RGBL18xx

400A, 60/96V
Single Channel
Brushless DC Motor
Controller

Roboteq’s RGBL18xx is a very high-current, feature-packed mo- Features List

tor controller for brushless DC motors. The controller can oper-
• 0-5V Analog, RS232 or TTL Serial, RS485 or Pulse (RC
ate in one of several modes in order to sense the rotor position
radio) command modes
and sequence power to the motors’ three windings so that it
generates a smooth continuous rotation. The controller also • CAN bus interface up to 1Mbit/s with multiple protocol
uses the Hall sensor and/or Encoder information to compute support
speed and measure traveled distance inside a 32-bit counter. • Auto switch between serial, Analog, or Pulse based on
user-defined priority
The motors may be operated in open or closed loop speed • Built-in dual 3-phase high-power drivers for one brushless
mode, position mode or in torque mode. The RGBL18xx features DC motor at up to 400A
several Analog, Digital and Pulse I/Os which can be remapped • Full for ward and reverse control. Four quadrant operation
as command or feedback inputs, limit switches, or many other
• Supports regeneration
functions. The RGBL18xx accepts commands received from
an RC radio, Analog potentiometer, wireless modem, PLC, or • Operates from a single power source
microcomputer. Using CAN bus, as many as 127 controllers can • Programmable current limit up to 400A for protecting
be networked at up to 1Mbit/s on a single twisted pair. controller, motors, wiring and battery
• Connector for Hall Sensors
Numerous safety features are incorporated into the controller • Multiple Motor Operating mode
to ensure reliable and safe operation. The controller’s operation - Trapezoidal with Hall Sensors
can be extensively automated and customized using Basic
- Sinusoidal
Language scripts. The RGBL 18xx can be configured, moni-
tored and tuned in real-time using a Roboteq’s free PC utility. • Support for absolute angle encoders
The controller can also be reprogrammed in the field with the - sin/cos analog
latest features by downloading new operating software from - SSI
Roboteq.
- Resolver
• Field Oriented Control in Sinusoidal modes
Applications • Efficient Field Oriented Control (FOC) in sinusoidal modes
• Electric vehicles • Accurate speed and Odometry measurement using Hall
• Personnel carriers Sensor or encoder data
• Golf carts • Up to eight Analog Input for use as command and/or
• Materials handling equipment feedback
• Electric boats • Up to eight Pulse Width, Duty Cycle or Frequency Inputs
for use as command and/or feedback
• Automatic Guided Vehicles
• Up to 10 Digital Inputs for use as Deadman Switch, Limit
• Agricultural robots
Switch, Emergency stop or user inputs

RGBL18xx Motor Controller Datasheet 1

 • Two Quadrature Encoder input with 32-bit counters • Programmable maximum forward and reverse power
• Built-in Programming language for automatic operation • Ultra-efficient 0.33 mOhm ON resistance MOSFETs
and/or customized functionality • Separate current sensors for Motor Amps and Battery
• Five general purpose 1A output for brake release or acces- Amps measurement
sories. • Stall detection and selectable triggered action if Amps is
• Selectable min/max, center and deadband in Pulse and outside user-selected range
Analog modes • Overvoltage and Undervoltage protection
• Selectable exponentiation factors for each command • Programmable Watchdog for automatic motor shutdown
inputs in case of command loss
• Trigger action if Analog, Pulse or Encoder capture are • Overtemperature protection
outside user selectable range (soft limit switches) • Diagnostic LEDs
• Open loop or closed loop speed control operation • Efficient heat sinking using conduction bottom plate
• Closed loop position control with encoder, hall sensors, • Dustproof and weather resistant. IP56 NEMA rating
analog or pulse/frequency feedback
• Power wiring via high amperage power terminals
• Precise speed and position control when Encoder feed-
• Dimmensions: 5.51” (140mm) L, 7.87” (200mm) W, 2.28”
back is used
(58mm) H
• Torque mode
• -40° to +85° C operating environment
• PID control loop
• Controller Weight is 6.48lbs (2.94kg)
• Configurable Data Logging of operating parameters on
• Easy configuration, tuning and monitory using provided
Serial Output for telemetry or analysis
PC utility
• Built-in Battery Voltage and Temperature sensors
• Field upgradeable software for installing latest features via
• Regulated 5V output for powering Encoders, RC radio, RF the Internet
Modem or microcomputer
• Programmable acceleration and deceleration

