Solo MEGA SLSGB002PW2000 User manual
SOLO MEGA User Manual
Part Number: SLSGB002PW2000
Product Description
Power Range
SOLO MEGA with part number of
SLSGB000PW2000 is a member of the SOLO
motor controllers family of devices capable of
driving and controlling various types of
electrical motors like DC brushed, BLDC,
PMSM and EC coreless motors in a single
platform.They are made to be easy to use with
state of art technologies and Dual Core
parallel processing architecture on top of FOC
control methods.
SOLO MEGA supports sensor-based Torque,
Speed and Position controlling plus other
options like full digital and analog controls and
active safety measures to keep the
applications safe from unforeseen behaviors.
Supply Voltage Range : 8- 60 VDC
Peak Current: 220A peak to peak
Continuous Current: 120A DC, 110A RMS
Features
●Easy to use
●Drives and Controls DC brushed,
BLDC, PMSM and EC coreless motors
●Torque, Speed and Position controlling
●Four Quadrant Regenerative operation
●Automatic parameter Identification
and self-tuning
●Isolated STO(Safe Torque off)
●Isolated USB, UART and CANopen
●Supports PT1000 temperature sensors
●Sleep mode with consumption of
2.6mA
●Field Oriented Control with Nested
Position-Speed-Torque loops
●Dual Core with Parallel Processing
Architecture
●Bus over-voltage, Bus under-voltage ,
over-current and over temperature
protections
●Active Brake Chopper
●Full Digital and Analogue Control
●Space Vector Modulation (SVM)
●Embedded Motion Profile (St-Curve)
for Position and Speed
Modes of Operation
Commands and feedbacks Source
●Analogue or Digital commanding
●Torque Control
●Speed Control
●Position Control
●0-10V Analogue/ PWM inputs for
Speed or Torque control
●Analogue torque and speed feedbacks
●Optically isolated quadrature Encoder
and Hall sensor inputs
●Isolated UART, USB and CAN bus
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
Applications
●Industrial Automations
●Robotics and Traction Units
●Drones
●Automotive Industries
●Household Appliances
●Medical Devices
●Aerospace
●Textile Industry
●Automated Guided Vehicles (AGVs)
●Heating, Ventilation and Air-Conditioning (HVAC)
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
Identification of hazards and instructions on how to prevent them
Danger
Immediate dangers which can lead to death or serious injuries.
Warning
Hazards that can cause serious damages or injuries.
Caution
Hazards that can cause minor injuries or material damage.
Recommendations, tips, references to other documentation.
Essential or useful accessories.
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
Table of Contents
Power Specifications: 7
Control and Timings specifications: 8
Thermal Specifications: 9
Mechanical Specifications: 9
Mechanical Dimensions: 10
Absolute Maximum Voltage Ratings: 11
Standards and Conformities: 13
Overview of the product 14
Functional Block Diagram: 15
Theory of Operation: 16
FOC control Architecture in SOLO MEGA for 3-phase Motors: 17
Cascade control Architecture in SOLO MEGA for DC Motors: 18
SOLO MEGA’s Interactional Sections: 19
Connectors and Sections: 20
Sections [2, 4, 6] - Motor Outputs 20
Sections [17, 18] - Supply Inputs 21
Section [5] J3 - Analogue I/O Port 22
Section [15] - Isolated USB Connection 27
Section [1] J2 - Encoder/Hall Connector 28
Section [3] J7 - Communication Connector 30
Section [7] J6 - Future Reserved Connector 31
Sections [11,12] - Functionality LEDs 32
Section [13] - Power Up LED 33
Section [10] J9 -STO and Sleep Connector 34
Section [9] J8 - Active Brake Chopper 36
Section [8] - Brake Activation LED 38
Connectors and their Matings Part Number: 39
Analogue versus Digital Control in SOLO MEGA 40
SOLO MEGA Wirrings 41
Wiring Legend: 41
