FDC32xx Datasheet
Contents
1. lRoboteQ FDC3260 Advanced Features Triple Channel 60A Brushed DC Motor Controller with USB and CAN Roboteq s FDC3260 is a features packed high current triple channel controller for brushed DC motors The controller fea tures a high performance 32 bit microcomputer and quadrature encoder inputs to perform advanced motion control algorithms The motors may be operated in open or closed loop speed mode position mode or in torque mode The FDC3260 features several Analog Pulse and Digital I Os which can be remapped as command or feedback inputs limit switches or many other functions The FDC3260 accepts com mands received from an RC radio Analog Joystick wireless modem PLC or microcomputer For mobile robot applications two of the controller s three motor channels can either be oper ated 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 Lan guage scripts The controller can be configured monitored and tuned in realtime using a Roboteq s free PC utility The control ler can also be reprogrammed in the field with the latest fea tures by downloading new operating software from Roboteq Applications e Motion simulators e XYZ platforms e Un2. Motor 3 I O Connector Note 5 Do not Connect 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 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 Pwr Ctrl tab Use a suitable high current fuse F1 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 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 t
3. Input Impedances AIN DIN Input to Ground 53 kOhm Digital Input O Level Ground to Input pins 1 1 Volts Digital Input 1 Level Ground to Input pins 15 Volts Analog Input Range Ground to Input pins 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 10 FDC3260 Motor Controller Datasheet Version 1 0 December 19 2014 lRoboteQ Electrical Specifications Operating amp Timing Specifications TABLE 6 Parameter Measure Point Min Typ Max Units Command Latency Command to output change 1 0 5 1 ms PWM Frequency Motor Output 10 18 20 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 115200 8 bit no parity 1 stop bit no flow control Note 2 May be disabled with value 0 Scripting TABLE 7 Parameter Measure Point Min Typ Max Units Scripting Flash Memory Internal 16384 Bytes Max Basic Language programs Internal 1000 1500 Lines Integer Variables Internal 1024 Words 1 Boolean Variables Internal 1024 Symbols Execution Speed Internal 50 00
4. exception status information FIGURE 8 Normal Operation Flashing Patterns Idle Waiting for Command RS232 USB Mode RC Pulse Mode Analog Mode ECCO C OTCCC CEO0OOHE FIGURE 9 Exception or Fault Flashing Patterns Short Detected Overheat Under or Over Voltage Power Stage Off Additional status information may be obtained by monitoring the controller with the PC utility 8 FDC3260 Motor Controller Datasheet Version 1 0 December 19 2014 lRoboteQ Electrical Specifications Electrical Specifications Absolute Maximum Values The values in the table below should never be exceeded permanent damage to the controller may result TABLE 3 Parameter Measure point Min Typ Max Units Battery Leads Voltage Ground to VBat 63 Volts Reverse Voltage on Battery Leads Ground to VBat 1 Volts Power Control Voltage Ground to Pwr Control wire 63 Volts Motor Leads Voltage Ground to M and M wires 63 1 Volts Digital Output Voltage Ground to Output pins 30 Volts Analog and Digital Inputs Voltage Ground to any signal pin on 15 pin amp 15 Volts Hall inputs RS232 I O pins Voltage External voltage applied to Rx Tx 15 Volts pins Case Temperature Case 40 85 oC Humidity Case 100 2 Note 1 Maximum regeneration voltage in normal operation Never inject a DC voltage from a battery or other fixed source Note 2 Non condensing Power Stage Electr
