AP RoboteQ FBL2360A User manual

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
controller can operate in one of several modes in order to
sense the rotor position and sequence power on the motor’s
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 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
• 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 RS232 serial port
• CAN bus interface up to 1Mbit/switch 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
- Sinusoidal with Encoders
- Sinusoidal with Hall Sensors
• Support for absolute angle encoders
• sin/cos analog
• SSI (A & T version)
• Resolver (A & T version)
• Field Oriented Control in Sinusoidal modes
• Full forward & reverse motor control. Four quadrant
operation. Supports regeneration
• Operates from a single 10V-60V power source
• STO - Safe Torque Off support (T-version) - Certification
No. M6A 104504 0001 Rev. 00
• Design compliant/approval UL 61800-5-1
• Programmable current limit up to 60A (120Aon 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
Advanced Features
2 x 60A or 1 x 120A
Brushless DC
Motor Controller
with USB and CAN
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2FBL2360 Brushless DC Motor Controller Datasheet Version 1.3 August 29, 2019
Specifications and Listings
Controller is designed and build to comply with UL and IEC specifications and standards, but is approved only
under the mentioned standards on this datasheet.
Orderable Product References
Reference Number of Channels Amps/Channel Volts Ethernet STO
FBL2360(A) 2 60 60 No No
FBL2360(A)S 1 120 60 No No
FBL2360T 2 60 60 No Ye s
FBL2360TS 1 120 60 No Ye s
FBL2360E 2 60 60 Ye s No
FBL2360ES 1 120 60 Ye s No
FBL2360TE 2 60 60 Ye s Ye s
FBL2360TES 1 120 60 Ye s Ye s
• Up to 8 Analog Inputs for use as command and/or feedback
• Up to 8 Pulse Length, Duty Cycle or Frequency Inputs
for use as command and/or feedback
• Up to 10 Digital Inputs for use as Deadman Switch,
Limit Switch, Emergency stop or user inputs
• Inputs for up to 2 Quadrature Encoders
• 4 general purpose 24V, 1.5A output for brake release or
accessories
• Selectable min, max, center and dead band 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 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
• Separate Programmable acceleration and deceleration
for each motor
• Ultra-efficient 2.5 mOhm ON resistance MOSFETs
(1.25 mOhm on Single Channel)
• Stall detection and selectable triggered action if Amps is
outside user-selected range
• Short circuit protection
• 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. IP40 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
• 1 lbs (500g)
• Easy configuration, tuning and monitory using provided
PC utility
• Field upgradeable software for installing latest features
via the internet Orderable Product References
• Field upgradeable software for installing latest features
via the internet Orderable Product References
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FBL2360 Brushless DC Motor Controller Datasheet 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. 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.
I/O ConnectorHall Sensors
Connector
USB
Connector
LEDsSTO
Jumper
(T-version)
FIGURE 1. FBL2360 front view
Pwr
CtrlVMOTGND U1V1W1U2V2W2
FIGURE 2. FBL2360 rear view
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4FBL2360 Brushless DC Motor Controller Datasheet Version 1.3 August 29, 2019
The diagram below shows how to wire the controller and how to turn power On and Off.
Controller Power
Motor Wires
VMot Ground Ground
(top)
Power Control
VMot
PwrCtrl
SW1 Main
On/Off Switch 1A
F2
1A
Diode
>20A
Resistor
1K, 0.5W
+-
SW2
Emergency
Contactor or
Cut-off Switch
F1
Hall sensor
Connector
I/O Connector
Ground
Ground
Main
Battery
Backup
Battery
Note 6
Do not Connect!
Note 1
2etoN3etoN
U1 U2 V1 V2 W1 W2
Note 5
Note 4
Motor1
Hall
Sensors1
HA1/HB1/HC1
GND/+5V
U1
V1 W1
Motor2
Hall
Sensors2
HA2/HB2/HC2
U2
V2 W2
U1
V1
W1
U2
V2
W2
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 PwrCtrl
tab. Use a suitable high-current fuse F1 (check table 12) 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.
Electrostatic Discharge Protection
In accordance with IEC 61000-6-4, Roboteq Motor Controllers are designed to withstand
ESD up to 4kV touch and 8kV air gap. This protection is implemented without any
additional external connections required.
Some specifications, such as EN12895, require a higher level of protection. To maximize
ESD protection, up to 8kV touch and 15kV air gap, you may connect the metallic heatsink
of the controller to your battery negative terminal. See App Note 062918 for example
connections.
