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2x75A High Performance Dual Channel Brushless DC Motor Controller with USB, Encoder Inputs and CAN Interface

Roboteq’s HBL2350 is a high-current, dual channel controller for hall-sensor equipped Brushless DC motors. The controller uses the position information from the sensors to sequence power on the motors’ 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. The HBL2350 features several Analog, Pulse and Digital I/Os which can be remapped as command or feedback inputs, limit switches, or many other function. The HBL2350 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 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

Key Features

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USB, RS232, 0-5V Analog, or Pulse (RC radio) command modes CAN bus interface up to 1Mbit/s Auto switch between USB, RS232, Analog, or Pulse based on user-defined priority Built-in dual 3-phase high-power drivers for two brushless DC motor at up to 75A Trapezoidal switching based on Hall Sensor position information Full forward & reverse control on each channel. Four quadrant operation. Supports regeneration Operates from a single 10V-50V power source Built-in programming language for automation and customization Programmable current limit for each channel up to 2x75A for protecting controller, motors, wiring and battery. Connector for Hall Sensors Accurate speed and Odometry measurement using Hall Sensor data Up to 11 Analog Inputs for use as command and/or feedback Up to 6 Pulse Length, Duty Cycle or Frequency Inputs for use as command and/or feedback Up to 21 Digital Inputs for use as Deadman Switch, Limit Switch, Emergency stop or user inputs Dual Quadrature Encoder inputs with 32-bit counters 8 general purpose 24V, 1A output for brake release or accessories Selectable min, max, center and deadband in Pulse and Analog modes Selectable exponentiation factors for each command inputs

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Industrial Automation Small Electric Vehicles, Electric Bikes Terrestrial and Underwater Robotic Vehicles Automatic Guided Vehicles Police and Military Robots Hazardous Material Handling Robots Balancing Robots Telepresence Systems Animatronics

HBL2350 Motor Controller Datasheet


Pulse or Encoder capture are outside user selectable range (soft limit switches) Open loop or closed loop speed control operation Closed loop position control with analog or pulse/frequency feedback Precise speed and position control when Encoder feedback is used PID control loop with separate gains for each channel Optional Mixed control (sum and difference) for tank-like steering Configurable Data Logging of operating parameters on RS232 Output for telemetry or analysis Built-in Battery Voltage and Temperature sensors Optional 12V 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 Encoders. tuning and monitory using provided PC utility Field upgradeable software for installing latest features via the internet Orderable Product References Reference HBL2350 Number of Channels 2 Amps/Channel 75 Volts 50 2 HBL2350 Motor Controller Datasheet Version 1.350g) Easy configuration. May 3. RF Modem or microcomputer Separate Programmable acceleration and deceleration for each motor Separate Programmable maximum forward and reverse power Support for CANopen and two simplified CAN protocols • • • • • • • • • • • • • • • • • Ultra-efficient 3 mOhm ON resistance MOSFETs Auto stop if no motion is detected Stall detection and selectable triggered action if Amps is outside user-selected range Short circuit protection with selectable sensitivity levels Overvoltage and Undervoltage protection Programmable Watchdog for automatic motor shutdown in case of command loss Overtemperature protection Diagnostic LED Extruded aluminum.5” W (140mm). Operates without a fan in most applications Dustproof and weather resistant. 2012 . heat sinking enclosure for operation harsh shock and temperature environment Efficient heat sinking.6” (40mm) H -40o to +85o C operating environment 3 lbs (1. IP51 NEMA rating Power wiring via AWG8 battery cables and AWG10 motor cables 9” (228.5mm) L. 1. 5.0.• • • • • • • • • • • • • • • Trigger action if Analog. RC radio.

but not limited to: command or feedback wiring failure. or controller hardware failure.Power Wires Identifications and Connection Important Safety Disclaimer Dangerous uncontrolled motor runaway condition can occur for a number of reasons. faulty firmware. HBL2350 Motor Controller Datasheet 3 . configuration error. Rear Controller Layout The diagram below shows how to wire the controller and how to turn power On and Off. Motor Wires U1 U2 V1 V2 W1 W2 (top) VMot Ground Controller Power Ground Power Control FIGURE 8. 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. errors in user script or user program. Power Wires Identifications and Connection Power connections are made by means of heavy gauge wires located at the back of the controller. including.