5. feedback e Torque mode FDC3260 Motor Controller Datasheet lRoboteQ 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 0 mOhm ON resistance MOSFETs 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 IP51 NEMA rating Orderable Product References Power wiring 0 25 Faston tabs 5 5 139 7mm L 5 5 W 1389 7mm 1 0 25mm H 400 to 850 C operating environment 0 5 Ibs 250g Easy configuration tuning and monitory using provided PC utility Field upgradeable software for installing latest features via the internet Reference Number of Channels FDC3260 3 Amps Channel 60 Volts 60 FDC3260 Motor Co
6. 0 100 000 Lines s Note 1 32 bit words Thermal Specifications TABLE 8 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 9 Parameter Measure Point Min Typ Max Units Weight Board 250 0 5 g Ibs Power Connectors width Terminal tab 0 25 Inches FDC3260 Motor Controller Datasheet lIRoboteQ 0 98 z 0 25 25mm 0 57 _ 4 6 3 mm 0 7 17 8mm 14 5mm y 0 3 m 7 6 mm o16 4 0mm 0 325 8 3 mm FIGURE 10 FDC3260 side view and dimensions 5 50 139 7mm Jat gt i 0 24 6 0mm A A I I E E 4 aod J Ug A A a l J E E elektro Be Sect cee AN he a a etl 1 Q y 1 8 A doses J Ue re ete Ne a o 2 qa ot SS Se Se Se T 177 ig a ae PEPE Pe el EN NENEN IEEE ee a E l l jd Y 125 31 8mm 3 00 76 2mm FIGURE 11 FDC3260 top view and dimensions 12 FDC3260 Motor Controller Datasheet Version 1 0 December 19 2014
7. GND 8 DOUT1 Motor Brake 1 6 DOUT2 Motor Brake 2 9 DOUT3 Contactor 6 FDC3260 Motor Controller Datasheet Version 1 0 December 19 2014 IRoboteQ Commands and I O Connections TABLE 2 Connector Pin Power Dout Com Pulse Ana Dinput Default Config 7 DOUT4 Unused 20 CANH Unused 8 CANL Unused 21 RC5 ANA5 DIN5 Unused 9 DIN9 Unused 22 RC6 ANAG DING Unused 10 DIN10 Unused 23 RS485A RS485 11 RS485B RS485 24 RC7 ANA7 DIN7 Unused 12 RC8 ANA8 DIN8 Unused 25 5VOut 13 GND Note 1 Analog command is disabled in factory default configuration Default I O Configuration While the controller can be configured so that practically any Digital Analog and RC pin can be used for any pur pose 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 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 prior ity orde
8. derwater Robotic Vehicles e Stabilization Gimbals e Machine tools e Industrial automation e Telepresence Systems e Animatronics Key Features USB RS323 RS485 0 5V Analog or Pulse RC radio com mand modes e CAN bus interface up to 1Mbit s with multiple protocol support e Auto switch between Serial USB CAN Analog or Pulse based on userdefined priority e Built in dual 3 phase high power drivers for three brushed DC motor at up to 60A each e Full forward amp reverse motor control Four quadrant opera tion Supports regeneration e Operates from a single 10V 60V power source e Programmable current limit up to 60A per motor for pro tecting controller motor wiring and battery e Dedicated connector for 3 quadrature encoders e Upto 8 Analog Inputs for use as command and or feed back e Upto 8 Pulse Length Duty Cycle or Frequency Inputs for use as command and or feedback e Upto 10 Digital Inputs for use as Deadman Switch Limit Switch Emergency stop or user inputs e 4 general purpose 24V 1 5A output for brake release or accessories e Selectable min max center and deadband in Pulse and Analog modes e Selectable exponentiation factors for each command inputs e Trigger action if Analog Pulse or Encoder counter capture are outside user selectable range soft limit switches e Open loop or closed loop speed control operation e Closed loop position control with encoder analog or pulse frequency
9. e surge current Protection fuse needed if battery polarity inversion is possible Max milli seconds 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 9 Controller will stop until restarted in case of short circuit detection Note 8 Factory default value Time in ms that Stall current must be exceeded for detection Note 10 Approximate value Note 11 Factory default value Time in ms for power to go from O to 100 Command I O and Sensor Signals Specifications TABLE 5 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