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FBL2360 Brushless DC Motor Controller Datasheet 5
Single Channel Wiring
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.
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.
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.
U1
V1
W1
U2
V2
W2 U
V
W
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6FBL2360 Brushless DC Motor Controller Datasheet Version 1.3 August 29, 2019
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.
PwrCtrl
SW1 Main
On/Off Switch 1A
F2
1A
Diode
>20A
Resistor
1K, 0.5W
+-
F1
I/O Connector
VMot
to +40V Max Digital Out
Ground
Ground
Main
Battery
FIGURE 1.Contactor wiring diagram
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 surface of the case making
direct contact with a metallic surface (chassis, cabinet). The mounting has to be like that,
so that the thermal-safety limits are not exceeded.
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.
FIGURE 6. Hall Sensors connector
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FBL2360 Brushless DC Motor Controller Datasheet 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.
FIGURE 7. Hall Sensors sequence
Connection to SPI Absolute Encoder
In Sinusoidal Mode, the FBL2360 and FBL2360S models 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. The SPI Encoder is not available on
‘A’, ‘T’ and ‘E’ versions of Roboteq products.
FIGURE 8. Hall Sensor connector used for SPI encoders
U
VW
1234561
4
2
5
3
6
4
1
5
2
6
3
Hall A
Hall B
Hall C
U
V
W
+
--
-- --
-- --
--
++ ++
++ ++
++ +
1
Row 2
Row 2
Row 1
Row 1
1
5
5
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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 differential
clock signal and expects a 12-bit differential data signal from the encoder. When two
motors are used, these signals must be connected to both sensors. Serial data from
each sensor is captured on separate input pins. The SSI Encoder is only featured on ‘A’, ‘T’
and ‘E’ versions of Roboteq products.
TABLE 3.
Pin Number 1 2 3 4 5
Row 1 5V CLK – Data 2 – Data 1 – GND
Row 2 5V Clock + Data 2 + Data 1 + 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 4.
Signal Pin Number Pin Name
Sin1 9 ASIN1
Cos1 10 ACOS1
Sin2 24 ANA7/ASIN2
Cos2 12 ANA8/ACOS2
Connecting Resolver
Resolver wiring is similar to a Sin/Cos sensor with the addition of an excitation signal.
Diagram below shows the necessary connections.
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FBL2360 Brushless DC Motor Controller Datasheet 9
Commands and I/O Connections
Primary
Secondary 1
Channel
1
Channel
2
ASIN1
ACOS1
Secondary 2
Primary
Secondary 1 ASIN2
ACOS2
EXC
GND
Secondary 2
The table below shows the signals assignment on the 25-pin connector.
TABLE 5.
Signal Pin Number Pin Name
Sin1 9 ASIN1
Cos1 10 ACOS1
Sin2 24 ANA7/ASIN2
Cos2 12 ANA8/ACOS2
Exc 17 ANA4/EXC
GND 1-5 or 13 GND
Commands and I/O Connections
Connection to RC Radio, Microcomputer, Joystick and other low current sensors and
actuators is done via the DB25 connector. The functions of many pins vary depending on
controller model and user configuration. Pin assignment is found in the table below.
FIGURE 9. Main Connector pin locations
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TABLE 6.
Connector
Pin Power Dout Com Pulse Ana Dinput Enc Hall (4)
Default
Config
1 GND
14 5VOut
2RS TxD RS232Tx
15 RC1 ANA1 DIN1/
STO1 (2)
Hall1A RCRadio1 (3)
3RS RxD RS232Rx
16 RC2 ANA2 DIN2/
STO2 (2)
Hall1B RCRadio2 (3)
4RC3 ANA3 DIN3 Hall1C AnaCmd1 (1)
17 RC4 ANA4/EXC DIN4 Hall2A AnaCmd2 (1)
5 GND
18 DOUT1 Motor Brake 1
6DOUT2 Motor Brake 2
19 DOUT3 Contactor
7DOUT4 Unused
20 CANH Unused
8 CANL Unused
21 RC5 ANA5 DIN5 ENC2A Hall2B Unused
9 ASIN1 DIN9 Unused
22 RC6 ANA6 DIN6 ENC2B Hall2C Unused
10 ACOS1 DIN10 Unused
23 485 + RS485 +
11 485 – RS485 –
24 RC7 ANA7/
ASIN2
DIN7 ENC1A Unused
12 RC8 ANA8/
ACOS2
DIN8 ENC1B Unused
25 5VOut
13 GND
Note 1: Analog command is disabled in factory default configuration.