The user must be able to deactivate the switch or contactor at any time. 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. May 3. 4 HBL2350 Motor Controller Datasheet Version 1.F2 1A Note 1 SW1 Main On/Off Switch 1A PwrCtrl/Yellow Ground/Black White/U1 U1 Motor1 Green/V1 Resistor 1K. The controller must be powered On/Off using switch SW1on the Yellow wire.0. The information on this datasheet is only a summary. Precautions and Optional Connections Note1: Backup battery to ensure motor operation with weak or discharged batteries.5W Resistor to prevent switch arcing. 0. independently of the controller state. Note3: Insert a high-current diode to ensure a return path to the battery during regeneration in case the fuse is blown. connect a second battery to the Power Control wire/terminal via the SW1 switch. All connections shown as thick black lines line are mandatory. 0. Note2: Use precharge 1K.5W Note 2 VMot/Red SW2 Emergency Contactor or Cut-off Switch Hall sensor Connector HA1/HB1/HC1 GND/+5V HA2/HB2/HC2 Hall Sensors2 Blue/W1 Hall Sensors1 V1 W1 Backup Battery Diode >20A Note 3 F1 Yellow/W2 Orange/V2 Ground/Black V2 W2 Motor2 Brown/U2 U2 Earth Tab Note 5 Do not Connect! Note 4 + Main Battery I/O Connector FIGURE 9. Thick lines identify MANDATORY connections Important Warning Carefully follow the wiring instructions provided in the Power Connection section of the User Manual. Emergency Switch or Contactor The battery must be connected in permanence to the controller’s Red wires via a high-power emergency switch or contactor SW2 as additional safety measure. Note4: Optionally ground the VMot 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. Use a suitable high-current fuse F1 as a safety measure to prevent damage to the wiring in case of major controller malfunction. Powering the controller. 2012 .

HBL2350 Motor Controller Datasheet 5 . Note6: Beware not to create a path from the ground pins on the I/O connector and the battery minus terminal.Use of Safety Contactor for Critical Applications Note5: Connect the controller’s earth tab to a wire connected to the Earth while the charger is plugged in the AC main. This circuit will not protect against other sources of failure such as those described in the “Important Safety Disclaimer” on page 3.5W F1 to +40V Max Digital Out VMot I/O Connector + Main Battery - Ground FIGURE 10.5s. 0. Contactor wiring diagram The contactor coil must be connected to a digital output configured to activate when “No MOSFET Failure” The . F2 1A SW1 Main On/Off Switch 1A PwrCtrl Ground Diode >20A Resistor 1K. 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. 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. or if the controller is powered by an AC power supply.

2012 . 43025-1000. ref. Pin Number Row Ch1 Row Ch2 1 5V 5V 2 Hall1 C Hall2 C 3 Hall1 B Hall2 B 4 Hall1 A Hall2 A 5 Ground Ground 6 HBL2350 Motor Controller Datasheet Version 1. USB connect.0.0. Power and Status LEDs Hall Sensors Connector USB Connector Communication and I/O Connectors FIGURE 11. Front Controller Layout The Hall sensor connector is a 10-pin Molex Microfit 3. May 3. Pin assignment is in the table below. The figure below shows the location of the various low-voltage connectors and LEDs on the controller.Hall Sensors Connection Connection to the Hall Sensors is done using a special connector on the front side of the controller. Row Ch1 Row Ch2 Row Ch1 Row Ch2 5 1 FIGURE 12. Hall Sensors connector 5 1 TABLE 4.

The controller’s 3-phase bridge will activate each of the motor winding according to the sequence shown in the figure below. Microcomputer. The functions of many pins vary depending on controller model and user configuration. Hall Sensors sequence Commands and I/O Connections Connection to RC Radio. 14 25 1 13 FIGURE 14. Pin assignment is found in the table below. Main Connector pin locations TABLE 5. Joystick and other low current sensors and actuators is done via the 25 and 9 pin connectors located in front of the connector. Connector Pin 1 14 2 15 3 16 4 17 5 18 6 19 7 GND DOUT1 DOUT2 DOUT3 DOUT4 DIN12 DIN13 DIN14 DIN15 Motor Brake 1 Motor Brake 2 Contactor Unused RxData RC2 RC3 RC4 ANA2 ANA3 ANA4 DIN2 DIN3 DIN4 Power GND 5VOut TxData RC1 ANA1 DIN1 RS232Tx RCRadio1 RS232Rx RCRadio2 AnaCmd1 (1) AnaCmd2 (1) Dout Com Pulse Ana Dinput Enc Default Config HBL2350 Motor Controller Datasheet 7 .Hall Sensor vs Motor Output sequencing Hall Sensor vs Motor Output sequencing The controller requires the Hall sensors inside the motor to be 120 degrees apart. 1 Hall A Hall B 2 3 4 5 6 1 2 3 4 5 6 U 1 3 4 6 5 W 2 V Hall C U V W + + + + + + + + + + + + FIGURE 13.