Safe Torque Off (STO) Wiring: 42
1- Wire STO to a safety relay using external +5V DC supply voltage: 42
2- Wire STO to a safety relay using internal +5V isolated supply voltage: 43
3- Wire STO to a safety relay using internal +5V non- isolated supply voltage: 44
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
4- By Passing STO without external commanding devices: 45
STO Timing Diagram 45
Analogue wiring in SOLO MEGA: 47
1- Analogue wiring in case of controller with NPN outputs: 47
2- Analogue wiring in case of controller with PNP outputs: 48
3- Analogue wiring in case of Embedded MCU Boards: 49
Wiring with HALL Sensors: 50
Wiring with Incremental Encoders: 51
1- Wiring in case of Single Ended Incremental Encoders: 51
2- Wiring in case of Differential Incremental Encoders: 52
Wiring of Sleep Mode input: 53
Wiring of DFU Mode input: 53
PT1000 temperature sensor wiring: 54
Wiring and Setup of Active Brake Chopper: 56
Analogue Torque and Speed Feedbacks and Wiring: 58
Digital Mode Wirings: 60
Isolated USB Interface Wiring 60
Isolated UART Interface Wiring 61
Isolated CAN bus Interface Wiring 62
Full Wirings of SOLO MEGA: 63
In this section some full wiring of SOLO MEGA will be demonstrated. 63
Standalone Wiring (No External Modules): 63
Embedded MCU Boards using Analogue/PWM: 65
Embedded MCU Boards Using UART: 66
Embedded MCU Boards Using CANopen: 67
General Wiring Considerations in SOLO MEGA: 68
1- Avoid running feedbacks and power wires together 68
2- Avoid making ground loops 68
Temperature and Max Current Behaviour: 69
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
Power Specifications:
Description
Units
Values
DC Supply Voltage Range (continuous)
VDC
8 to 60
Active Brake Chopper Activation Voltage
VDC
61
Software Overvoltage Activation Voltage
VDC
63V
Hardware Overvoltage Activation Voltage
VDC
66.4
DC Bus Undervoltage Limit
VDC
7
Maximum Peak Output Current
A
220A peak to peak
Maximum Continuous Output Current
A
120A DC, 110A RMS
Maximum Continuous Output Power
W
6000
Internal Bus Capacitance
µF
4700
Switching Frequency (Output PWM Frequency)
kHz
8 to 80
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
Control and Timings specifications:
Description
Units
Values
Analogue Speed or Torque Commands
VDC
0-10V Analogue voltages or PWM inputs
with frequency above 5kHz
Digital Direction Control
VDC
0 - 3.3/5/12V
Modes of Operation
-
Torque - Speed- Position
Motors supported
-
DC brushed - BLDC - PMSM - EC Coreless
Hardware Protections
-
Bus over-voltage, Bus under-voltage,
over-current and over temperature
Current (Torque) Loop sampling time
µs
Synched to PWM frequency ( Min 7 µs)
Current (Torque) Loop execution time
µs
7
Speed controller Loop sampling time
µs
500
Speed controller Loop execution time
µs
75
Position controller Loop sampling time
µs
500
Position controller Loop execution time
µs
75
Maximum Encoder Frequency (Pre-Quad)
MHz
2
Current Measurement Resolution
mA
80
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
Thermal Specifications:
Description
Units
Values
Board Temperature Range
°C
-20 to 85
Heatsink (base) Temperature Range
°C
0 - 85
Cooling system
-
Natural Convection
Mechanical Specifications:
Description
Units
Values
Size (H x W x D)
mm
42.21 x 154 x 94
Weight (with heatsink)
gr
933
Form Factor
-
Wall Mount
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
Absolute Maximum Voltage Ratings:
- All The sections are referred to Figure 5 below
-The +3.3V parts are NOT +5V tolerant, and in case of applying more than 3.3V, the device
might get permanently Damaged.
-The users should refer to “Typical Max” for the maximum voltage allowed on each pin, the
“Absolute Max” is just for very short times considering the effect of spikes and fast
harmonics.