Note 2: STO functionality only available in T versions. See STO section for details.
Note 3: Pulse input enable by default on firmware version prior to v2.0
Note 4: Hall inputs are activated in DB25 connector in firmware v2.0 or later and only if Molex input is
configured as SSI Input. In that case user has to install 1K pull up resistor between each hall signal and 5VOut.
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
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FBL2360 Brushless DC Motor Controller Datasheet 11
RS485 Communication
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, 2-RC Pulse, 3-None. If needed, use
the Roborun+ PC Utility to change the pin assignments and the command priority order.
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. 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 an 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 CAN interface.
RS485 Communication
RS485 is an industry standard for defining serial communication. Due to its balanced
signalling, RS485 is effective over distances, even if other electrical signals are present.
Its stability makes it well suited to connect multiple receivers to a single network.
You can operate RS485 in half-duplex mode and it is well suited for use with the Modbus
protocol. On the 25-pin connector, RS485+ and RS485- pins are present.
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12 FBL2360 Brushless DC Motor Controller Datasheet Version 1.3 August 29, 2019
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. The flashing pattern and
colour provides operating or exception status information.
FIGURE 11. Normal Operation Flashing Patterns
FIGURE 12. Exception or Fault Flashing Patterns
Additional status information may be obtained by monitoring the controller with the PC
utility.
Battery Backed Clock and Variables
The battery backed clock and variables feature allows accurate time/date stamping of
information such as status and error reports. It is important to note that the only Roboteq
products that include this feature are ones that specifically say that battery backed clock
is a product feature. If your Roboteq product has displayed time/date information but
the product does not specifically list the battery backed clock as a feature, then the
information displayed is random and not accurate.
The location of the battery is dependent on the product. However, any Roboteq product
with this feature will run it on a 3V, 12.5mm coin style battery. The clock is accessible via
the ^BEE commands and user input variables will remain even if the unit is powered off.
Please Note: Customers will be required to install the battery for the clock (type BR-1225),
themselves. Units do not ship with the battery for the Battery Backed Clock, installed.
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FBL2360 Brushless DC Motor Controller Datasheet 13
SafeTorque Off - STO (Certification No. M6A 104504 0001 Rev 00)
Measured and Calculated Amps
The controller includes Amps sensors in line with the motor terminals. Motor Amps are
measured with precision. Battery Amps are estimated mathematically.
When motor is rotating, amps are AC. The FBL2360 measures and is rated based on
RMS Amps. The table below shows the relation between the RMS current and the DC
Equivalent in Sinusoidal and Trapezoidal modes. In sinusoidal mode, DC equivalent are the
amps resultant from the torque (Iq) and quadrature (Id) vectors. In trapezoidal mode, they
are the DC amps that flow through the two coils that are active at any one time.
Amps RMS DC Equivalent
Sinusoidal 120A 170A (Irms * 1.414)
60A 85A (Irms * 1.414)
Trapezoidal 120A 147A (Irms * 1.225)
60A 73.5 (Irms * 1.225)
SafeTorque Off - STO (Certification No. M6A 104504 0001 Rev 00)
Safe Torque Off is a safe method for switching controller in a state where no torque is
generated, regardless whether the controller is operating normally or is faulty. When
STO is enabled, two digital inputs, DIN1 and DIN2 are remapped as STO1 and STO2. The
inputs are redundant and both must have a 6V to 30V signal present at the same time in
order for the Power MOSFETs to be energized. The controller will perform a self-check
of the STO circuit at every power on and every time the STO inputs go from any state
to both high. Once the STO hardware is verified to work, the controller will safely allow
the motors to be energized. If either input is below 1V, the controller’s outputs will be
disabled. The STO circuit is verified and validated and can therefore be trusted instead of
external relays. See STO Manual for more information and maintenance instructions.
By factory default STO functionality is disabled. It must be enabled by removing the
jumper located on the controller’s PCB. STO functionality is only available in the T version
of the controller.
6 to 30V
6 to 30V
STO1
STO2
High
Low
High
Low
STO1 STO2 Motors Output
Disabled
Disabled/Fault
Disabled/Fault
Enabled
Low Low
Low
Low
High
High High
High
Figure 13. STO input levels effects on controller output
The STO function is compliant to:
• IEC 61800-5-2:2007, SIL 3
• IEC 61508:2010, SIL 3
• IEC 62061:2005, SIL 3
• ISO 13849-1:2015, Category 3 Performance Level e
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14 FBL2360 Brushless DC Motor Controller Datasheet Version 1.3 August 29, 2019
Important Warning
Activating STO does lead to no more torque generation on the motor. The motor will not
be actively stopped but run out. In case of a multiple fault in the power stage a rotation
might occur.
