGBL 18xx can be conﬁgured, moni-

tored and tuned in real-time 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

• Electric vehicles

• Personnel carriers

• Golf carts

• Materials handling equipment

• Electric boats

• Automatic Guided Vehicles

• Agricultural robots

Features List

• 0-5V Analog, RS232 or TTL Serial, RS485 or Pulse (RC

radio) command modes

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

support

• Auto switch between serial, Analog, or Pulse based on

user-deﬁned priority

• Built-in dual 3-phase high-power drivers for one brushless

DC motor at up to 400A

• Full for ward and reverse control. Four quadrant operation

• Supports regeneration

• Operates from a single power source

• Programmable current limit up to 400A for protecting

controller, motors, wiring and battery

• Connector for Hall Sensors

• Multiple Motor Operating mode

- Trapezoidal with Hall Sensors

- Trapezoidal Sensorless

- Sinusoidal

• Support for absolute angle encoders

- sin/cos analog

- SSI

- Resolver

• Field Oriented Control in Sinu

• Efﬁcient Field Oriented Control (FOC) in sinusoidal modes

• Accurate speed and Odometry measurement using Hall

Sensor or encoder data

• Up to eight Analog Input for use as command and/or

feedback

• Up to eight Pulse Width, Duty Cycle or Frequency Inputs

for use as command and/or feedback

400A, 60/96V

Single Channel

Brushless DC Motor

Controller

Summary of content (14 pages)

PAGE 1
RGBL18xx 400A, 60/96V Single Channel Brushless DC Motor Controller Roboteq’s RGBL18xx is a very high-current, feature-packed motor controller for brushless DC motors. The controller can operate in one of several modes in order to sense the rotor position and sequence power to the motors’ three windings so that it generates a smooth continuous rotation. The controller also uses the Hall sensor and/or Encoder information to compute speed and measure traveled distance inside a 32-bit counter.
PAGE 2
•• •• •• •• •• •• •• •• •• •• •• •• •• •• •• Up to 10 Digital Inputs for use as Deadman Switch, Limit Switch, Emergency stop or user inputs Two Quadrature Encoder input with 32-bit counters Built-in Programming language for automatic operation and/or customized functionality Five general purpose 1A output for brake release or accessories.
PAGE 3
Power Terminals 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
Figure 2, below, shows how to wire the controller and how to turn power On and Off. Resistor 1K, 0.5W Note 3 Emergency Disconnect B+ U Motor U + Note 4 Do not Connect! - OFF W V Sensors Power Control GND Note 1 V W B- Hall A/B/C or Encoder Main On/Off Switch ON Note 2 + Main Battery 1A Optional Backup Battery - FIGURE 2. Powering the Controller.
PAGE 5
Sensor and Commands Connection Note 3: Use precharge 1K, 0.5W Resistor to prevent switch arcing. Note 4: Beware not to create a path from the ground pins on the I/O connector to the battery minus terminal. Controller Mounting During motor operation, the controller will generate heat that must be dissipated. The published amps rating can only be fully achieved if adequate cooling is provided.
PAGE 6
13 1 Power Control - pin 25 14 FIGURE 4. Main Connector Pin Locations TABLE 3.
PAGE 7
Connection to SSI Absolute Encoder FIGURE 5 . DSub Connector with Waterproof Hood 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, as shown in Figure 6: 1 2 3 4 5 6 1 2 3 4 5 6 Hall A U Hall B Hall C U 1 + V + W 6 4 - + - + - + + - + + - - + - + + - 3 2 W V 5 + FIGURE 6.
PAGE 8
Connecting Resolver Resolver wiring is similar to a Sin/Cos sensor with the addition of an excitation signal. Figure 7, below, shows the necessary connections. Secondary 1 ASIN Primary EXC Secondary 2 ACOS GND FIGURE 7. Resolvering Wiring Table 5 shows the signals assignment on the 8-pin circular connector. TABLE 5.
PAGE 9
Status LEDs and Flashing Patterns USB communication Only use USB for configuration, monitoring and troubleshooting. USB is not a reliable communication method when used in electrically noisy environments. If disrupted, communication will not always recover after it is lost without unplugging and replugging the connector, or restarting the controller. RS232 is the preferred communication method when interfacing to a computer. It is possible for USB and CAN to operate at the same time on the RGBL18XX.
PAGE 10
Always off: No USB, No CAN Always On: USB Active, No CAN Flashing On: No USB, CAN Enabled Flashing Off: USB Active, CAN Enabled FIGURE 11. Communication LED ______________________________________________________ Battery Backed Clock and RAM The controller includes a real-time clock/calendar and RAM storage for user variables. Both the clock and the RAM storage require a battery to continue running and for the stored data not to be lost while the controller is powered down.
PAGE 11
Electrical Specifications Power Stage Electrical Specifications (at 25ºC ambient) TABLE 7.
PAGE 12
Command, I/O and Sensor Signals Specifications TABLE 8. Parameter Measure point Min Typical Max Units 5V Out Voltage 5V Output Current Ground to 5V pin Output to ground 4.8 5.1 5.2 100 Volts mA Digital Output Voltage Ground to Output pins 40 Volts Digital Output Current Output pins, sink current 1 Amps Digital Input 0 Level Ground to Input pins -1 1 Volts Digital Input 1 Level Ground to Input pins 3 25 Volts Analog Input Range Ground to Input pins 0 5.
PAGE 13
Electrical Specifications Thermal Specifications TABLE 11. Parameter Measure Point Min Board Temperature PCB -40 Thermal Protection range PCB 70 Thermal resistance Power MOSFETs to heats sink Typical Max Units 85 (1) ºC 80 (2) ºC 2 ºC/W 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 12.
PAGE 14
57 51 25 200 FIGURE 13. RGBL18xx Side View and Dimensions 14 RGBL18xx Motor Controller Datasheet Version 1.