Orderable Product References

TABLE 1.
Reference Number of Channels Amps/Channel Volts Ethernet
RGBL1860 1 400 60 No
RGBL1896 1 300 96 No

2 RGBL18xx Motor Controller Datasheet Version 1.2 May 6, 2022

 Power Terminals 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 Terminals Identifications and Connection

Power connections are made by means of high amperage power terminals located at the top of the controller,
as shown in Figure 1:

Warning: Properly identify PowerControl pin 25 before applying high voltage to it

FIGURE 1. Top Controller Layout

RGBL18xx Motor Controller Datasheet 3

 Figure 2, below, shows how to wire the controller and how to turn power On and Off.

Resistor
1K, 0.5W

Note 3

Emergency
Disconnect
B+
U
Motor
W V
U V W

Note 4
+ - Do not Connect! Power Control Sensors
GND +50V Max
Hall A/B/C
B- or Encoder

Main On/Off
Note 1 Switch
OFF ON

Note 2
+

Main 1A Optional
Battery Backup
Battery
-

FIGURE 2. Powering the Controller. NOTE: 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 Figure 2, 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 Power Control input.

Emergency Switch or Contactor

The battery must be connected in permanence to the controller’s B+ terminal via a high-power emergency
switch or contactor 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.

4 RGBL18xx Motor Controller Datasheet Version 1.2 May 6, 2022

 Sensor and Commands Connection

Precautions and Optional Connections

Note 1: The power control (pin 25 on DSUb connector) must be grounded to turn off the controller. Floating the
power control or connecting it to a battery will turn on the internal logic.
Note 2: A separate power supply may be used to power the controller’s internal logic to keep the controller alive
in case of voltage drop at the main battery because of motor load. Voltage on Power Control pin must not
exceed 50V Max. Make sure you correctly identified pin 25 before applying voltage to it.
Note 3: Use precharge 100Ω, 10W Resistor to prevent switch arcing.
Note 4: Beware not to create a path from the ground pins on the I/O connector to the battery minus
terminal.

Controller Mounting
During motor operation, the controller will generate heat that must be dissipated. The published amps rating
can only be fully achieved if adequate cooling is provided. Good conduction cooling can be achieved by mount-
ing the controller to a metallic surface, such as the chassis, cabinet, etc.

Sensor and Commands Connection

Connection to RC Radio, Microcomputer, Potentiometer, and other low current sensors and actuators is done
via the 25-pin DSub connectors and the 8-bit circular connector located at the top of the controller. The func-
tions of many pins vary depending on controller configuration. Use mating connector Conxall/Switchcraft mod-
el 6282-8SG-3DC, or the equivalent. Pin assignments are found in Figure 3 and Table 2 below. The color are
those of the cable assembly CABLE-RGBx1 available from Roboteq.

1
7 6 Use mating connector
2
Conxall/Switchcraft
8 5 6282-8SG-3DC
3
4
Top view
FIGURE 3. Circular Connector male pins location

TABLE 2.

Connector Hall Default

Pin Wire Color Power Sensors Ana SSI DOUT Configuration
1 Red +5V
2 White Hall A CLK+ Hall Input
3 Green Hall B CLK- Hall Input
4 Blue Hall C ASIN DATA+ Hall Input
5 Orange ACOS DATA- Unused
6 Brown DOUT 5 Digital Output
7 Yellow EXC
8 Black GND

NOTE: The above cable, CABLE-RGBx1, can be ordered from the Ordering Online section of Roboteq’s website at https://www.
roboteq.com.