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. For maximum current handling,
use connectors for AWG8 wires.
FASTON connectors have an extremely tight fit and will not come off on their own. It is
recommended, nevertheless, that the wiring is made so that the cables are never pulling
the connector outward.
Frequent disconnects and reconnects will eventually loosen the connector’s grip on the
tab. If frequent disconnection is required, consider using Positive Lock connectors from TE
Connectivity or their equivalent. These connectors have a spring-loaded tab latch pin that
will lock into the hole of the male tab.
Electrical Specifications
Absolute Maximum Values
The values in the table below should never be exceeded, permanent damage to the
controller may result.
TABLE 7.
Parameter Measure point Min Typ Max Units
Battery Leads Voltage Ground to Vmot 60 (1) Volts
Reverse Voltage on Battery Leads Ground to Vmot -1 Volts
Power Control Voltage Ground to PwrCtrl wire 60 (1) Volts
Motor Leads Voltage Ground to U, V, W wires 60 (1) Volts
Digital Output Voltage Ground to Output pins 30 Volts
Analog and Digital Inputs Voltage Ground to any signal pin on
DB25 & Hall inputs
30 Volts
RS232 I/O pins Voltage External voltage applied to Rx
pins
30 (2) Volts
Case Temperature Case -40 85 ºC
Humidity Case 100 (3) %
Note: Only PELV/SELV voltages shall be used
Note 1: Can be even higher because of regeneration voltage. Never inject a DC voltage from a battery or
other fixed source
Note 2: No voltage must be applied on Tx pin
Note 3: Non condensing
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FBL2360 Brushless DC Motor Controller Datasheet 15
Electrical Specifications
Power Stage Electrical Specifications (at 25ºC ambient)
TABLE 8.
Parameter Measure point Model Min Ty p Max Units
Input Voltage Ground to Vmot All 0 (1) 60 Volts
Input continuous Max Current Power source current All 80 Amps
Output Voltage Ground to U, V, W wires All 0 (1) 60 (2) Volts
Power Control Voltage Ground to Power Control
wire
All 0 (1) 65 Volts
Minimum Operating Voltage VBat or PwrCtrl wires All 10 (3) Volts
Over Voltage protection range Ground to Vmot All 5 60 (4) 63 Volts
Under Voltage protection range Ground to Vmot All 0 5 (4) 63 Volts
Idle Current Consumption Vmot or PwrCtrl wires All 50 100 (5) 150 mA
ON Resistance (Excluding
wire resistance)
Vmot 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
Continuous Max Current
per channel
Motor current FBL2360 40 (6) Amps
FBL2360S 80 (6) Amps
Current Limit range Motor current FBL2360 10 50 (7) 60 Amps
FBL2360S 20 100 (7) 120 Amps
Stall Detection Amps range Motor current FBL2360 10 60 (7) 60 Amps
FBL2360S 20 120 (7) 120 Amps
Stall Detection timeout range Motor current All 1 500
(8)
65000 msec
Short Circuit Detection
threshold (9)
Between Motor wires
or Between Motor wires
and ground or Between
Motor wires and Vmot
FBL2360 125(10) Amps
FBL2360S 250 (10) Amps
Motor Acceleration/
Deceleration range
Motor Output All 100 500(11) 65000 msec
Power cable thickness Power input and output All 8 AWG
Note 1: Negative voltage will cause a large surge current. Protection fuse needed if battery polarity
inversion is possible
Note 2: Can be even higher because of regeneration voltage. 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” change with “Controller will
stop until zero command given 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%
15 FBL2360_1691-21588-0001-D-0720

16 FBL2360 Brushless DC Motor Controller Datasheet Version 1.3 August 29, 2019
Command, I/O and Sensor Signals Specifications
TABLE 9.
Parameter Measure point Min Typ Max Units
Main 5V Output Voltage Ground to 5V pins on 4.6 4.9 5.2 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 0.25 0.5 Ohm
Output Short circuit threshold Output pin 1. 7 3.5 Amps
Digital Output Current Output pins, sink current 1. 5 Amps
Input Impedances (except DIN11-19) AIN/DIN Input to Ground 53 kOhm
Digital Input 0 Level Ground to Input pins -1 1 Volts
Digital Input 1 Level Ground to Input pins 3 30 Volts
Analog Input Range Ground to Input pins 0 5.1 Volts
Analog Input Precision Ground to Input pins 0.5 %
Analog Input Resolution Ground to Input pins 1 mV
Encoder Frequency 500 kHz
Pulse durations Pulse inputs 20000 10 us
Pulse repeat rate Pulse inputs 50 250 Hz
Pulse Capture Resolution Pulse inputs 1 us
Frequency Capture Pulse inputs 100 1000 Hz
Note 1: Sum of all 5VOut outputs
Operating & Timing Specifications
TABLE 10.
