Data Sheet
Contents
1. Connection to the Hall Sensors is done using a special connector on the front side of the controller The figure below shows the location of the various low voltage connectors and LEDs on the controller me ne a Be Bi ux om Be i arene Power Status ee O O O Communication and Power and Status LEDs Hall sensors I O Connector connector FIGURE 10 Front Controller Layout 4 VBL1650 Motor Controller Datasheet Version 1 2 July 20 2010 RoboteQ Hall Sensor vs Motor Output sequencing The Hall sensor connector is a 6 pin Molex Microfit 3 0 model 43645 Pin assignment is in the table below FIGURE 11 Hall Sensors connector TABLE 4 Pin Number 1 2 3 4 5 6 Signa 5V Reserved Hall C Hall B Hall 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 1 2 3 45 61 2 3 4 5 6 W FIGURE 12 Hall Sensors sequence Commands and I O Connections Connection to RC Radio Microcomputer Joystick and other low current sensors and actuators is done via the 15 pin connector located in front of the controller The functions of man2. TABLE 8 Parameter Measure point Min Typ Max Units Main 5V Output Voltage Ground to 5V pins on 4 6 4 75 4 9 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 AIN DIN Input to Ground 53 kOhm DIN 11 19 Digital Input O Level Ground to Input pins 1 1 Volts Digital Input 1 Level Ground to Input pins 3 15 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 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 10000 Hz Note 1 Sum of all 5VOut outputs VBL1650 Motor Controller Datasheet 9 IRoboteQ Operating amp Timing Specifications TABLE 9 Parameter Measure Point Min Typ Max Units Command Latency Command to output change 1 0 5 1 ms PWM Frequency Motor Output 10 18 32 kHz Closed Loop update rate Internal 1000 Hz RS232 baud rate Rx amp Tx pins 115200 1 Bits s RS232 Watchdog timeout Rx pin 1 2 65000 ms Note 1 11520
3. lRoboteQ 150A Brushless DC Motor Controller Roboteq s VBL1650 is a high current controller for hall sensor equipped Brushless DC motors The controller uses the posi tion information from the sensors to sequence power on the motor s 3 windings in order to generate smooth continuous rotation The controller also uses the Hall sensor information to compute speed and measure travelled distance inside a 32 bit counter The motor may be operated in open or closed loop speed mode Using low cost position sensors they may also be set to operate as heavy duty position servos The VBL1650 accepts commands received from an RC radio Analog Joystick wireless modem or microcomputer Numer ous 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 realtime 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 e Small Electric Vehicles Electric Bikes Electric Boats e Heavyweight heavy duty robots e Terrestrial and Underwater Robotic Vehicles e Automatic Guided Vehicles e Police and Military Robots e Hazardous Material Handling Robots Telepresence Systems e Animatronics e Industrial Controls e Hydraulic Pumps c
4. Detection threshold Between Motor wires and VBat No Protection Permanent damage will result 8 VBL1650 Motor Controller Datasheet Version 1 2 July 20 2010 IRo b oteQ Electrical Specifications TABLE 7 Continuous Max Current per channel Measure point Min Typ Max Units Motor Acceleration Deceleration Motor Output 100 500 11 65000 millisec range onds Note 1 Negative voltage will cause a large surge current Protection fuse needed if battery polarity inversion is possible Note 2 Maximum regeneration voltage in normal operation 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 Note 10 Sensitivity selectable by software Note 11 Factory default value Time in ms for power to go from 0 to 100 Command I O and Sensor Signals Specifications
5. pin amp 15 Volts age Hall inputs RS232 I O pins Voltage External voltage applied to Rx Tx pins 15 Volts Case Temperature Case 40 85 oC Humidity Case 100 2 Note 2 Non condensing Note 1 Maximum regeneration voltage in normal operation Never inject a DC voltage from a battery or other fixed source Power Stage Electrical Specifications at 250C ambient TABLE 7 Continuous Max Current per channel Measure point Min Typ Max Units Battery Leads Voltage Ground to VBat 0 1 50 Volts Motor Leads Voltage Ground to U V W wires 0 1 50 2 Volts Power Control Voltage Ground to Power Control wire 0 1 65 Volts Minimum Operating Voltage VBat or Pwr Ctrl wires 9 3 Volts Over Voltage protection range Ground to VBat 5 50 4 55 Volts Under Voltage protection range Ground to VBat 0 5 4 55 Volts Idle Current Consumption VBat or Pwr Ctrl wires 50 100 5 150 mA ON Resistance Excluding wire VBat to U V or W Ground to U V 3 mOhm resistance or W Max Current for 30s Motor current 150 Amps Continuous Max Current per chan Motor current 75 6 Amps nel Current Limit range Motor current 10 100 7 150 Amps Stall Detection Amps range Motor current 10 100 7 150 Amps Stall Detection timeout range Motor current 1 65000 8 65000 millisec onds Short Circuit Detection threshold 9 Between Motor wires or Between 280 10 800 10 Amps Motor wires and Ground Short Circuit