RGBL18xx Motor Controller Datasheet 5

 13 1

Power Control - pin 25 14

FIGURE 4. Main Connector Pin Locations

TABLE 3.
Connector Pin Power Dout Com Pulse Ana Dinput Enc Default Config

1 GND
14 5VOut
2 RS TxD RS232Tx
15 PIN1 (1) ANA1 DIN1
3 RS RxD RS232Rx
16 PIN2 (1) ANA2 DIN2
4 PIN3 ANA3 DIN3
17 PIN4 ANA4 DIN4
5 GND
18 DOUT1
6 DOUT2
19 DOUT3
7 DOUT4
20 CANH
8 CANL
21 PIN5 ANA5 DIN5 ENC2A
9 DIN9
22 PIN6 ANA6 DIN6 ENC2B
10 DIN10
23 RS485+ RS485+
11 RS485- RS485-
24 PIN7 ANA7 DIN7 ENC1A
12 PIN8 ANA8 DIN8 ENC1B
25 PwrCtrl
13 GND
Note 1: Not recommended for MultiPWM.

For use in environments where liquid particles or fine dust may present, the controller’s cover is shaped for
DSub connectors with waterproof hoods. Product references EDAC 627-230-025-010, CONEC 165X14839X or
Assmann A-DS25-HOOD-WP.

6 RGBL18xx Motor Controller Datasheet Version 1.2 May 6, 2022

 Connection to SSI Absolute Encoder

FIGURE 5 . DSub Connector with Waterproof Hood

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, as shown in Figure 6:

1 2 3 4 5 6 1 2 3 4 5 6

Hall A U
Hall B
4 6
Hall C 1 3

U + - - + + - - +
2
V + + - - + + - - W V
5
W - - + + - - + +
FIGURE 6. Hall Sensors Sequence

Connection to SSI Absolute Encoder

In Sinusoidal Mode, the controller can use motors equipped with absolute angle sensors with SSI interface.
When enabled, the SSI signals are found on the 8-pin circular connector that is otherwise used for the Hall
Sensors. The controller issues a differential clock signal and expects a 12-bit differential data signal from the
encoder. Table 4 shows the signals assignment on the 8-pin circular connector.

TABLE 4.
Signal Pin Number Description
5V 1 5V Power Out
CLK+ 2 Differential Clock Output +
CLK- 3 Differential Clock Output -
DATA+ 4 Differential Clock Output +
DATA- 5 Differential Clock Output -
GND 8 Ground

RGBL18xx Motor Controller Datasheet 7

 Connecting Resolver
Resolver wiring is similar to a Sin/Cos sensor with the addition of an excitation signal. Figure 7, below, shows
the necessary connections.

Secondary 1 ASIN

Primary EXC

Secondary 2 ACOS
GND

FIGURE 7. Resolvering Wiring

Table 5 shows the signals assignment on the 8-pin circular connector.

TABLE 5.
Signal Pin Number Description
ASIN 4 Sin input
ACOS 5 Cos input
EXC 7 Excitation output
GND 8 Ground

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. Use the PC utility to enable and assign analog inputs.

RS485 Communication
The RGBL18xxx has a half-duplex RS485 interface. Two signals are present on the 25-pin DSub connector for
connecting to RS485 networks. Connecting these two wires with the correct polarity is all that is needed to
establish a connection. The RS485+ is the positive signal and RS485- is the inverted signal. Once enabled, the
RS485 can be used to communicate data under the Modbus protocol, or Roboteq’s native serial commands.

CAN Bus Operation

The controller can interface to a standard CAN Bus network, using four possible protocols: Standard
CANOpen, a simple and efficient meshed networking scheme (RoboCAN), and two simplified proprietary
schemes (MiniCAN and RawCAN). Please refer to the User Manual for details.

8 RGBL18xx Motor Controller Datasheet Version 1.2 May 6, 2022

 Status LEDs and Flashing Patterns

USB communication
Only use USB for configuration, monitoring and troubleshooting. USB is not a reliable communication method
when used in electrically noisy environments. If disrupted, communication will not always recover after it is
lost without unplugging and replugging the connector, or restarting the controller. RS232 is the preferred com-
munication method when interfacing to a computer. It is possible for USB and CAN to operate at the same
time on the RGBL18XX. Connecting via USB to a computer will not disable the CAN interface.

Status LEDs and Flashing Patterns

The controller is equipped with three LEDs.

