RoboteQ FBL2360 Datasheet

Advanced Features
2 x 60A or 1 x 120A
Brushless DC
Motor Controller
with USB and CAN

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

FBL2360 Brushless DC Motor Controller Datasheet 1

• 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

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

2 FBL2360 Brushless DC Motor Controller Datasheet Version 1.3 August 29, 2019

Power Wires Identifications and Connection

(T-version)

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.

Jumper

FIGURE 1. FBL2360 front view

FIGURE 2. FBL2360 rear view

Connector

I/O ConnectorHall Sensors

LEDsSTO

USB

Connector

Pwr
CtrlVMOTGND U1V1W1U2V2W2

FBL2360 Brushless DC Motor Controller Datasheet 3

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

2 etoN 3 etoN

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

4 FBL2360 Brushless DC Motor Controller Datasheet Version 1.3 August 29, 2019

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.

Single Channel Wiring

U1

V1

W1

U2

V2

W2

U

V

W

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.

FBL2360 Brushless DC Motor Controller Datasheet 5

Use of Safety Contactor for Critical Applications

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

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.

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

6 FBL2360 Brushless DC Motor Controller Datasheet Version 1.3 August 29, 2019