an RC radio. 3-None.0. 9 6 5 1 FIGURE 15.TABLE 5. The figure below shows how to wire the controller to two analog potentiometers. Secondary Connector pin locations TABLE 6. use the Roborun+ PC Utility to change the pin assignments and the command priority order. and the RS232 port. Connector Pin 20 8 21 9 22 10 23 11 24 12 25 13 5VOut GND GND RC6 ANA6 ANA7 ANA8 ANA9 ANA10 ANA11 DIN6 DIN7 DIN8 DIN9 DIN10 DIN11 ENC2B ENC2A ENC1B ENC1A Unused Unused Unused Unused Unused Unused Power Dout DOUT5 DOUT6 RC5 ANA5 Com Pulse Ana Dinput DIN16 DIN17 DIN5 Enc Default Config Unused Unused Unused Note 1: Analog command is disabled in factory default configuration. Connector Pin 5 9 4 8 3 7 2 6 1 GND DOUT8 DIN19 Unused GND CANH CANL CAN High CAN Low 5VOut SCLI SDAI Reserved Reserved Power Dout DOUT7 Com Pulse Ana Dinput DIN18 Default Config Unused Default I/O Configuration While the controller can be configured so that practically any Digital. The controller automatically arbitrates the command priorities depending on the presence of a valid command signal in the following order: 1-RS232. May 3. You may omit any connection that is not required in your application. 8 HBL2350 Motor Controller Datasheet Version 1. It also shows how to connect two outputs to motor brake solenoids and another output to an external status LED. 2RC Pulse. the controller’s factory default configuration provides an assignment that is suitable for most applications. 2012 . If needed. Analog and RC pin can be used for any purpose.

Waiting for Command RS232/USB Mode RC Pulse Mode Analog Mode FIGURE 17 Normal Operation Flashing Patterns . the Power LED will tun on. Short Detected Overheat Under or Over Voltage Power Stage Off FIGURE 18. Idle .Status LED Flashing Patterns RC Ch1 RC Ch2 1 2 Pot 1 Pot 2 14 25 1 13 RS232 TxOut RxIn Ground Contactor Motor Brake 2 Motor Brake 1 FIGURE 16. The flashing pattern provides operating or exception status information. Exception or Fault Flashing Patterns Additional status information may be obtained by monitoring the controller with the PC utility. Status LED Flashing Patterns After the controller is powered on. Factory default pins assignment Analog command mode is disabled by default. Use the PC utility to enable and assign analog inputs. The drawing shows suggested assignment of Pot 1 to ANA1 and Pot 2 to ANA4. The Status LED will be flashing at a 2 seconds interval. indicating that the controller is On. HBL2350 Motor Controller Datasheet 9 .

Continuous Max Current per channel Battery Leads Voltage Motor Leads Voltage Power Control Voltage Minimum Operating Voltage Over Voltage protection range Under Voltage protection range Idle Current Consumption ON Resistance (Excluding wire resistance) Max Current for 30s Continuous Max Current per channel Current Limit range Stall Detection Amps range Stall Detection timeout range Short Circuit Detection threshold (9) Short Circuit Detection threshold Measure point Ground to VMot Ground to U. TABLE 7 . V or W Motor current Motor current Motor current Motor current Motor current Between Motor wires or Between Motor wires and Ground Between Motor wires and VMot Min 0 (1) 0 (1) 0 (1) 9 (3) 5 0 50 Typ Max 50 50 (2) 65 Units Volts Volts Volts Volts Volts Volts mA mOhm 50 (4) 5 (4) 100 (5) 6 50 50 150 75 40 (6) 10 10 1 140 (10) 50 (7) 75 (7) 500 (8) 75 75 65000 400 (10) Amps Amps Amps Amps milliseconds Amps No Protection. May 3. V or W. Permanent damage will result 10 HBL2350 Motor Controller Datasheet Version 1. V. M1-. 2012 . M2+. W wires Ground to Power Control wire VMot or Pwr Ctrl wires Ground to VMot Ground to VMot VMot or Pwr Ctrl wires VMot to U.0. M2Ground to Output pins Ground to any signal pin on 25 & 9-pin connectors External voltage applied to Rx/Tx pins Case Case -40 -1 65 50 (1) 40 15 15 85 100 (2) Min Typ Max 50 Units Volts Volts Volts Volts Volts Volts Volts oC % Note 1: Maximum regeneration voltage in normal operation. Ground to U. Never inject a DC voltage from a battery or other fixed source Power Stage Electrical Specifications (at 25oC ambient) TABLE 8. permanent damage to the controller may result. Parameter Battery Leads Voltage Reverse Voltage on Battery Leads Power Control Voltage Motor Leads Voltage Digital Output Voltage Analog and Digital Inputs Voltage RS232 I/O pins Voltage Case Temperature Humidity Note 2: Non-condensing Measure point Ground to VMot Ground to VMot Ground to Pwr Control wire Ground to M1+.Electrical Specifications Absolute Maximum Values The values in the table below should never be exceeded.