Section
PIN/Connector name
Input / Output
Units
Min
Typical Max
Absolute Max
]17,18[
Supply Input
Input
VDC
+8
+60
+66
[5]
S/T (speed/torque)
Input
VDC
0
+10
+10.25
[5]
P/F (current limit/power/flux)
Input
VDC
0
+10
+10.25
[5]
Speed-FB
Output
VDC
0
+10
+10.25
[5]
Torque-FB
Output
VDC
0
+10
+10.25
[5]
PT1000-IN
Input
VDC
0
+3.3
+3.75
[5]
DFU
Input
VDC
0
+3.3
+3.75
[5]
DIR (Direction control)
Input
VDC
0
+12
+12.25
[10]
STO1(Safe Torque off input 1)
Input
VDC
0
+5
+5.25
[10]
STO2(Safe Torque off input 2)
Input
VDC
0
+5
+5.25
[5]
+5V-NISO (External supply)
Output
VDC
+4.95
+5.0
+5.05
[5]
+12V-NISO(External supply)
Output
VDC
+11.95
+12
+12.05
[1]
+5V-ISO(External supply)
Output
VDC
+4.95
+5
+5.05
[1]
ENC-A(Encoder channel A)
Input
VDC
0
+12
+12.25
[1]
ENC-B(Encoder channel B)
Input
VDC
0
+12
+12.25
[1]
ENC-C(Encoder channel C)
Input
VDC
0
+12
+12.25
[3]
ISO-UART_RX
Input
VDC
-0.5
-
+5.5
[3]
ISO-UART_TX
Output
VDC
-0.5
-
+5.5
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
Standards and Conformities:
Standard
Code
Class*
Radiated emissions – enclosure port
CISPR 16-2-3 EN 55016-2-3
B
Enclosure ports – Electrostatic discharges
IEC / EN 61000-4-2
B
Enclosure ports – Radio-frequency
electromagnetic field (AM)
IEC / EN 61000-4-3
B
I/O DC power ports – Fast transients
IEC / EN 61000-4-4
B
I/O DC power ports – Surges
IEC / EN 61000-4-5
B
I/O DC power ports – Radio-frequency
common mode
IEC / EN 61000-4-6
B
Enclosure ports – Power-frequency magnetic
field
IEC / EN 61000-4-8
B
ROHS
2011/65/EU
-
* : Without using any external Filters.
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
Overview of the product
SOLO MEGA is a family of high-power motor controllers that are designed for high-current
applications. This product is designed to support various types of electrical motors like DC
brushed, Brushless DC and PMSM motors up to 60V with the supply voltage and the continuous
current of up to 120 Amps DC or 110 Amps RMS, this will enable SOLO MEGA to be utilized in
wide range of products and projects and eventually speeding up the developments and time to
market for its users.
SOLO MEGA can be commanded in two different ways, either by sending Analogue voltages or
PWM pulses which is called Analogue Mode, or totally by sending Digital data packets through
isolated UART, isolated USB or isolated CAN bus lines. This will give a high flexibility in terms of
system setup to the users and they can choose the best way to wire up their systems using SOLO,
The main features of SOLO MEGA are listed as below:
●Wide input voltage supply range from 8V to 60V
●The continuous output current of 120 Amps DC or 110 Amps RMS
●Capable of controlling DC brushed, BLDC and PMSM motors
●Dual Core with parallel processing architecture
●Isolated CAN, USB and UART Communications
●Isolated STO(Safe Torque off) for safe emergency stops
●Active Brake Chopper with selectable activation voltage using an external resistor
●Extremely fast F.O.C loop-rate up to 140kHz (7µs complete execution time)
●Over-current, Over-voltage, Over-Temperature and Under-voltage Protection
●Selectable output PWM switching frequency from 8kHz to 80kHz
●Automatic self-tuning and identification of Motor parameters
●Closed-loop Torque, Speed or Position control
●Advance Field Oriented Control
●PWM and Analogue voltage input for Controlling Speed and Torque
●Pure Analogue feedbacks output for Speed and Torque
●Optically isolated Encoder and Hall Sensor Input with up to +12V supply
●+5V/1A (5W) and +12/0.25A(3W) outputs to supply external modules
●2.6mA current consumption in sleep mode
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
Architecture:
Figure 2 - Architecture of SOLO MEGA
Theory of Operation:
SOLO MEGA is designed to operate in closed-loop fashion with nested Torque, Speed and Position
controlling loops, this type of topology gives the possibility of controlling each of these
phenomenons (Torque, Speed, Position) separately and almost independently, resulting in very
robust and smooth control for systems with variable dynamics and loads, for 3-phase motors like
Brushless DC and PMSM this topology is known as Field Oriented Control or Vector Control.