6. 0 8 bit no parity 1 stop bit no flow control Note 2 May be disabled with value 0 Scripting TABLE 10 Parameter Measure Point Min Typ Max Units Scripting Flash Memory Interna 8192 Bytes Max Basic Language programs Interna 1000 1500 Lines Integer Variables Interna 1024 Words 1 Boolean Variables Interna 1024 Symbols Execution Speed Interna 50 000 100 000 Lines s Note 1 32 bit words Thermal Specifications TABLE 11 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 100 3 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 Parameter Measure Point Min Typ Max Units Weight Case 1 0 2 0 kg lbs Wire Length Case 17 43 inches mm 10 VBL1650 Motor Controller Datasheet Version 1 2 July 20 2010 IRo b oteQ Electrical Specifications TABLE 12 Parameter Measure Point Min Typ Max Units Power Wire Gauge Wire 8 AWG Power Wire Diameter Outside diameter 0 26 6 6 inches mm Pi Aux 1 60 a 40 mm mm Power Status 4 00 102 mm 5 50 140 mm FIGURE 17 VBL1650 front view and dimensi
7. ing and monitory using provided PC utility Field upgradeable software for installing latest features via the internet Reference Number of Channels VBL1650 1 Amps Channel Volts 150 50V 2 VBL1650 Motor Controller Datasheet Version 1 2 July 20 2010 RoboteQ Power Wires Identifications and Connection Power Wires Identifications and Connection Power connections are made by means of heavy gauge wires located at the back of the controller Motor Wires U V W top E a ES En Per DEE BT EEE VBat Ground Ground Power Control Controller Power FIGURE 8 Rear Controller Layout The diagram below shows how to wire the controller and how to turn power On and Off F2 SW1 Main 1A On Off Switch 1A PwrCtrl Yellow White U Ground Black Green V Blue W Note 3 ps Hall sensor 7 Hall oO _ 9 VBat Red Connector C Sensors HA HB HC GND 5V Emergency Cut off Switch Note 4 Ground Black Earth Tab ote VO Connector Note 5 Do not Connect FIGURE 9 Powering the controller Thick lines identify MANDATORY connections VBL1650 Motor Controller Datasheet 3 RoboteQ Important Warning Carefully follow the wiring Instructions provided in the Read Me First sheet that comes with the control ler or in the Power Connection section of the User Manual The information on this datasheet is only a summary Mandato
8. k e PID control loop e Configurable Data Logging of operating parameters on RS232 Output for telemetry or analysis e Built in Battery Voltage and Temperature sensors e Optional 12V backup power input for powering safely the controller if the main motor batteries are discharged e Power Control wire for turning On or Off the controller from external microcomputer or switch e No consumption by output stage when motors stopped e Regulated 5V output for powering RC radio RF Modem or microcomputer e Separate Programmable acceleration and deceleration for each motor e Ultra efficient 3 mOhm ON resistance MOSFETs e Auto stop if no motion is detected e Stall detection and selectable triggered action if Amps is outside userselected range e Short circuit protection with selectable sensitivity levels e 10 to 32kHz user programmable Pulse Width Modulation PWM output Orderable Product References Overvoltage and Undervoltage protection Watchdog for automatic motor shutdown in case of command loss Overtemperature protection Diagnostic LED Extruded aluminum heat sinking enclosure for opera tion harsh shock and temperature environment Efficient heat sinking Operates without a fan in most applications Dustproof and weather resistant IP51 NEMA rating Power wiring via heavy AWG8 cables 9 228 5mm L 5 5 W 140mm 1 6 40mm H 400 to 850 C operating environment 3 Ibs 1 3509 Easy configuration tun
9. ons 140 mm 5 50 7 00 177 8 mm J 8 00 203 mm 9 00 228 6 mm re FIGURE 18 VBL1650 top view and dimensions VBL1650 Motor Controller Datasheet 11 IRoboteQ 12 VBL1650 Motor Controller Datasheet Version 1 2 July 20 2010