Communication LED
Power LED
Status LED

FIGURE 8. Status LEDs

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 two second interval. TheIdle
flashing patternfor
- Waiting provides operating or exception status infor-
Command
mation.
RS232/USB Mode
Idle - Waiting for Command
RC Pulse Mode
RS232/USB Mode
Analog Mode
RC Pulse Mode

Analog Mode

FIGURE 9. Normal Operation Flashing Patterns

Short Detected

Overheat
Short Detected

Under or Over Voltage

Overheat
Power Stage Off
Under or Over Voltage
FIGURE 10. Exception or Fault Flashing Patterns
Power Stage Off
Additional status information may be obtained by monitoring the controller with the PC utility. The communica-
tion LED gives status information on the CAN and USB, as shown in Figure 11:

RGBL18xx Motor Controller Datasheet 9

 Always off: No USB, No CAN

Always On: USB Active, No CAN

Flashing On: No USB, CAN Enabled

Flashing Off: USB Active, CAN Enabled

FIGURE 11. Communication LED

______________________________________________________
Battery Backed Clock and RAM
The controller includes a real-time clock/calendar and RAM storage for user variables. Both the clock and the
RAM storage require a battery to continue running and for the stored data not to be lost while the controller is
powered down. The battery is not installed by Roboteq. Users who wish to use the clock and/or battery backed
RAM variables must install a battery themselves. The battery socket can be reached by removing the screws
that are holding the cover. Lift the cover to reach the board and insert a 3V, 12.5mm coin-style battery. Use bat-
tery type CR1225 or equivalent.

Measured Amps

The controller includes Amps sensors in line with the motor terminals and on the battery ground terminal. Both
Motor Amps and Battery Amps are therefore measured with precision.

Electrical Specifications
Absolute Maximum Values
The values in Table 6, below, should never be exceeded. Permanent damage to the controller can result.

TABLE 6.
Parameter Measure point Model Min Typical Max Units

Battery Leads Voltage Ground to VBat RGBL1860 63 Volts

RGBL1896 100 Volts
Reverse Voltage on Battery Leads Ground to VBat All -1 Volts

Motor Leads Voltage Ground to M+, M- RGBL1860 63 Volts

RGBL1896 100 Volts
Digital Output Voltage Ground to Output pins All 40 Volts
Power Control Ground to PowerControl pin All -1 60 Volts
Analog and Digital Inputs Voltage Ground to any signal pin on I/O All 25 Volts
connectors
RS232 pin Voltage External voltage applied to Rx/ All -25 25 Volts
Tx pins
CAN pins Voltage External voltage applied to All -25 25 Volts
CANH/CANL pins
Temperature Board All -40 85 ºC
Humidity Board All 100 (2) %

Note 1: Maximum regeneration voltage in normal operation. Never inject DC voltage from a battery or other fixed source
Note 2: Non-condensing

10 RGBL18xx Motor Controller Datasheet Version 1.2 May 6, 2022

 Electrical Specifications

Power Stage Electrical Specifications (at 25ºC ambient)

TABLE 7.

Parameter Measure point Model Min Typical Max Units

Battery Leads Voltage Ground to VBat RGBL1860 10 (1) 63 Volts
RGBL1896 40 (1) 100 Volts
Motor Leads Voltage Ground to M+, M- RGBL1860 63 (2) Volts
RGBL1896 100 (2) Volts
Over Voltage protection Ground to VBat RGBL1860 65 (2) Volts
range
RGBL1896 96 100 (2) Volts
Under Voltage protection Ground to VBat All 20 20 (4) Volts
range
Idle Current Consumption VBat or Pwr Ctrl wires All 50 (5) 100 mA
ON Resistance (Excluding VBat to A/B/C , plus All 0.7 mOhm
wire resistance) A/B/C to Ground
Max Current for 30s Motor current RGBL1860 400 Amps
RGBL1896 300 Amps
Continuous Max Current Motor current RGBL1860 300 (6) Amps
RGBL1896 200 (6) Amps
Current Limit range Motor current RGBL1860 10 300 (7) 400 Amps
RGBL1896 10 200 (7) 300 Amps
Short Circuit Detection Between Motor wires RGBL1860 480 Amps
threshold (9) or Between Motor
wires and ground or
RGBL1896 360 Amps
Between Motor wires
and Vmot
Motor Acceleration/ Motor current All 100 500 (8) 65000 milliseconds
Deceleration range