In general we can divide the whole control architecture of SOLO for two different types of Motors,
the 3-phase motors that can be seen in Figure 3 and Brushed DC motors that can be seen in Figure
4 below. As can be seen in these figures, the main foundation of the architecture of motor
controlling in SOLO is based on four fundamental controllers:
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
1- The Torque Controller: This is the closest controller to the motor and the fastest one, it will
only control the Torque of the Motor which is generated by injection of Current into the stator,
that’s why this controller is known as Current Controller too, this controller will try to stabilize the
required torque (current) in the motor to make the whole system capable of overcoming the
dynamics changes in the load.
2- The Speed Controller: The Speed Controller comes behind the Torque Controller, it is slower
than the Torque controller (at least around tenfold) and it basically tries to fix the Speed on a
desired value, this controller will keep the rotational speed fixed regardless of the load variation
and it will adjust the torque accordingly. One might ask why the Speed controller comes after the
Torque controller, this is a big topic, but to simplify it drastically , in principle an Electrical Motor is
a Torque Generation machine, even the Speed is controlled finally by controlling the Torque, so the
Speed commands to the Torque Controller to increase or decrease the Torque on the Motor to
stabilize the motor on a specific desired Speed based on the effect of the load on the shaft.
3- The Position Controller: This is the last controller coming behind the speed controller, it
basically tries to set the exact position of the Motor on a specific value, so to make this loop
functional, the user needs to make sure the Torque and Speed loops are firstly tuned and ready.
FOC control Architecture in SOLO MEGA for 3-phase Motors:
Figure 3 - FOC Control Architecture of SOLO MEGA for 3-phase Motors
As can be seen in Figure 3, to control any of the Torque, Speed and even position of a 3-phase
motor in FOC fashion, there is a need to have at least 4 different feedbacks:
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
1- Current Feedback: This feedback is necessary to control the current inside of the motor and for
Torque Controlling and it’s measured internally by SOLO, the accuracy of current measurement is
80mA in SOLO MEGA.
2- Speed Feedback: This feedback is measured using the sensors mounted on the motor
(Encoders, Halls, …), and it’s used for Speed Controlling purposes.
3- Position Feedback: This feedback comes from external sensors like Encoders, and it enables the
Servo-Driving Capabilities of SOLO
4- Motor Electrical Angle: This feedback is essential for any type of closed-loop control on SOLO,
this feedback is Measured by SOLO internally.
Cascade control Architecture in SOLO MEGA for DC Motors:
Figure 4 - Control Architecture of SOLO MEGA for DC Brushed Motors
As can be seen in Figure 4, the main architecture of Motor Controlling for DC brushed motors in
SOLO follows a very similar pattern to 3-phase Motors Controlling with FOC, however the
architecture is generally simple with only one cascade loop of Torque, Speed and Position.
Similar to 3-phase motors, for DC brushed Motors, SOLO offers Sensor-based controls as well as
Servo-Driving in case an Incremental Encoder is attached to the Motor, so the whole control
strategy and tunings are identical to the 3-phase motors with minor differences on the processing
methods.
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
SOLO MEGA’s Interactional Sections:
SOLO MEGA can be decomposed into 18 main interactional sections as shown in Figure 5, all the
sections will be explained in detail and their electrical and maximum ratings will be mentioned
later in this user manual, the user has to make sure they don’t exceed those maximum ratings to
avoid damaging themselves or the SOLO MEGA unit.
Figure 5 - SOLO MEGA’s interactional sections
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SOLO MEGA User Manual
Part Number: SLSGB002PW2000
Connectors and Sections:
Sections [2, 4, 6] - Motor Outputs
Name
Descriptions / Notes
I/O
A
Motor Output 1
-
B
Motor Output 2
-
C
Motor Output 3
-
Description
This connector of SOLO should be connected to the Motors’ wires. You can find out more about
how to connect them by looking at the “SOLO MEGA Wirings” Section, but in general for 3
phase motors the A,B,C pins should get connected to the 3 phase wires of the motor and for DC
brushed motors only B and C pins are required to be connected to the motor.
- While wiring SOLO MEGA avoid connecting power supply cables into motor outputs,
this can cause serious damages to the unit.
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