10. ontrol VBL1650 Key Features RS232 0 5V Analog or Pulse RC radio command modes Auto switch between RS232 Analog or Pulse based on user defined priority Built in 3 phase high power drivers for one brushless DC motor at up to 150A Trapezoindal switching based on Hall Sensor position infor mation Full forward amp reverse motor control Four quadrant opera tion Supports regeneration Operates from a single 10V 50V power source Programmable current limit up to 150A for protecting con troller motor wiring and battery Connector for Hall Sensors Accurate speed and Odometry measurement using Hall Sensor data Up to 4 Analog Inputs for use as command and or feed back Up to 5 Pulse Length Duty Cycle or Frequency Inputs for use as command and or feedback Up to 6 Digital Inputs for use as Deadman Switch Limit Switch Emergency stop or user inputs Two general purpose 24V 1 5A output for brake release or accessories Custom scripting in Basic language Execution speed 50 000 lines per second Selectable min max center and deadband 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 VBL1650 Motor Controller Datasheet IRoboteQ e Closed loop position control with encoder analog or pulse frequency feedbac
11. ry Connections It is imperative that the controller is connected as shown in the above diagram in order to ensure a safe and trou ble free operation All connections shown as thick black lines line are mandatory The controller must be powered On Off using switch SW1on the Yellow wire Use a suitable high current fuse F1 as a safety measure to prevent damage to the wiring in case of major controller malfunction The battery must be connected in permanence to the controller s Red wires via a high power emergency switch SW2 as additional safety measure Precautions and Optional Connections Note1 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 Note2 Use precharge 1K 0 5W Resistor to prevent switch arcing Note3 Insert a high current diode to ensure a return path to the battery during regeneration in case the fuse is blown Note4 Optionally ground the VBat wires when the controller is Off if there is any concern that the motors could be made to spin and generate voltage in excess of 50V Note5 Connect the controller s earth tab 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 Note6 Beware not to create a path from the ground pins on the I O connector and the battery minus terminal Hall Sensors Connection
12. teQ Status LED Flashing Patterns RS232 Ground TxOut RxIn 0000090 FIGURE 14 Factory default pins assignment 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 2 seconds interval The flashing pattern provides operating or exception status information EERE dic Waiting for Command BERBER RS232 USB Mode EHHEHEEEEEEEEEERHEEM RC Pulse Mode BEEBE Analog Mode FIGURE 15 Normal Operation Flashing Patterns EHEENHENHEEEREREEREEM Short Detected EHEHENHEREEEEHEHEHERHEEM Overheat BEER Under or Over Voltage BEER Power Stage Off FIGURE 16 Exception or Fault Flashing Patterns Additional status information may be obtained by monitoring the controller with the PC utility VBL1650 Motor Controller Datasheet 7 IRoboteQ Electrical Specifications Absolute Maximum Values The values in the table below should never be exceeded Permanent damage to the controller may result TABLE 6 Parameter Measure point Min Typ Max Units Battery Leads Voltage Ground to VBat 55 Volts Reverse Voltage on Battery Ground to VBat 1 Volts Leads Power Control Voltage Ground to Pwr Control wire 65 Volts Motor Leads Voltage Ground to U V W wires 55 1 Volts Digital Output Voltage Ground to Output pins 30 Volts Analog and Digital Inputs Volt Ground to any signal pin on 15
13. y pins vary depending on controller model and user configuration Pin assignment is found in the table below VBL1650 Motor Controller Datasheet 5 IRoboteQ 8 1 00000000 22 FIGURE 13 Connector pin locations 15 9 TABLE 5 Connector Pin Power Dout Com RC Ana Dinput Default Config 1 DOUT1 Brake release 1 9 DOUT2 Unused 2 TxOut RS232Tx 0 RC5 ANA1 DIN5 AnaCmd1 3 RxlIn RS232Rx 1 RC4 ANA4 DIN4 Unused 4 RC1 DIN1 RCRadio1 2 RC3 ANA3 DIN3 Unused 5 GND 3 GND 6 SCLI Reserved 4 5VOut 7 SDAI Reserved 5 DIN6 Unused 8 RC2 ANA2 DIN2 Default I O Configuration 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 an analog potentiometer an RC radio the RS232 port and the Digital output to a motor brake solenoid 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 Analog If needed use the Roborun PC Utility to change the pin assignments and the command priority order VBL1650 Motor Controller Datasheet Version 1 2 July 20 2010 Robo
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