Note 1: Voltage may drop to 0 if backup supply is connected to Power Control pin. Negative voltage will cause a large surge
current. A Protection is 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 heatsink 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 for power to go from 0 to 100%
Note 9: Controller will stop until zero command given in case of short circuit detection

RGBL18xx Motor Controller Datasheet 11

 Command, I/O and Sensor Signals Specifications

TABLE 8.
Parameter Measure point Min Typical Max Units
5V Out Voltage Ground to 5V pin 4.8 5.1 5.2 Volts
5V Output Current Output to ground 100 mA
Digital Output Voltage Ground to Output pins 40 Volts
Digital Output Current Output pins, sink current 1 Amps
Digital Input 0 Level Ground to Input pins -1 1 Volts
Digital Input 1 Level Ground to Input pins 3 25 Volts
Analog Input Range Ground to Input pins 0 5.1 Volts
Analog Input Precision Ground to Input pins 0.5 %
Pulse durations Pulse inputs 20000 10 us
Pulse repeat rate Pulse inputs 50 250 Hz
Pulse Capture Resolution Pulse inputs 1 us
Minimum Pulse on or Pulse Pulse inputs 25 us
off duration
Frequency Capture Pulse inputs 100 1000 Hz
Encoder count Internal -2.147 2.147 10^9 Counts
Encoder frequency Encoder input pins 500 kHz

Operating & Timing Specifications

TABLE 9.
Parameter Measure Point Min Typical Max Units

Command Latency Command to output change 0 1 2 ms

Maximum PWM duty cycle Motor outputs 90.6 %
Closed Loop update rate Internal 1000 Hz
Serial baud rate Rx & Tx pins 115200 (1) Bits/s
Serial 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

Motor Characteristics Requirement for FOC current control

For proper FOC current control and motor operation under sinusoidal commutation, it is necessary for the
motor to meet a minimum load inductance, minimum load L/R and maximum electric operating speed
requirements. The minimum required inductance is necessary in order to ensure low Total Harmonic Distortion
(THD) of the motor current. Furthermore, to achieve proper current response and stability, the controller’s
current loop sampling rate will limit the minimum permissible motor time constant τ=L/R and the maximum
operating electric speed.

12 RGBL18xx Motor Controller Datasheet Version 1.2 May 6, 2022

 Electrical Specifications

TABLE 10.
Parameter Input DC Voltage (V) Value Units
Minimum load phase inductance (1) 12 25 uH
24 40 uH
48 60 uH
60 80 uH
96 110 uH
Minimum load inductance/resistance ratio (1) 0 - 96 1 msec
Maximum operating electric speed (2) 0 - 96 15000 RPM
Note 1: Star connected three phase load considered. In case the motor phase inductance does not fulfill the above require-
ments (minimum phase inductance and inductance/resistance ratio) an external AC inductor with proper inductance value is
recommended to be added.

Note 2: Maximum rotor speed is calculated from the maximum operating electric speed and pole pairs. For example, in a mo-
tor with 4 pole pairs the maximum operating rotor speed is 15000/4 = 3750 rpm

Scripting

TABLE 11.
Parameter Measure Point Min Typical Max Units

Scripting Flash Memory Internal 32000 32768 Bytes

Integer Variables Internal 4096 Words (1)
Boolean Variables Internal 8192 Symbols
Execution Speed (2) Internal 30,000 70,000 Lines/s
Note 1: 32-bit words
Note 2: Execution Speed was calculated based on low communication load with the controller. In high communication
workload, minimum time might be reduced drastically.

Thermal Specifications

TABLE 12.
Parameter Measure Point Min Typical Max Units

Board Temperature PCB -40 85 (1) ºC

Thermal Protection range PCB 70 80 (2) ºC
Thermal resistance Power MOSFETs to heats sink 2 ºC/W
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 13.
Parameter Measure Point Min Typical Max Units

Weight Unit 2940 (6.48) g (lbs)

Power Terminals Connection M6 (1) Thread
Note 1: Use M6 x 12mm long screws with washer between screw head and cable.

RGBL18xx Motor Controller Datasheet 13

 140 70

200

FIGURE 12. RGBL18xx Top View and Dimensions

57
51

25

200

FIGURE 13. RGBL18xx Side View and Dimensions

14 RGBL18xx Motor Controller Datasheet Version 1.2 May 6, 2022