10. er 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 bot tom edges of the case making contact with a metallic surface chassis cabinet FDC3260 Motor Controller Datasheet 5 lIRoboteQ Encoder Connection Connection to the Encoders is done using a special connector on the front side of the controller The connector is a 10 pin Molex Microfit 3 0 ref 43025 1000 Pin assignment is in the table below Row Ch1 Row Ch2 Row Ch1 Row Ch2 FIGURE 5 Encoder connector TABLE 1 Pin Number 1 2 3 4 5 Row Ch1 5V Enc3 A Enc1 B Encl A Ground Row Ch2 5V Enc3 B Enc2 B Enc2 A Ground Commands and I O Connections Connection to RC Radio Microcomputer Joystick and other low current sensors and actuators is done via the 25 connector The functions of many pins vary depending on controller model and user configuration Pin assignment is found in the table below 14 25 1 13 FIGURE 6 Main Connector pin locations TABLE 2 Connector Pin Power Dout Com Pulse Ana Dinput Default Config 1 GND 4 5VOut 2 RS TxD RS232Tx 5 RC1 ANA1 DIN1 RCRadio1 3 RS RxD RS232Rx 6 RC2 ANA2 DIN2 RCRadio2 4 RC3 ANA3 DIN3 AnaCmd1 1 7 RC4 ANA4 DIN4 AnaCmd2 1 5
11. he 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 4 FDC3260 Motor Controller Datasheet Version 1 0 December 19 2014 RoboteQ Use of Safety Contactor for Critical Applications 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 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 F2 SW1 Main 1A On Off Switch 1A PwrCtrl Ground Resistor to 40V Max Digital Out 1 0 Connector Ground FIGURE 4 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 controll
12. ical Specifications at 250C ambient TABLE 4 Continuous Max Current per channel Measure point Min Typ Max Units Battery Leads Voltage Ground to VMot 0 1 63 Volts Motor Leads Voltage Ground to M and M wires 0 1 63 2 Volts Power Control Voltage Ground to Power Control wire 0 1 65 Volts Minimum Operating Voltage VMot or Pwr Ctrl wires 9 3 Volts Over Voltage protection range Ground to VMot 5 60 4 63 Volts Under Voltage protection range Ground to VMot 0 5 4 63 Volts Idle Current Consumption VMot or Pwr Ctrl wires 50 100 5 150 mA ON Resistance Excluding wire VMot to M Ground to M 2 5 mOhm resistance Max Current for 30s Motor current 60 Amps Continuous Max Current per Motor current 40 6 Amps channel Current Limit range Motor current 10 50 7 60 Amps Stall Detection Amps range Motor current 10 60 7 60 Amps Stall Detection timeout range Motor current 1 500 8 65000 milli seconds Short Circuit Detection Between Motor wires or Between 500 10 Amps threshold 9 Motor wires and Ground Short Circuit Detection Between Motor wires and VBat No Protection Permanent damage will result threshold FDC3260 Motor Controller Datasheet RoboteQ TABLE 4 Continuous Max Current per channel Measure point Motor Output Motor Acceleration Deceleration range 100 Typ 500 11 65000 Note 1 Negative voltage will cause a larg
13. ntroller Datasheet Version 1 0 December 19 2014 IRoboteQ 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 NEY Sense uss O O Hall Sensors I O Connector LEDs USB Connector Connector FIGURE 1 FDC3260 front view Pwr GND M3 M3 M2 M2 M1 M1 VMOT Ctrl FIGURE 2 FDC3260 rear view The diagram below shows how to wire the controller and how to turn power On and Off FDC3260 Motor Controller Datasheet 3 lRoboteQ F2 SW1 Main 1A On Off Switch 1A PwrCtrl Ground Motor 1 Resistor 1K 0 5W Motor 2 sw2 Emergency Note 4 Contactor or Cut off Switch
14. r RC Ch1 RC Ch2 RS232 TxOut Contactor RxIn Motor Brake 2 Ground Motor Brake 1 FIGURE 7 Factory default pins assignment FDC3260 Motor Controller Datasheet 7 lIRoboteQ 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 a 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 FDC3260 Plugging USB to a com puter will not disable the CAN interface 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
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