Parameter Main 5V Output Voltage 5V Output Current Digital Output Voltage Digital Output Current Output On resistance Output Short circuit threshold Input Impedances (except DIN12-19) Input Impedance (DIN12-19) Digital Input 0 Level Digital Input 1 Level Analog Input Range Analog Input Precision Analog Input Resolution Pulse durations Pulse repeat rate Pulse Capture Resolution Frequency Capture Encoder count Encoder frequency Note 1: Sum of all 5VOut outputs Note 2: Total average current on all outputs not to exceed 4. I/O and Sensor Signals Specifications TABLE 9. Current may be higher with better cooling Note 7: Factory default value. Limited by case temperature. Time in ms for power to go from 0 to 100% Command.75 Max 4.5 1.75 Units Volts mA Volts Amps Ohm Amps kOhm kOhm Volts Volts Volts % mV us Hz us Hz 10^9 Counts kHz HBL2350 Motor Controller Datasheet 11 . Adjustable in 0.4 53 50 1 15 5. sink current Output pin to ground Output pin AIN/DIN Input to Ground Input to 5V Ground to Input pins Ground to Input pins Ground to Input pins Ground to Input pins Ground to Input pins Pulse inputs Pulse inputs Pulse inputs Pulse inputs Internal Encoder input pins 100 -2.5A Measure point Ground to 5V pins on 5V pins on RJ45 and DSub15 Ground to Output pins Output pins. Never inject a DC voltage from a battery or other fixed source Note 3: Minimum voltage must be present on VMot or Power Control wire Note 4: Factory default value.75 1.05 0.5 1 10 250 1.147 250 -1 3 0 0. 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. Continuous Max Current per channel Motor Acceleration/Deceleration range Measure point Motor Output Min 100 Typ 500 (11) Max 65000 Units milliseconds Note 1: Negative voltage will cause a large surge current.6 Typ 4.1V increments Note 5: Current consumption is lower when higher voltage is applied to the controller’s VMot or PwrCtrl wires Note 6: Estimate. Adjustable in 0.9 200 (1) 30 1 (2) 1. Protection fuse needed if battery polarity inversion is possible Note 2: Maximum regeneration voltage in normal operation.1A increments Note 8: Factory default value.1 Min 4.147 20000 50 1 10000 2.Electrical Specifications TABLE 8.

0) 17 (43) Max Units kg (lbs) inches (mm) 12 HBL2350 Motor Controller Datasheet Version 1.5 18 (1) 1000 12 Max 1 20 Units ms kHz Hz MBits/s Bits/s ms Note 1: May be adjusted with configuration program Note 2: 115200.Operating & Timing Specifications TABLE 10.0 (2. 1 stop bit.0. Parameter Command Latency PWM Frequency Closed Loop update rate USB Rate RS232 baud rate RS232 Watchdog timeout Measure Point Command to output change Ch1. Parameter Scripting Flash Memory Max Basic Language programs Integer Variables Boolean Variables Execution Speed Note 1: 32-bit words Measure Point Internal Internal Internal Internal Internal 50 000 1000 1024 1024 100 000 Min Typ 8192 1500 Max Units Bytes Lines Words (1) Symbols Lines/s Thermal Specifications TABLE 12. May 3. no parity. Ch2 outputs Internal USB pins Rx & Tx pins Rx pin 1 (3) 115200 (2) 65000 Min 1 10 Typ 0. 8-bit. down to 0 at max of range Mechanical Specifications TABLE 13. no flow control Note 3: May be disabled with value 0 Scripting TABLE 11. 2012 .6 Units oC oC Watts oC/W Note 1: Thermal protection will protect the controller power Note 2: Max allowed power out starts lowering at minimum of range. Parameter Weight Wire Length Measure Point Case Case Min Typ 1. Parameter Case Temperature Thermal Protection range Power Dissipation Thermal resistance Measure Point Case Case Case Power MOSFETs to case Model All All All All Min -40 80 Typ Max 85 (1) 90 (2) 70 0.

HBL2350 front view and dimensions 0.Electrical Specifications TABLE 13.26 (6.6 mm) 5.00" (177.6) Max Units AWG inches (mm) 1.50" (140 mm) 3.4 mm) 4.2 mm) 7.60" (40 mm) 4. HBL2350 top view and dimensions HBL2350 Motor Controller Datasheet 13 .3 mm) 3.50" (140 mm) FIGURE 19.00" (203 mm) 9.00" (101.25" (6.6 mm) FIGURE 20.8 mm) 8.00" (76.00" (228. Parameter Power Wire Gauge Power Wire Diameter Measure Point Wire Outside diameter Min Typ 8 0.60" (91.00" (102 mm) 5.