Parameter Measure Point Min Typ Max Units
Command Latency Command to output change 0 0.5 1 ms
PWM Frequency Motor Output 10 16 25 kHz
Closed Loop update rate Internal 1000 Hz
RS232 baud rate Rx & Tx pins 115200 (1) Bits/s
RS232 Watchdog timeout Rx pin 1 (2) 65000 ms
Note 1: 115200, 8-bit, no parity, 1 stop bit, no flow control
Note 2: May be disabled with value 0
16 FBL2360_1691-21588-0001-D-0720

FBL2360 Brushless DC Motor Controller Datasheet 17
Electrical Specifications
Scripting
TABLE 11.
Parameter Measure Point Min Typ Max Units
Scripting Flash Memory Internal 32K Bytes
Max Basic Language programs Internal 2000 3000 Lines
Integer Variables Internal 4096 Words (1)
Boolean Variables Internal 8192 Symbols
Execution Speed Internal 50000 100000 Lines/s
Note 1: 32-bit words
Thermal Specifications
TABLE 12.
Parameter Measure Point Min Typ Max Units
Case Temperature Case -40 85 (1) oC
Thermal Protection range Case 80 90 (2) oC
Power Dissipation Case 70 Watts
Thermal resistance Power MOSFETs to case 0.6 oC/W
Humidity Case 95 %
Ambient temperature Ambient 55 oC
Pollution Degree -
Fast fuse to install (3) FBL2360 (4) 40 2 x 40 Amps
FBL2360S (4) 2 x 40 Amps
Overload motor protection - Check note 5
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
Note 3: There are two power terminal tabs. Fuse should be installed in both of them for safety.
Note 4: In dual channel controller, for operating only one channel install 40A fuse and for operating both
channels 2 x 40A fuse should be installed. Power source must be capable to blow the fuse instantly in
case of short circuit
Note 5: Current limiting mechanism available through firmware. External overload motor protection can
be used if required (provided by user)
17 FBL2360_1691-21588-0001-D-0720

18 FBL2360 Brushless DC Motor Controller Datasheet Version 1.3 August 29, 2019
STO Specifications
TABLE 13.
Parameter Measure Point Min Typ Max Units
STO Input High Level Ground to STO input pin 6 30 (1) Volts
STO Input Low Level Ground to STO input pin 0 1 Volts
STO Response Time Input to output change 5 msec
STO Operating temperature -20 55 ºC
STO Storage temperature -20 70 ºC
Humidity 5 95 %
IP degree IP40
Operating Altitude 2000 m
Cable Length 2 m
EMC Immunity According to IEC 61800-3 and IEC 61800-5-2 Annex E
CE Declaration Available at www.roboteq.com
Mechanical Specifications
TABLE 14.
Parameter Measure Point Min Typ Max Units
Weight Board 500 (1) g (lbs)
Power Connectors width Terminal tab 0.25 Inches
0.7" (17.8mm)
0.16" (4.0mm)
0.325" (8.3 mm)
0.25"
(6.3 mm)
0.3"
(7.6 mm)
0.57"
(14.5mm)
0.98"
(25mm)
FIGURE 14. FBL2360 side view and dimensions
18 FBL2360_1691-21588-0001-D-0720

FBL2360 Brushless DC Motor Controller Datasheet 19
Electrical Specifications
Pwr
CtrlVMOTGND M1+M1-M2+M2-M3+M3-
I/O ConnectorHall Sensors
Connector
USB
Connector
LEDs
5.50" (139 .7mm)
5.50" (139.7mm)
3.00" (76.2mm)1.25" (31.8mm)
0.24" (6.0mm)
5.00" (127.0mm)
FIGURE 15. FBL2360 top view and dimensions
Revision Date Additions/Changes
1. 1 April 23, 2019 Added T-version with STO support
1. 2 May 21, 2019 STO certification change
1. 3 August 29, 2019 UL certification changes
Revision history
19 FBL2360_1691-21588-0001-D-0720

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